Related Manuals for Formech IMD508
Summary of Contents for Formech IMD508
- Page 1 High Performance . . . Thermoforming Machine IMD508 Installation, Operating and Service Manual For Parts, Service & Technical Assistance North and South America Telephone: 312.396.4072 Fax: 312.396.4073...
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Page 2: Table Of Contents
Cooling & Release Operation - Setup functions for Semi-Automatic cycle Semi-automatic screen & buttons Process Timer Settings Pyrometer Option Heater Security Function Machine Adjustments and Settings Speed Adjusment Clamp Frame rear spring adjustment Cooling Fan Adjustment Manual - Formech IMD508... - Page 3 Auto-Levelling & Bottom Heater Safety Sensing. Fault Diagnostics / Maintenance Vacuum Pneumatics General lubrication Clamp & Table Seals Replace a damaged or worn seal Cleaning Service Support Periodic Maintenance Warranty Heating Elements Vacuum System Electrical Schematics (Index) Parts Listing EC Certificate Manual - Formech IMD508...
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Page 4: Safety
Safety Thank you for choosing Formech. Please read and follow the below safety instructions before attempting to install or operate your machine. Special attention should be paid to sections dealing with safety. It is impossible to cover all aspects of thermoforming within the scope of this manual, we are therefore available to offer advice on special problems regarding thermoforming techniques, tooling and materials. - Page 5 BE EXTRA CAUTIOUS WHEN DEALING WITH COMPRESSED AIR. EVEN AFTER MAIN SUPPLY HAS BEEN SHUT OFF DANGEROUS RESIDUAL PRESSURE MAY STILL BE PRESENT WITHIN THE SYSTEM. NEVER ATTEMPT TO OVERIDE ANY CONTROL SYSTEM INTERLOCK OR SAFETY RELATED CONTROL SYSTEM SUCH AS THE 2 HANDED CONTROL SYSTEM. Manual - Formech IMD508...
- Page 6 Ensure that you DO NOT work on your own when working at height. ENSURE THAT LOCAL LIFTING HANDLING AND HIGH LEVEL WORKING PROCEDURES ARE APPLIED AND MONITORED BY A PERSON RESPONSIBLE FOR HEALTH AND SAFETY. Manual - Formech IMD508...
- Page 7 THIS IS NOT AN EXHAUSTIVE LIST OF THE POSSIBLE MISSUSE OF THIS MACHINERY. THIS LIST IS WHAT IS CONSIDERED TO BE FORESEEABLE MISSUSE. THE USE OF THIS MACHINE MUST BE ASSESSED, MONITORED AND CONTROLLED BY THE PERSON RESPONSIBLE FOR THE HEALTH AND SAFTEY IN THE ORGANISATION THAT OWNS AND OPERATES THIS MACHINE. Manual - Formech IMD508...
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Page 8: Specifications
• Cooling Bolster (Option) • 40 Job setting memory capability • Plug Assist with mechanical dead stop (Option) • Vacuum & Pressure gauge indication • Safety light curtain guarding • WAGO PLC • Air flow regulation control Manual - Formech IMD508... -
Page 9: Noise Emissions
Noise emissions on the Formech IMD508 are less than 70dB(A). Machine storage The Formech IMD508 must be stored in a dry environment. If the machine is not used for a long period of time, run the pump periodically (once a month). -
Page 10: Installation
The IMD508 must be installed and commissioned by Formech. It is essential to read and fully understand all the information in this manual relating to safety and the Safety Hazards specific to this machine before installing and operating. -
Page 11: Introduction
Introduction The IMD508 is a large vacuum forming machine for sheet feed production suitable for forming a wide variety of plastic materials. It has been designed with operating simplicity high on the list of priorities. Operators who have previously used vacuum forming machines will quickly become familiar with the user- friendly controller programming. -
Page 12: Operation - Main Menu Fuctions
Operate the machine with each action of the machine being activated by the operator. Language Select the required language. HELP Function The question mark icon can be pressed at any time for an explanation of each of the icons. Manual - Formech IMD508... -
Page 13: Getting Started
Press the Manual Button – The Manual Operation Screen will open Control POD Functions The following section describes the manual controls of the IMD508. Operate these controls independently to ensure you are fully familiar with how the machine operates and how each action behaves. -
Page 14: Operation - Manual Functions
Plug Assist Press the plug UP & DOWN arrows on the button descend and retract the plug plate. Mould Table Press the Table UP & DOWN arrows on the button to raise and lower the table. Manual - Formech IMD508... - Page 15 Press again to turn OFF. In manual mode the timer counts up. Release The release icon is used to blow compressed air between the mould and the finished moulding. This is a momentary HOLD TO RUN button. Manual - Formech IMD508...
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Page 16: Manual Setup - Heaters
To change the heating zone settings press the heat zones settings button on the manual operation screen. There are 49 heating zones on the Top heater of the IMD508. The heater must be set to ‘ON’ to operate. Heating elements have... -
Page 17: Manual Setup - Table Settings
300mm plus the mould height. Values outside these limits will disable the bottom heater function • A confirmation message will occur when a program is opened, including startup, showing the mould height setting & requesting confirmation before starting a cycle. Manual - Formech IMD508... -
Page 18: Manual Cycle
At the appropriate time the fans may be turned on to start the plastic cooling process. Once the plastic has cooled sufficiently the release icon may be pressed to blow the moulding off of the mould. The moulding is now complete and the table may be lowered and the clamp frame raised. Manual - Formech IMD508... -
Page 19: Operation - Setup Functions For Semi-Automatic Cycle
This button will start the auto cycle. When pressed the STOP button will show. STOP This button will perform a controlled stop. A small rectangle will show when activated. The machine will stop at the end of the cycle. Manual - Formech IMD508... - Page 20 The temperature of the pyrometer is shown above the button and the target temperature is shown below the button. Press this toggle button to set to the timed heat cycle. Manual - Formech IMD508...
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Page 21: Process Timer Settings
Set the Table parameters by pressing the Table button on the Semi-Auto screen. Set the Table delay times (if required) by pressing on the time value and using the pop up keypad. Manual - Formech IMD508... - Page 22 Set the Cycle Counter parameters by pressing the cycle count button. The RESET button will reset the count to zero. Set the batch counter to set a required batch quantity. Manual - Formech IMD508...
- Page 23 SAVE button. To save as another program select another program number and press the SAVE button. The Save Parameters screen will open showing the parameters set. This allows final review and adjustment. Press the SAVE button to complete. Manual - Formech IMD508...
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Page 24: Pyrometer Option
Adjust the set times for optimum performance and monitor the output. Simply press the button of a function, make the setting changes and return to the operating screen. Remember to save any changes. Manual - Formech IMD508... -
Page 25: Heater Security Function
‘Bottom Heater retract advance temperature setting’ must be set from 1-5 deg. This will retract the bottom heater at the set value (1-5 deg) before the pyrometer target temperature and thus allow the table to rise at the target temperature while the top heater remains forwards. Manual - Formech IMD508... -
Page 26: Machine Adjustments And Settings
Ensure the plug is UP and adjust the 2 large nuts to the required lower stop level. Ensure that the stop nuts at the same level on each side of the cylinder. Manual - Formech IMD508... -
Page 27: Fixing Mould Tools
If the reserve air supply pressure falls then the heaters will turn off and the symbol will show on the control screen. The pyrometer air supply may be adjusted using the regulator situated on top of the reserve tank. Manual - Formech IMD508... -
Page 28: Electrical
The Ceramic heating elements should be periodically inspected for damage to the Ceramic elements and to make sure that they are securely mounted and that the electrical connections are tight. For the reasons stated the elements, associated cables, connectors, fuses and are specifically excluded from our standard warranty. Manual - Formech IMD508... -
Page 29: Replacement Of Heating Elements - Top Heater
When a faulty element is discovered, disconnect it and remove the clips. The fitting of the new element is in reverse. Elements on the IMD508 are fitted with thermocouples and hence they are required to be connected correctly; 1.The 2 centre wires are the thermocouple wires, one of these is marked, take note when disconnecting to ensure it is connected in the same way when reconnecting. -
Page 30: Fault Diagnostics / Maintenance
THE VACUUM TANK IS FITTED WITH A NON RETURN VALVE TO PREVENT IT FROM EVER BECOMING PRESSURISED. UNDER NO CIRCUMSTANCES SHOULD THE MACHINE BE RETURNED TO SERVICE (AFTER REPAIR) WITHOUT THIS DEVICE. IF ALLOWED TO PRESSURISE THE VACUUM TANK MAY EXPLODE! Manual - Formech IMD508... -
Page 31: Pneumatics
Bearing housings, slide and rails should be checked periodically, and lubricated when necessary using high temperature lithium grease. Clamp & Table Seals These are regarded as a consumable part and should be replaced when signs of wear become apparent. (See section dealing with Vacuum) Manual - Formech IMD508... -
Page 32: Replace A Damaged Or Worn Seal
If you are unable to cure any problem relating to your machine, or if you wish to order spare parts please contact us on the numbers and emails shown on the back cover of this manual stating the model IMD508, the serial number (on the specification plate), and a full description of the fault or parts you need. -
Page 33: Periodic Maintenance
The following Periodic Maintenance Schedule summarises the regular maintenance required by the IMD508. Owners, designated responsible people and persons required to perform any level of maintenance / servicing must read the Formech IMD508 manual thoroughly. Particular attention must be paid to references and notices regarding safety. -
Page 34: Warranty
Warranty Reliability and a long service life are synonymous with the Formech brand. However, as with any machinery, certain parts will require periodic replacement. The silicon seals applied to the mould table and to the top aperture of the machine (clamp) are seen as being consumable parts, their service life will depend on how the machine is treated and how often it is used. -
Page 35: Electrical Schematics (Index)
Electrical Schematic 29 BOTTOM HEATER OUTPUT 2 Electrical Schematic 30 BOTTOM HEATER OUTPUT 3 Electrical Schematic 31 TOP HEATER LAYOUT Electrical Schematic 32 BOTTOM HEATER LAYOUT Electrical Schematic 33 PNEUMATICS DRAWING 1 Electrical Schematic 34 PNEUMATICS DRAWING 2 Manual - Formech IMD508... - Page 36 Electrical Schematic 1 & 2 Manual - Formech IMD508...
- Page 37 Electrical Schematic 3 & 4 Manual - Formech IMD508...
- Page 38 Electrical Schematic 5 & 6 Manual - Formech IMD508...
- Page 39 Electrical Schematic 7 & 8 Manual - Formech IMD508...
- Page 40 Electrical Schematic 9 & 10 Manual - Formech IMD508...
- Page 41 Electrical Schematic 11 & 12 Manual - Formech IMD508...
- Page 42 Electrical Schematic 13 & 14 Manual - Formech IMD508...
- Page 43 Electrical Schematic 15 & 16 Manual - Formech IMD508...
- Page 44 Electrical Schematic 17 & 18 Manual - Formech IMD508...
- Page 45 Electrical Schematic 19 & 20 Manual - Formech IMD508...
- Page 46 Electrical Schematic 21 & 22 Manual - Formech IMD508...
- Page 47 Electrical Schematic 23 & 24 Manual - Formech IMD508...
- Page 48 Electrical Schematic 25 & 26 Manual - Formech IMD508...
- Page 49 Electrical Schematic 27 & 28 Manual - Formech IMD508...
- Page 50 Electrical Schematic 29 & 30 Manual - Formech IMD508...
- Page 51 Electrical Schematic 31 & 32 Manual - Formech IMD508...
- Page 52 Electrical Schematic 33 & 34 Manual - Formech IMD508...
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Page 53: Parts Listing
Parts Listing IMD508 Major Component Parts & Options Heating Element, 125W QSF TCK Top Heater 125W QSF TCK Heating Element, 125W HSF TCK Bottom Heater 125W HSF TCK 110 3 Pole Ceramic Block Heater 703-3855 Cable 1.63mm Solid Heater DG 1.63mm... - Page 54 Parts Listing IMD508 Major Component Parts & Options Supply Module inc Fuse Holder CTRL 750-601 HMI MT-8100i Weintek 10" CTRL MT-8100i RJ45 lead 10m GREY CTRL 556-354 Cabinet Fan CTRL 37-0668 Cabinet Grill CTRL 37-0878 Contactor DIL-EM10 G 24VPump CTRL...
- Page 55 Parts Listing IMD508 Major Component Parts & Options 10mm Equal Elbow compression fitting Bolster A13260-10 10mm Olive Bolster A9740-10 10mm Internal support bush 7mm ID, 8mm OD Bolster A10770-1008 10mm Bulkhead compression 26mm od Bolster A360-3/8 10mm PTFE Tube, 5m...
- Page 56 If you are unable to cure any problem relating to your machine, or if you wish to order spare parts please contact us, stating the model (IMD508), the serial No. (on specification plate) and a full description of the fault.
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Page 57: Ec Certificate
Is in conformity with the provisions of the following other EC Directives: 2004 / 108/EC – EMC 2006 / 95/EC – LVD Technical File Compiled by: Andrew Berry at address below. Formech International Limited, Unit 4, Thrales End Farm, Thrales End Lane, Harpenden ………………………………………………………………………………………………………… Hertfordshire AL5 3NS, United Kingdom …………………………………………………………………………………………………………... - Page 58 South America Telephone: 312.396.4072 Fax: 312.396.4073 spares@formechinc.com Formech International Limited Unit 4, Thrales End Farm, Thrales End Lane, Harpenden, Hertfordshire, AL5 3NS U.K. Tel: +44 (0)1582 469 797 Fax: +44 (0)1582 469 646 Email: info@formech.com Manual - Formech IMD508...
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