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OMG MF 64 Instructions For Use Manual

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Forming Machine
Model: MF 64
INSTRUCTIONS FOR USE
ORIGINAL INSTRUCTIONS
2020
Matr. nr. 1490
Construction year 2020
Donato Gavino Murru
donato.gavino.murru@omgitaly.com
OMG

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  • Page 1 2020 Forming Machine Model: MF 64 Matr. nr. 1490 Construction year 2020 INSTRUCTIONS FOR USE ORIGINAL INSTRUCTIONS Donato Gavino Murru donato.gavino.murru@omgitaly.com...
  • Page 2 MF 64 Dear Sir, We thank you and we congratulate with you for choosing this thermoforming machine O.M.G. We are sure to offer you a machine technologically very advanced. This handbook has got the aim of explaining the most common operations that can be done, in conformity with security laws.
  • Page 3 You should assume that anything not described in this manual is not possible. 2. Although care has been given in documenting the product, please contact Your OMG representative if you have any suggestions on improving this manual. 3. The product contains dangerous high voltage inside. Turn OFF the power and wait for the least 15 minutes to allow the power to discharge before handling or working with the product.

  • Page 4: Table Of Contents

    MF 64 Table of Contents Table of Contents............................3 Starting ................................7 General Warning ............................8 Installation and Wiring Precautions ......................10 Operation and Adjustment Precautions....................12 Label ................................13 Overview ................................ 15 Generalities about the machine – description – performances ............15 Allowed working materials ........................
  • Page 5 MF 64 Electrical Connections ..........................64 Connect the cables, on the appropriate terminal, following these instructions: ......65 Water connections ............................ 69 Water scheme ............................70 Cooling System ............................70 Main manifold ............................71 Cooling sections of the machine ......................72 Pneumatic connection ..........................
  • Page 6 MF 64 Safety ................................ 102 Index Device ..............................103 General Description ..........................103 Schematic ..............................103 Adjustments & Setup ..........................104 Rails chain cooling system ........................ 108 Automatic Cycle ............................109 Main Spare Parts ............................ 111 Troubleshooting ............................112 Safety ................................ 113 Heating Device ............................
  • Page 7 MF 64 Automatic Cycle ............................152 Main Spare Parts ............................ 155 Troubleshooting ............................156 Safety ................................ 156 Stacker Device ............................157 General Description ..........................157 Schematic ..............................158 Common Adjustments ..........................159 Stacker mode: type G ........................... 163 Automatic Cycle ............................166 Main Spare Parts ............................

  • Page 8: Starting

    No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMG is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of the manual.

  • Page 9: General Warning

    Do not touch any rotating or moving parts in operations. Do so may result in injury. Do not modify parts of the machines without authorization of OMG. Doing so may result in injury or damage to the product Securities release key is positioned in the front of the machine electric board;...
  • Page 10 MF 64 knowing the dangers of the securities releasing. The key is furnished for setting up and allows the manual motion only low jog speed. Pay attentions anyway that no peoples are near the devices movements, and use carefully this mode; also keep some mechanical part for security.

  • Page 11: Installation And Wiring Precautions

    MF 64 Installation and Wiring Precautions Do not step on fragile parts or place heavy object on. Doing so may result in injury Do not cover the inlet or outlet ports and prevent any foreign object from entering on the machine. Doing so may result mechanical damages, fire….
  • Page 12 Locations subject to strong electromagnetic fields and magnetic fields Locations subject to possible exposure to radioactivity Locations close to power supplies For any extra-ordinary maintenance ask to technical assistance of OMG Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 11 a 179...

  • Page 13: Operation And Adjustment Precautions

    When for some maintenance you provide to demounting some parts from the machine, must be sure to re connecting in same place and in same way that is provided form OMG. Doing so may result in unstable operation and injury When an alarm occurs, remove the cause, reset the alarm after confirming safety, and then resume operation.

  • Page 14: Label

    MF 64 Label General Information, Danger, Warning, Caution Warning label are pasted on the product as shown in the following. Item Description Label for CE Other safety It’s the label that define that the machine is marked General values of...
  • Page 15 MF 64 Place in which is present an electrical power; It’s placed to pay attention and prevent death or injury Place in which there is residual risk to injury for the operator Place in which there is residual risk to hot surface for the operator Stop of warning.

  • Page 16: Overview

    MF 64 Overview Generalities about the machine – description – performances This thermoforming line is designed to obtain products starting from a thermoplastic roll. This material is in a film state, dragged through the process by a special high strength pin chain system.

  • Page 17: Allowed Working Materials

    MF 64 Allowed working materials Present equipment has been studied for working the following materials: Name Material Description Non-woven fabric material used for the NON-WOVEN production of FPP1 / FPP2 safety Sound TEx C1986S MATERIAL masks. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...

  • Page 18: Right And Wrong Use

    We remind you that in compliance with the laws in effect, penetrating inside the secured area of the machine is allowed only by skilled and authorized personnel from OMG customer.

  • Page 19: Features

    MF 64 Features (For all not reported data, please refer to attached schemes) Features Standard Units Max. forming width Min. forming width Max. forming index Min. forming index Max sheet width Max. depth drawing (top) Max. depth drawing (bottom) Min. Pneumatic work pressure (For general purpose)

  • Page 20: List Of Functional Groups

    7. Rails chains (Film Index): It guides linear movement of pin chains for film indexing. Interchangeable tools (to be done by the user)  Mold (also supplied in this case by OMG)  Die cuttings tools (also supplied in this case by OMG) Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 19 a 179...

  • Page 21: Dimension Of The Machine

    MF 64 Dimension of the machine Lifting and transport Weight : ~20 Ton Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 20 a 179...

  • Page 22: Safety

    We remind you that the company OMG declines any responsibility for the damage caused by the falsification of the security devices, including the partial or partial removal of the mobile and fixed protections.

  • Page 23: Front Side

    MF 64 Front side Sliding security doors Electrical cabinet - Security doors with door lock release control Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 22 a 179...

  • Page 24: Left Side

    MF 64 Left Side Fixed safety guards Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 23 a 179...

  • Page 25: Right Side

    MF 64 Right Side Fixed safety guards Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 24 a 179...

  • Page 26: Rear Side

    MF 64 Rear Side Fixed safety guards Sliding security doors Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 25 a 179...
  • Page 27 MF 64 Sliding security door Safety micro switches mounted inside the machine on each sliding door Tamper proof screws Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 26 a 179...
  • Page 28 MF 64 Location of the emergency buttons Emergency button on machine input (material insertion) Emergency button on the oven area Emergency button on the touchscreen area Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 27 a 179...
  • Page 29 MF 64 Emergency button on the unloading area (scrap winding device) Description of Safety Functions Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 28 a 179...
  • Page 30 MF 64 Machines guards Manual reset function Emergency stop function Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 29 a 179...
  • Page 31 MF 64 SRP/CS components Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 30 a 179...

  • Page 32: Machine Limits

    MF 64 Machine limits Limits of use This forming machine MUST be used ONLY and EXCLUSIVELY for the processing of the materials indicated in the corresponding paragraph. Any other use not foreseen in this manual is strictly prohibited. Improper use of the machine as a whole or its components is strictly prohibited.
  • Page 33 MF 64 During use, cleaning and maintenance operations use personal protective equipment. Before pressing the consent switch to reset the safety system, make sure that there are no personnel inside the machine. In case of failure or malfunction contact the manufacturer. Do not perform recovery operations through tampering.

  • Page 34: Safety Requirements: Applicability

    MF 64 Safety requirements: Applicability 1. Access to dangerous areas Applicable 2. Electrical system Applicable 3. Gravity fall of suspended elements Not applicable 4. pneumatic system Applicable 5. Hydraulic system Applicable 6. Precautions for emergencies Applicable 7. Noise Applicable 8. Inhalation of dusts, fumes and harmful gases Not applicable 9.
  • Page 35 MF 64 Ergonomics The lifting of the material being processed is mechanized. Unexpected start The machine is equipped with interlocked guards and emergency switches which act on the safety system of the control system preventing unexpected starts in the presence of personnel.

  • Page 36: Evaluation Form For Essential Safety Requirements

    MF 64 Evaluation form for essential safety requirements Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 35 a 179...
  • Page 37 MF 64 Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 36 a 179...
  • Page 38 MF 64 Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 37 a 179...

  • Page 39: Transport, Install & Maintenance

    MF 64 Transport, Install & Maintenance General Description To facilitate lifting and preserve components integrity during transport, some parts of the machine are removed or securely attached to the main structure. Note: The enroller device will be disassembled, by untighten the screws which are fixed on the machine frame and the pneumatic / electric plugs will be disconnected.
  • Page 40 MF 64 Electrical plugs for enroller. Enroller (Unwind) Air connection Enroller (Unwind) Air connection Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 39 a 179...
  • Page 41 MF 64 Note: The ovens carriage is locked in forward position to avoid possible swings during transportation and the ovens support is removed because of container/truck width. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 40 a 179...
  • Page 42 MF 64 Plates to be reassembled on the support Don’t forget to remove these vertical bars when support is re-putted in position Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 41 a 179...
  • Page 43 MF 64 Note: Remove the X lock wood pieces (rear right and left) the locked ovens carriage during transportation. Don’t forget to remove these two pieces of wood Note: Re-position the manifold for chiller and thermoregulator water connections on the rear side of machine frame.
  • Page 44 MF 64 Note: Re-position the chiller and thermoregulator on the rear of the machine and re-Connect the plugs and pipes of chiller and thermoregulator (every pipe and wire have one plate where you need to plug). Chiller Thermoregulator Re-connect pipes on the...
  • Page 45 MF 64 Re-connect pipes on the chiller Re-connect plugs of chiller and thermoregulator Note: Re-fill water on chiller and thermoregulator circuit (also follow instruction of chiller and thermoregulator manual). Add 20-30% of glycol. Fill the water here and check the level on the right Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...
  • Page 46 MF 64 The water dispenser is managed as follows: Chiller water Inlet connection 2. Chiller water Outlet connection 3. Thermoregulator water Inlet connection 4. Thermoregulator Water Outlet Connection 5. Electrical valve for Delivery of cooling water to the chain rails 6.
  • Page 47 MF 64 Fix the lateral rear door on the machine frame by using the Hex screws Fix the switch door detection Note: Fix at same way at the opposite side the fix saftey panel Fix the lateral rear safety panel on the machine frame by using the Hex screws Note: Fix the first rear safety panel.
  • Page 48 MF 64 Fix the rear safety panel on the machine frame by using the #2 Hex screws Take look how will be the situation after the first panel lock in position Note: Fix the second rear safety panel. Fix the rear safety panel on the machine frame by using the #2 Hex screws Note: Connect the first and the second rear safety panel.
  • Page 49 MF 64 Connect the first and second rear panel by using platens and the #6 Hex screws Note: Re-Connect flashing light for machine signaling with the two screws. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 48 a 179...
  • Page 50 MF 64 Note: Re-Connect the little cabinet for machine control Open the little cover on the video control support arm. This is needed to drive the cables inside the arm to re-connect to the control panel Fix the arm of the control panel by tighten...
  • Page 51 MF 64 Note: Re-plug the wires and cables inside the control cabinet (please check also the electrical drawing annexed to the documentation) Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 50 a 179...
  • Page 52 MF 64 Note: The electrical brakes resistors for the trim press platens servomotors will be removed and must reinstalled as showed in next pictures. Open the doors of the main cabinet Fix the electrical brakes resistor on the top of the main cabinet by using Hex and nuts...
  • Page 53 MF 64 Use the grey systems for introducing the cables of the main cabinet Tight the screws from the sockets to unlock the wires related to the Electrical brakes resistors Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 52 a 179...
  • Page 54 MF 64 Note: Fixing the main cabinet conditioner and re-connect Put #2 lifting eyebolts and lift the conditioner near the door Fix the conditioner to the door by tight the Hex screws Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 53 a 179...
  • Page 55 MF 64 Re-plug the cables of the conditioner Note: The cutting press and the stacking device are locked at the frame also. Before using the machine, the supports must be removed. Remove this lock systems in front side of the machine Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...
  • Page 56 MF 64 Remove this lock systems in rear side of the machine Untight the Hex Screws to remove the #2 pillars used for delivery (front and rear) Remove the #2 pillars used for delivery (front and rear) Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...
  • Page 57 MF 64 Final look after remove the #2 pillars used for delivery (front and rear) and all security system (Photo taken from the rear sides of the machine) Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 56 a 179...

  • Page 58: Lifting Points

    Pillars fixed for machine delivery. Used for machine lifting Use for machine lifting IN CASE OF DAMAGES DURING TRANSPORTATION AND UNOLADING OMG CANNOT BE HELD RESPONSIBLE. RESPONSIBILITY BELONG TO THE CARRIER. PLEASE ANY DAMAGE AND DUE MACHINE TRANSPORTATION NEED TO NOTE IN THE CMR DOCUMETATION.
  • Page 59 MF 64 Note: The machine gripping points are as follows: Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 58 a 179...
  • Page 60 MF 64 Main part machine Weight: 15600 Kg Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 59 a 179...

  • Page 61: Foundations And Positioning On Floor

    MF 64 Foundations and positioning on floor Note: Drawing show in red all the points where the feet must be re-positioned during machine positioning on the floor. For correct operation, as well as for its stability, the machine must rest on a well-levelled surface in accordance with state laws.

  • Page 62: Machine Levelling

    MF 64 Machine Levelling Once the foundation and positioning is done and electrical & pneumatical are re-connected (see next description), proceed as follows: - turn CW or CCW the levelling screws of the anti-vibration feet (see more photo below) - Carry out the levelling operations of the machine both horizontally and transversely by adjusting the screws of the feet (see description).
  • Page 63 MF 64 Open the forming station lock, remove the station stop screw and test its extraction. Note: with the machine off, the lock status lamp will not be able to signal any feedback. To adjust the support feet, screw or unscrew with the appropriate wrench until the correct planarity of the machine is found.
  • Page 64 MF 64 Periodically perform a flatness check of the machine. With correct positioning, it is possible to avoid the occurrence of irregular wear of the moving parts. The frequency of periodic checks depends on the quality of the soil and its foundations.

  • Page 65: Electrical Connections

    MF 64 Electrical Connections Electrical connection must be done on the main disconnect switch located inside the main control panel. If technician open the cabinet for the operation just done in the above description please don’t take in account the first two photos.

  • Page 66: Connect The Cables, On The Appropriate Terminal, Following These Instructions

    MF 64 Note: If a cable with neutral (4 pins) is needed, it must be connected on the left side of the main switch (the main switch will have 4 connectors). Neutral terminal Phase 1 terminal Phase 2 terminal Phase 3 terminal...
  • Page 67 MF 64 1 ground cable ATTENTION: the operation must be done by a qualified electrician authorised by the customer. Bad peeling of the cables can cause an accidental contact between phases or ground. ATTENTION: Before applying voltage to the machine, make sure main disconnect switch cover is installed and that all previously operations are done properly.
  • Page 68 MF 64 Note: what’s need to do if the main wires phases are not well connected to the main switch When power is on before any movements please turn left and right this switch on the enroller. If is mark with arrow up and moving...
  • Page 69 MF 64 Power on lamp USB port Security exclusion End cycle Use blue button to reset the machine after an alarm or e-stop. Emergency stop button will stop all movements of the machine when activated. Pull back to reset. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...

  • Page 70: Water Connections

    MF 64 Water connections Water is necessary to cool down some parts of the machine like: mold. guides chains “pin chain system for index”. trim press cooling water table. For that purpose, we supplied a connection system for the water. We suggest that you use water between + 10 °...

  • Page 71: Water Scheme

    MF 64 The water dispenser is managed as follows: Cooling water Inlet connection 9. Cooling water Outlet connection 10. Thermoregulation water Inlet connection 11. Thermoregulation Water Outlet Connection 12. Delivery of cooling water to the chain guides 13. Return of cooling water from the chain guides 14.

  • Page 72: Main Manifold

    MF 64 Main manifold All the systems that are using the cooling are hook up to the same place. From this location, you can turn on or off some cooling systems if needed for maintenance or for process. An automatic valve is opening the water system to the mold in automatic cycle.

  • Page 73: Cooling Sections Of The Machine

    MF 64 Cooling sections of the machine Index system: Cooling down the rails when the heating ovens are located in position during the automatic mode. Entry of index system cooling system. End of rails cooling. Bypass for recirculating water to the beginning.
  • Page 74 MF 64 Forming station: Mold need to be cool down to keep formed products identical and conform to control and quality expectation. Cooling system manifold to attach mold cooling system. Cutting press station: When using the cutting die heating system, you need to cool down the water plate to avoid transferring heat to the press system.

  • Page 75: Pneumatic Connection

    MF 64 Pneumatic connection Pneumatic connection is made with tubes with minimal 1” diameter. The air supply pressure must be 6 bar (or 90 PSI) minimum and 8 bar (or 120 PSI) maximum. Be sure that the compressor is supplying air with low humidity percentage to avoid emptying frequently the filter of the FRL from water accumulation.

  • Page 76: Unpacking, Positioning And Assembly

    MF 64 Turn clockwise for purging air in the system. Supply gradual valve. Particulate Filter Pressure sensor. Status led. Air gauge system. Clogged signal filter Water tank. Turn clockwise for increasing line pressure. Must emptied when is full. Push down button to lock setting.

  • Page 77: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Pneumatic main gauge Metalwork Safety Don’t remove air while the machine is in operation. Don’t supply air to the machine before controlling if something is inside. This can damage some devices.

  • Page 78: Touch Screen

    MF 64 Touch Screen General Description Touch Screen Video device is the most important instrument to communicate with the machine. With touch screen is possible to set many parameters and watch performances, warning and alert. In the next paragraphs are shown the main usefully pages.

  • Page 79: Schematic

    MF 64 Schematic Voltage on/off selector Voltage light USB port Security exclusion selector Video End Cycle button Reset button Emergency button Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 78 a 179...

  • Page 80: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Touch Screen NA5-15W101B Omron Video Troubleshooting Symptom Probable cause Item to check Countermeasures Intervention mode Touch screen isn’t Touch screen is Connection Connect cables All modes blank connected Safety Do not remove cover or guard without shut down the power. Before operating machine with power, make sure to re-install guarding system and make sure that all safety devices are working properly.

  • Page 81: Remote Assistance

    MF 64 Remote Assistance This machine is provided by a Ubiquity Ethernet router which allow simply connection between machine and OMG factory through internet connection of your factory. Remote Assistance Router External connection to factory network If assistance is needed connect Ethernet cable to the plug on the left side of electrical box of machine as shown in picture above and contact us.

  • Page 82: Machine Management

    MF 64 Machine Management Starting and main pages Turn on the machine operating on general switch first placed on main electical box then turn to the right the key switch Turn to the right When turn on the machines follow screen appears.
  • Page 83 Home stations button You can return to the main page pushing “OMG” button on the top left or the first-left button on the case video. If you want return to the previous page pushing the second button on the case video.

  • Page 84: Unwind Reel

    MF 64 Unwind Reel General Description To be able to supply film to the machine, the unroller is necessary. It is consisting of a lifting device, moved by two screws and a single motor. This device is equipped with a blocking system that keeps the roll with tension and let it rotate freely on its own axis. The rotation can be controlled with the brake, avoiding that the roll moves because of inertia.

  • Page 85: Adjustments & Setup

    MF 64 Adjustments & Setup When inserting a roll of different width for the first time, you need to adjust the side part, where there is a screw with handle-wheel. Adjust the width of the unroller accordingly to the dimension of the roll.
  • Page 86 MF 64 Use the up / down selector switch to move the roll up or down. Adjust the height of the centering cones until they match the center of material roll. Up / down lifting roll selector. Maintain the selector to go up or down the lifting support.
  • Page 87 MF 64 Lift the roll from ground to avoid the material to get scratch from the floor. Pull manually the end material to unwind, a sufficient quantity to install I inside the calendar. Lift the two handles located on both side of the unwinder.
  • Page 88 MF 64 Unroller sensors. Introduce the extremity of the material inside the film index rails advancement using the jog button (Refer to Chapter of Film Index to learn about this mode). Notes: If the internal diameter of the roll (carton part that allows keeping the roll together or coring) is different from the center’s cone, it is possible to add an optional cone to attach with screws in...
  • Page 89 MF 64 Unroller sensor. Disk to keep non-woven sheet on the roll. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 88 a 179...

  • Page 90: Automatic Cycle

    MF 64 Automatic Cycle Before starting with the automatic cycle, to produce pieces, be sure to enable the calendar function using the selector switch. No Doing so, the material can pull excessively and damage the devices. Use this selector switch to activate the calendar.
  • Page 91 MF 64 To give more restriction to the roll, turn screw clockwise. Release this nut to adjust. If for some reason, the material sagging is too short, a safety device located in front of the calendar will stop the machine and a message will be displayed on the touchscreen immediately.

  • Page 92: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Lifting Gear BN71B4 Bonfiglioli Motor cod.830720156 VF 49 F1 18 P71 B14 B3 Calendar Gear BN71B4 Bonfiglioli Motor cod.830720156 MVF 44 F1 P71 B14 Photoeyes for E3S-DBP21 Omron unroller control. Safety Switch...

  • Page 93: Troubleshooting

    MF 64 Safety Switch SHL-W255 Omron lift Safety down switch Lock roll Iso 63 stroke 300 Metalwork cylinder Type 1210630300CP Pneumatic MAV 26 LES OC Metalwork switch for Locking roll Type cylinder 7010000900 Troubleshooting Symptom Probable cause Item to check...

  • Page 94: Safety

    MF 64 unrolling. Tape is stuck At the end of roll, Material Open upper carter Shut down the inside the supplier tape plastic and clean the power calendar. to hold to the core. calendar rolls. The material is The roll scratching...

  • Page 95: Edges Pre-Heater

    MF 64 Edges Pre-Heater General Description This device is used to heat the edges of the material before it reaches the film feed chain. The need to use this device arises because there is a rapid advancement of the material inside the chain guide system through the drilling of the material by the points on the chain.

  • Page 96: Schematic

    MF 64 Schematic Left blade Right blade Cartridge heater Pneumatic cylinder Pneumatic cylinder spacer Film sliding plate Film sliding plate adjustment knobs Thermocouple Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 95 a 179...

  • Page 97: Adjustments & Setup

    MF 64 Adjustments & Setup The two lateral parts of the preheating are connected to the chain guides of the film advancement device. By adjusting the film advancement device, the two sides of the preheating unit are also automatically adjusted For the fine adjustment of the part of the edge to be heated, there are two knobs "7"...
  • Page 98 MF 64 There is also a pneumatic regulator "9" which allows the adjustment of the up and down speed of the blades on the non-woven material Turning the knobs "10" clockwise and counterclockwise respectively reduces or increases the air flow to the cylinders that control the blades, thus speeding up or slowing down their stroke.
  • Page 99 MF 64 On the edges pre heater page, you can test the device (blade opening and closing) by pressing the "1" button shown in the figure. On the man page, you can check the temperature of the blades, set the temperature, turn the heaters on.
  • Page 100 MF 64 Automatic Cycle Before proceeding with the automatic cycle, make sure that the heaters are on and have reached the operating temperature set by the user. When the film is embarked in the machine and you want to activate the automatic cycle, it is recommended that in the cases described at the beginning of the chapter, activate the preheating device by pressing in correspondence of the edges on the layout of the main page.

  • Page 101: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Pneumatic cylinders for SSCY CIL- Metalwork the movement 2120320020CN of the blades Thermocouple TC “K” 6x15 for blade ATT.BAION. ¼ Delcom temperature GITTS HT2 control Cartridge D=15,8 L=700 1500 heater for...

  • Page 102: Troubleshooting

    MF 64 Troubleshooting Symptom Probable cause Item to check Countermeasures Intervention mode Check the Maintenance heating fuses. Checking the technician. One or both sides Fuse or resistance Check the components with the Machine in do not heat up break integrity of the...

  • Page 103: Safety

    MF 64 Safety Do not touch moving parts or place your hands inside the preheating pliers during the adjustment phase. otherwise, serious accidents can result. Do not remove the casing and protections before having disconnected the machine from all the power supplies. Before starting the machine, reset all the safety devices.

  • Page 104: Index Device

    MF 64 Index Device General Description The index system is a device design for plastic film travelling. It is composed of two rails in which is driven two pin chains. They are travelling all around the rails of the machine.

  • Page 105: Adjustments & Setup

    MF 64 Adjustments & Setup Adjusting the discs guide that allow the material to follow the index system straight. Fix internal dimension equal to width of material. Be sure that the material is centered with the machine center. There are 4 disc guides.
  • Page 106 MF 64 The index devices are providing the possibility to stretch the material from the entering zone after the forming press. It will avoid non-woven film to sag too much when material will be process. For this reason, two rail adjustment screws are adjusted independently one from the other.
  • Page 107 MF 64 Release this screw. Turn this hexagonal part to modify the position of the wheel. The groove in the wheel is pushing the material against the pin chain. Don’t adjust the wheel excessively low on chain. Make sure to leave approximately the thickness of material between chain and wheel.
  • Page 108 MF 64 Index Main Page Film advance buttons for step and discharge Index manual movements Push here for change index parameters Push here for adjust rails width Adjust the value of index, the speed, and acceleration with the HMI. Index manual movements Push here to change values.

  • Page 109: Rails Chain Cooling System

    MF 64 Rails chain cooling system On the rail system of the index, the heating system section is getting cool down by the main cold- water system of the machine. Water bypass. Water entrance. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 108 a 179...

  • Page 110: Automatic Cycle

    MF 64 Automatic Cycle Insert plastic film inside rollers like picture below. Make sure that the material goes through the bottom of the top roller. Lift mobile roller to introduce non- woven film manually. Push material until it touches the pin chain and the retaining wheel.
  • Page 111 MF 64 Film index advance jog mode button. Used when entering film in machine. Rails width selector for the entry film regulation Emergency button Reversing film index rotation button. If non-woven is misplace on the pin chain, reverse index to reinstalling it.

  • Page 112: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Gearbox A 302 UH35 P90 Bonfiglioli i=13,6 Servodrive R88M-K5K030F-S2 Omron motors Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 111 a 179...

  • Page 113: Troubleshooting

    MF 64 Troubleshooting Symptom Probable cause Item to check Countermeasures Intervention mode Error code from -Mechanical Materials Free mechanical All modes index servo excessive force thickness components or lower motor (refer to speed value. error chapter list). Variable in -Chains needs...

  • Page 114: Safety

    MF 64 Safety Do not remove cover or carter without shutting down the power. Before operating with power, make sure that all guards are re-installed and all safety devices are in good working orders. Installation, operation, maintenance, or inspection must be performed by authorized personnel.

  • Page 115: Heating Device

    MF 64 Heating Device General Description The heating system is a device that provides controlled heat to the non-woven film for melting. This is done with the help of a ceramic heater which provide an infrared wave that create heating.

  • Page 116: Adjustments & Setup

    MF 64 Adjustments & Setup Adjust heating carriage position according to the mold station. You don't want the heating panels to hit the mold! Upper panel Mold Pay attention that panels do not crash against mold. Pay attention to adjust the position of panels before moving carriage to avoid touching the mold.
  • Page 117 MF 64 Proximity switches for max and min position of heating carriage travelling. Note: Use the touch screen page to adjust the position of heating carriage. Upper panel settings Carriage mode work: A- Only upper oven B- Only lower oven...

  • Page 118: Heater Carriage Speed Adjustment In And Out Of The Machine

    MF 64 Heater carriage speed adjustment in and out of the machine. Use those flow controls to adjust the speed of carriage. Pay attention to adjust the flow controls without the machine being in automatic cycle. If speed is set too slow you could melt the plastic film in the lower heating elements and create a fire.

  • Page 119: Adjustment Of The Sagging Sensor For Non-Woven Film Indexing

    MF 64 Adjustment of the sagging sensor for non-woven film indexing. The light beam must be aligned with the reflector located in the front of the machine. Note: If the reflector is not aligned properly, the heater carriage will not move forward.

  • Page 120: Set Up For The Power Intensity Of Ceramic Heating Elements

    MF 64 Set up for the power intensity of ceramic heating elements. Arrows shift for advancement orange box correspondent step film Select all Cancel Save and write on PLC Selection Select Row or column Delete operation Select one You will find this screen by pushing the panel superior or inferior buttons in heating page.

  • Page 121: Temperature

    MF 64 Temperature From the main page is possible to set temperature of following heating devices: Upper Oven Lower Oven When devices are ready OK Trim press die-cut indication becomes green. Edge Pre-Heater Heaters state Check the actual Set desired...

  • Page 122: Automatic Cycle

    MF 64 Automatic Cycle We understood that heating panels are melting the material before entering in the forming press. For this purpose, the panel(s) come and stay on the material during the automatic cycle, and come back only when the machine stop for end cycle or for other safety reasons. In fact, there is a photocell(s) that control if the material is sagging too much due to overheating.
  • Page 123 MF 64 Picture Description Type Supplier Encoder on E6B2-CWZ5B Omron heater carriage travelling movement. Resolution 2000 Gear-motor for PCE 230 M31 Minimotor heater carriage 048114M travelling movement. i=475 Pneumatic Iso 63 /900CIL- Metalwork cylinder for 121-063-0900- panel(s) movements. Pneumatic valve...
  • Page 124 MF 64 Heating boards. HC510 Hetronik Safety proximity E2A-M18KS08- Omron for max – min M1_B3 travelling Safety Eye for E3ZM-R86 Omron material sagging system. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 123 a 179...

  • Page 125: Troubleshooting

    MF 64 Troubleshooting Note: Pictures for reference only. Number of heater boards and heater elements can differ. ETHERCAT COMUNCATION HC500-EC + TU TERMOCOUPLE WIRE DATA COMM.EXCHANGE WIRE Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 124 a 179...
  • Page 126 MF 64 Heating boards are mounted in rack that contains up to 8 boards. Each card can control a maximum 16 heaters. The resistances are fed by impulse trends sent to the card that is regulating those trends in function of the temperature sensed by the thermocouple functioning in percentage.

  • Page 127: Safety

    MF 64 Safety Do not remove cover or carter without shut down the power. Before turning on power, reinstall all removed guard and make that all safety device are in good working order. Installation, operation, maintenance, or inspection must be performed by authorized personnel.

  • Page 128: Forming Device

    MF 64 Forming Device General Description The forming press is use to give a shape to the hot material according to the mold morphology. The heated material is being dragged by the index system into the forming station. Which system to use to make a part depends on the operator’s knowledge, experience and the shape of the parts to be made.

  • Page 129: Swivel Out The Forming Station

    MF 64 Swivel out the forming station The forming station is composed of a welded main structure that can easily be turned out, for easy changes of the mold. At first, unlock the station stop column, until the light turns off, as shown in the figure.
  • Page 130 MF 64 Upper table. Lower table. The 4 rails are locking the tooling of the forming station. You must turn the key on the front of the table and pneumatically unlock the rails. You must install the mold with “T” inserts to keep the tooling on the table.
  • Page 131 MF 64 “T” insert “T” insert under the face of mold Lift the lower part of the mold and when the “T” inserts are inside the rails, push the lower part of the mold just against the positioning blocks (if provided) at the end of rails.
  • Page 132 MF 64 Water inlet and outlet port upper table. Water inlet and outlet port lower table. Put the upper part of mold on the upper Forming Table Turn the key to unlock the upper locking system. Push upper part of mold inside table and center it.
  • Page 133 MF 64 Close the forming station and lock the forming press. First, tighten the screw, and then close the station locking column (reverse procedure to unlocking). Tight the screw to keep the forming station inside the machine. Make sure that the forming...

  • Page 134: Tables Adjustments

    MF 64 Tables adjustments Note: Refer to general information on the chapter “Touch screen” to understand how it works. Pay attention to adjust the working positions of the forming press without crashing the mold against the rails of index. Perhaps, increase the amount of width of the rails.
  • Page 135 MF 64 The upper and lower toggles are now bent (open position). Upper forming table in open position Once Upper and Lower forming table are open, move upward the Lower forming table by using the jog push button as showed below (from the same page).
  • Page 136 MF 64 If it is possible Move the lower table until the toggle is straight. Lower toggle straight If lower table is lower that the sheet level, move it upward using lower forming table’s adjustment system. You need to be a little bit higher that the sheet level to start. You don’t need to have excessive pressure between the two tables.
  • Page 137 MF 64 Press this button to make lower forming table daylight adjustment Now close Lower forming table until this is aligned with the film. Use this arrows button to adjust lower forming table After adjusting the lower table, go to adjustment the upper forming table with the same procedure.
  • Page 138 MF 64 Push button below to perform movement. Press this button to make upper forming table daylight adjustment Now fine adjust the close position of Upper Forming Table. Move down Upper forming table till both tooling are touching together. Use this arrows button to...
  • Page 139 MF 64 Then move Upper forming table to close position to reach the final position. Next, set the amount of traveling in inches of the upper forming table (from the Forming page press from button layout). Push here for adjust...
  • Page 140 MF 64 Manual mov. speed: Panda: max speed (100%) Turtle: slow speed (20%) Manual movements Push here to change values. NOTE: If the machine is in security exclusion mode, the manual movements are enabled only pushed the reset button at the same time with the arrows for the direction shift.
  • Page 141 MF 64 In this page you can change all parameters according to your needs. Note: Use the manual buttons in manual page to try the air pressure system. Adjust the pressure by turning the regulator in the next picture. Turn clockwise for increase air pressure (Do not exceed required value).

  • Page 142: Automatic Cycle

    MF 64 Automatic Cycle To start the automatic cycle, press the under left button in this page and then enable station one at a time, pressing on the layout (if the stations are enabled, their word will be highlighted yellow).
  • Page 143 MF 64 Note: Don’t adjust the delays too low, you could have components touching the plastic film when it is still in movement. Setting from the page of “timers & counters”. Setting description This column is for delay timers. This column is for work timers.

  • Page 144: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Motor for table R88MK5K020CBS2 Omron movement. Gearbox for MVF 49A P71 B14 ; Bonfiglioli close i=36 positioning adjustment. Spring 2600630320CP Metalwork Cylinders for toggle movement. Valve for mold. 7010001900 Metalwork Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...

  • Page 145: Troubleshooting

    MF 64 Troubleshooting Symptom Probable cause Item to check Countermeasure Interventions mode The final shapes Need more hole in Holes in the Increase number Use a drilling machine are not so defined. the mold. mold. of holes in the to make more holes.

  • Page 146: Safety

    MF 64 Safety Do not remove cover or carter without shutting down the power. Before operating with power, re-install and check every safety system. Installation, operation, maintenance, or inspection must be performed by authorized personnel. Not doing so may result in electric shock or injury.

  • Page 147: Trim Press Device

    MF 64 Trim Press Device General Description Cutting press or trim press is a device that cut the peripheral of the pieces. It is made out of two mobile tables that are going up and down between guides. The table’s movement is provided by a system of servo motors mounted on the upper and lower table.

  • Page 148: Adjustments & Setup

    MF 64 Adjustments & Setup Lift and slide the tool into the rails as shown on the pictures. Cutting die tool Slide here Center the cutting tool and tight it with the set screws provided with the machine. Screws on the rails of upper and lower platen are used to hold cutting die in position.
  • Page 149 MF 64 Note: At this moment, the die tool is no perfectly centered on the masks shapes that arrived from the forming. To adjust the cutting die, we recommend to make sample and to go through the cutting station without cutting the product. With the shapes still inside the rails, it is possible to move the cutting press table movement in jog mode and looking to center the die tool perfectly.
  • Page 150 Note: Encoder increasing length is in the same direction than the index film travelling in automatic cycle. Note: At OMG, the internal convention regarding the direction of index movement is that the values will increase with the forward direction of the index.
  • Page 151 MF 64 Pay attention to the working position adjustment of the cutting press, not to hit any of the surrounding devices. Not doing so may result in injuries or damage to the product. For safety reasons, when recalling a recipe, the press adjustment need to made with automatic button of the adjustment page on the touch screen.
  • Page 152 MF 64 When all parameters have been set, both lower and upper platen can be cycle in manual mode, using the red button indicated below. Single cutting cycle Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 151 a 179...

  • Page 153: Automatic Cycle

    MF 64 Automatic Cycle For start the automatic cycle press the under left button in this page and then enable station one at a time, pressing on the layout (if the stations are enabled, their word will be highlighted yellow).
  • Page 154 MF 64 Setting description Delay timers Work timer Set heater temperature Machine state Turn the power on if cutting die needs to be heated. Die cut heating Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 153 a 179...
  • Page 155 MF 64 heating elements. Die cut heating Plate. Die cut heating thermocouple (type K). Pay attention when using press, otherwise it will crash with non-woven film not formed properly. Not doing so may result in damage. Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com...

  • Page 156: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Motor for R88M-K5K020C- Omron upper and lower table movement. Gear motor for PCE 230 M31 i=475 Minimotor position adjustment. Encoder for E62-CWZ5B Omron position Resolution 2000 P/R regulation control Gear Motor for...

  • Page 157: Troubleshooting

    MF 64 Troubleshooting Symptom Probable cause Item to check Countermeasures Interventions mode The pieces Die cut not good Exchange the die Remove the die. are not The pressure of % torque of Increase the % of Redo setup in cutting...

  • Page 158: Stacker Device

    In the next chart showing, OMG use letters to define which mode the stacker is in to. The choice is made by the operator and proper tooling must be installed regarding which mode is been choose.

  • Page 159: Schematic

    MF 64 Schematic Upper Stacker Upper Motor Conveyor Motor Lower Stacker Stacker Conveyor Lower Motor Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 158 a 179...

  • Page 160: Common Adjustments

    Note: Encoder increasing length is in the same direction than the index film travelling in automatic cycle. Note: At OMG, the internal convention regarding the direction of index movement is that the values will increase with the forward direction of the index.
  • Page 161 MF 64 Pay attention to adjust the working positions of the stacker without crashing it with surrounding devices. Not doing so may result in injuries or mechanical damage. Because of injuries or damage to the product that could occur, when one file is recalled, the stacker adjustment needs to be done manually.
  • Page 162 MF 64 Use this page for settings adjustment. Extraction Open Close Stacking Position position position position Manual mov. speed: Panda: max speed (100%) Turtle: slow speed (20%) Manual movements “Teach in” button Push here to change values. for setting the...
  • Page 163 MF 64 When the stacking counter movement is completed, it is indispensable to extract the piles from the conveyor. For this purpose, there is a system that pushes the piles out of the stacker, and pushes them on conveyor located at the side-exit of the machine.

  • Page 164: Stacker Mode: Type G

    MF 64 Stacker mode: type G This mode is referring to downward stacking, in which the pieces are stacked using conveyor and upperand lower stacker. On the upper stacker is mounted the pusher, on the lower stacker is mounted the web tool locking.
  • Page 165 MF 64 Number of stacking movement left. When the counter finishes, the conveyors empty the stacker magazine. Timers and counter Author: Donato Gavino Murru donato.gavino.murru@omgitaly.com Pag. 164 a 179...
  • Page 166 MF 64 In this page there are timer and counters of the stacker Parameters description Note: the number of stacking movement and discharge must be set on the time & counter page. Set a minimum stacker parking time and choose the number of stacked.

  • Page 167: Automatic Cycle

    MF 64 Automatic Cycle For start the automatic cycle press the under left button in this page and then enable station one at a time, pressing on the layout (if the stations are enabled, their word will be highlighted yellow).
  • Page 168 MF 64 Start setting Setting description Work timer Delay timers Machine state Note: Don’t adjust the delay too short (from the times &counters page). This can cause mechanical damage if device cycles when the index is still active. Check pictures below.

  • Page 169: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Motor for R88MK4K030C-BS2 Omron upper, lower and conveyor stacker movement Gear Motor for RC00134 MC2 i=2 Unimec lower table movement BN63B2 – External Motor Bonfiglioli conveyor cod.830610156 rotation Gear motor for...

  • Page 170: Troubleshooting

    MF 64 Troubleshooting Symptom Probable cause Item to check Countermeasur Interventions mode The final Trip of stacking not The sides of Increase the trip Adjust on the axis shapes are not sufficient pusher pages of stacker stacked The pieces The shapes are not...

  • Page 171: Scrap Wrap Device

    MF 64 Scrap Wrap Device General Description This device is design to wrap the scrap material that is coming out from the forming process. Usually, after the material is ready to be sent out to the recycling to produce new plastic film rolls. It is engineered to extract the plastic film that is not use from the process and rolling it as a roll following the index paste.

  • Page 172: Adjustments & Setup

    MF 64 Adjustments & Setup Regulate the weights on the two side, front and rear, in relation to the hardness and thickness of the material , and check if these work well by switch “on” the electrical selector By moving the weight from both side, it’s possible to...

  • Page 173: Automatic Cycle

    MF 64 Automatic Cycle Stop the rotation of the device by switch “Off” the electrical selector. For using this device in automatic cycle , put the boundary margin of the scrap material in one wrapping bar. This automatically wrapping the material when the motor is started.

  • Page 174: Main Spare Parts

    MF 64 Main Spare Parts Picture Description Type Supplier Gearmotor MVF 49 F1 P71 B14 Bonfiglioli i=36 Device check 6377681 Omron switch 16915 M Troubleshooting Symptom Probable cause Item to check Countermeasur Interventions mode The material is The control table...

  • Page 175: Safety

    MF 64 Safety Above all don’t introduce the hands inside the wrapping bar; Despite where is a friction for security reason, introducing the hand can make serious problem. Do not remove cover or carter without shut down the power. Before operating with power to put again every security at good work.

  • Page 176: File Save & Open

    MF 64 File Save & Open General Description Every time that you change the mold, it is needed to change the functioning parameters of the machine. All these info can be stored in a memory card. Unscrew and remove the case.

  • Page 177: Saving Function

    MF 64 Saving function The saving function is an operation useful to store recipes of your product inside the plc memory. It becomes easy to recall a recipe from a product that has been already produced with the thermoformer. The stored data are: Settings of the servo drive (positioning, speed, acceleration).
  • Page 178 MF 64 Select Recipe Push to open Then you have to confirm the upload. For delete the loaded recipe press to trash button and confirm in the next pop-up. With this button, it’s possible export the recipes on the usb stick This button open a page in which it’s...
  • Page 179 MF 64 You can find the mold recipe through the folders. Selecting one of three buttons up here (USB key, internal memory, SD), you enter into the dedicated memory. With the arrows you can select the folder or file that you want and the first red send key enters the folder or open the file.

  • Page 180: Work Data Updating

    MF 64 Work data updating If during automatic cycle mode some parameters variations are done to improve thermoforming of the pieces, it is important to update these variations in the recipe. It is to update the mold in working phase. Same procedure than for recording.

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