Formech IMD508 Installation, Operating And Service Manual Download Page 2

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Manual - Formech IMD508

Table Of Content

Safety 4

Specifications 8

Foreword 8

Machine Specifications

Features 8

Noise emissions

Machine storage

Machine transportation, lifting and moving

Installation 10

Electrical connection

Three phase supply

Pneumatic connection

Introduction 11

Operation - Main Menu Fuctions

Powering up

Main Screen Control

Getting started

Control POD Functions

Operation Screen Safety Indicators

Operation - Manual Functions

Control POD Manual Operation Screen

Manual Setup - Heaters

Manual Setup - Table settings

Manual Cycle

Manual Plastic Clamping

Heating 18

Auto-Level 18

Moulding 18

Pre-Stretch 18

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

Summary of Contents for IMD508

Page 1: ...1 IMD508 Installation Operating and Service Manual For Parts Service Technical Assistance North and South America Telephone 312 396 4072 Fax 312 396 4073 High Performance Thermoforming Machine ...

Page 2: ...g started 13 Control POD Functions 13 Operation Screen Safety Indicators 13 Operation Manual Functions 14 Control POD Manual Operation Screen 14 Manual Setup Heaters 16 Manual Setup Table settings 17 Manual Cycle 18 Manual Plastic Clamping 18 Heating 18 Auto Level 18 Moulding 18 Pre Stretch 18 Cooling Release 18 Operation Setup functions for Semi Automatic cycle 19 Semi automatic screen buttons 19...

Page 3: ...op Heater 29 Replacement of Heating elements Bottom Heater 29 Auto Levelling Bottom Heater Safety Sensing 29 Fault Diagnostics Maintenance 30 Vacuum 30 Pneumatics 31 General lubrication 31 Clamp Table Seals 31 Replace a damaged or worn seal 32 Cleaning 32 Service Support 32 Periodic Maintenance 33 Warranty 34 Heating Elements 34 Vacuum System 34 Electrical Schematics Index 35 Parts Listing 53 EC C...

Page 4: ...t high pressures may be present within parts of the pneumatic system even after the supply has been isolated Special care must be taken if any parts have become jammed to ensure that all pressure is removed before attempting a repair 5 Daily repetitive use of this or any other machine may lead to a fatigue and loss of concentration b possible strains Operators should be trained in the use of corre...

Page 5: ...SSISTING THE FORMING PROCESSS AND TOUCHING HOT SURFACES INFRARED RADIATION IS EMITTED BY THE QUARTZ HEATERS ENSURE THAT ANY EXPOSURE TO THIS TYPE OF RADIATION IS SHORT OR COMPLETELY AVOIDED 3 Injury from Compressed Air Pressures up to 100 PSI will be present in large volumes on this machine BE EXTRA CAUTIOUS WHEN DEALING WITH COMPRESSED AIR EVEN AFTER THE MAIN SUPPLY HAS BEEN SHUT OFF DANGEROUS RE...

Page 6: ...t exceeds the operating pressure of pneumatics valve and the machine specification may cause the plastic to be blown into the heaters and to be ignited Periodically monitor and check the condition of the infrared beam sensors ENSURE THE COMPRESSED AIR SUPPLY IS SET TO THE RECOMMENDED LEVEL AND ONLY USE THE HEATER FOR THE HEATING OF VACUUM FORMING PLASTIC MATERIALS RISK OF FIRE AS A RESULT OF HEAT ...

Page 7: ...F SHEET PLASTICS AS PART OF THE VACUUM FORMING PROCESS DO NOT USE THE RELEASE TABLE AIR FUNCTION TO APPLY PRESSURE FOR ANY OTHER MEANS OTHER THAN TO RELEASE THE MOULDING FROM A FITTED MOULD TOOL DO NOT USE THE TABLE VACUUM PORT TO SUPPLY VACUUM FOR ANY OTHER MEANS OTHER THAN TO APPLY VACUUM UNDER A MOULD TOOL AS PART OF THE VACUUM FORMING PROCESS DO NOT USE THE MACHINE TO STACK OR LEAN ITEMS AGINS...

Page 8: ...Air Supply Approx 10 cu ft min 100 psi approx 300l min 6 bar Width 1200mm Depth 2050mm Working height 1430mm Height with Plug assist 3080mm Weight 900Kg Features Semi automatic mode for sheet fed processes Manual Control for Sequence set up sheet fed processes System control PLC with Touch sensitive HMI Automatic sheet levelling Pre stretch Mould release 21 5m3 hr 60Hz Oil pump Air Fan Cooling Ele...

Page 9: ...y Before lifting remove all separate assemblies and leave the heater fixed in its position until positioning at its operating site Remove packaging where it assists with lifting and moving The centre of gravity is approximately at the machine centre Remove fixing blocks and the stand assembly from the crate base Ensure lifting forks pass through the main cabinet Fix the adjustable feet to the base...

Page 10: ...ld be via a lockable shut off valve Ensure that the pneumatic air supply is regulated to 6 BAR or less and is properly filtered lubricated using good quality airline oil A competent person must make compressed air connections If flexible hoses are used it is strongly advised that they are of Nylon canvas or wire reinforced rubber and suitably rated for pressure and temperature The connection hose ...

Page 11: ...totyping or sampling the IMD508 adapts quickly to most needs The Formech IMD508 uses the reliable and robust Wago PLC with Weintek 10 Touch screen user interface Formech have produced high quality functional graphic software to give an easy to use flexible and versatile Thermoforming machine for all forms of industrial and commercial use The IMD508 Software provides for both manual and semi automa...

Page 12: ...e programmed for manual operation Press this button to activate the heater The heater must be ON to use the machine The heater can also be switched off during machine or tooling set up Pump Press this to enable the pump The vacuum pump can be switched off when not required e g during machine or tooling set up Automatic Mode Operate the machine using the semi automatic cycle by selecting a stored p...

Page 13: ...splayed on the touch screen if pressed The button will need to be ma nually reset for normal operations to continue Only use this button in emergency situations AIR This indicator will show if the air supply to the machine is lost The heaters will shut off until air is restored Heating pyrometer option only Guard When the Light guard is broken power is cut to all critical outputs The Blue button o...

Page 14: ...e may be used to keep the plastic level while the heater is forward and until the heater is fully back Clamp Allows movement of the material clamp UP DOWN Heater Zone Settings These buttons allows direct adjustment of the heater zones This may only be performed when the other functions are not in use Heater Drive These buttons control the movement of the heater There are separate buttons for the t...

Page 15: ...l mode the timer counts up This button latches ON when pressed Press again to turn OFF Fans Pressing the fan icon will turn the cooling fans ON 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 ...

Page 16: ...es fitted and the element temperature is fed back to the control system Set a target temperature for each zone as required Temperatures can be set to Fahrenheit or Centigrade press button to select The power of each 2 square element is 125W The top value of each zone is the target temperature the lower value is the actual zone temperature All adjustments are real time so a target value may be set ...

Page 17: ...s stopped Table height setting distances are measured from the underside of the aperture where material is clamped to the table bolster top All values in mm Condition 1 The Mould tool height value is a mandatory setting Condition 2 The Mould height setting must be less than the Table Height setting to maintain the mould below the aperture level Condition 3 If Heater security function is turned OFF...

Page 18: ...will be blown in to the chamber under the heated plastic ensuring the plastic remains level Moulding Send the heater to the back position by pressing the heater button when the plastic is at the correct temperature for moulding When the heater has reached the back limit switch and stopped press both table buttons simultaneously to raise the mould into the plastic Press the vacuum button to apply v...

Page 19: ...button Changes are made immediately Other buttons are detailed below When the semi auto screen is opened the parameter settings for the last used job will show The purpose of the additional buttons is shown below RESET Press this button to return all assemblies to the home position The START button will show START This button will start the auto cycle When pressed the STOP button will show STOP Th...

Page 20: ...nter The number shown in the oval shows the batch counter setting The number shown at the top shows the actual count quantity BACK or RETURN This button will return to the main menu PAUSE This button is a manual over ride to pause the heating stage timer It is essential to monitor this manual intervention to prevent material overheating JUMP Advance This button is a manual over ride to end the hea...

Page 21: ...en Enable the pre stretch by setting the toggle button to ON Set the pre stretch time and the delay time if required by pressing on the time value and using the pop up keypad Set the Plug assist parameters by pressing the Plug button on the Semi Auto screen There are 2 plug stages 1 Mould plug 2 Release plug Enable the function by setting the toggle buttons to ON or OFF as required Set the Plug ti...

Page 22: ...to screen Enable the Cooling function by setting the toggle button to ON Set the fan time and the delay time if required by pressing on the time value and using the pop up keypad 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 Set the Release parameters by pressing the Release b...

Page 23: ...n auto semi auto mode Press the SAVE button to open and load a saved program To save an existing program select the required program and press the 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 ...

Page 24: ...eration to the timings set for the semi auto sequence It may be necessary to run the product in the manual mode first to establish the required time for settings The times for each stage of the process will affect the product produced The time settings can be adjusted while the machine is operating Adjust the set times for optimum performance and monitor the output Simply press the button of a fun...

Page 25: ...retract delay time will maintain the heater in position for a time set 1 5 seconds Value is also set in the Top Heater settings screen The timed bottom heater cycle may be used with this security function OFF but the bottom heater time must be set to 5 second less than the Top heater time to allow the bottom heater to retract before the table rises If the bottom heater time is not set as such then...

Page 26: ... adjusted for example when using thinner or thicker plastics materials to assist with correct clamping Panels will need to be removed when making this adjustment isolate the machine power before removing any cabinet panels Cooling Fan Adjustment The cooling fans may be adjusted to give the correct direction for cooling of the vacuum forming Loosen the nut and screws in the pivot block to rotate an...

Page 27: ... Pyrometer Air Pressure The pyrometer has air cooling to prevent over heat it is important that this air supply is always connected A pressure tank is provided to give the pyrometer air system a short term reserve supply if the main air supply is disconnected 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 sup...

Page 28: ...p frame is properly engaged and the limit switch operated Heater will not come forward Check that clamp and table are down and then plug is up and the carriage is to the right and the limit switches operated Heater The flexible cable chain between the heaters and the control cabinet contain a number of heatproof power and thermocouple cables Due to the continual motion of the heater these may even...

Page 29: ...re every 12 months thereafter Replacement of Heating elements Bottom Heater Bottom heater elements are rated at 230V 125Watts Test and replace in the same method as the top heater Access to the bottom heater is complex due to its position The rear of the bottom heater box would need to be removed and access to the rear of the machine may be required It is recommended that bottom heater servicing i...

Page 30: ...filter mounted on top of the pump should be inspected occasionally and blown clean or replaced Loss of vacuum may be caused by worn or damaged seals around the perimeter of the table These are regarded as a consumable part and should be replaced when signs of wear become apparent Other causes of vacuum loss are loose or damaged flexible hoses and fittings The vacuum tank is fitted with a drain plu...

Page 31: ...ust port Again seal kits can be provided please specify cylinder valve number model when ordering Other problems that solenoid valves may suffer from are 1 Lack of electrical supply Check appropriate circuitry 2 Solenoid has become open circuit Replace with new solenoid 3 Return mechanism jammed or broken Dismantle valve to investigate Replace if required 4 Wet or dirty air supply Check condition ...

Page 32: ...stretch the rubber seal it will contract back to its original size before the glue is dry Cut the ends at 45 degrees Continue this process for all 4 sides of the seal Fill up any gaps in the mitred joints with glue Place masking tape over the mitred corners to help keep them firmly positioned until the glue is dry Leave overnight then remove masking tape and trim any excess glue off with a sharp k...

Page 33: ... Clean Bottom heater glass if fitted X Inspect heating elements for damage and hairline cracks X X Replace clean vacuum pump filtering X X Drain vacuum tank X Lubricate major mechanical assemblies X X Inspect Pneumatics system X Clean Auto level bottom heater safety sensor optics X Check Security of Fan units X X X Full Formech major service routine dependant on utilisation X Areas to be monitored...

Page 34: ...g the elements The heating elements contain a length of resistance wire internally which becomes extremely hot when electricity is applied The wire expands and contracts as it heats and cools Eventually due to the continual expansion and contraction the wire will fracture and a new element will be needed This may take a decade or more Alternatively it could happen as a result of an impact or shock...

Page 35: ...al Schematic 15 PLC OUTPUT 2 Electrical Schematic 16 PLC OUTPUT 3 Electrical Schematic 17 PLC OUTPUT 4 Electrical Schematic 18 PLC OUTPUT 5 Electrical Schematic 19 PLC OUTPUT 6 Electrical Schematic 20 PLC OUTPUT 7 Electrical Schematic 21 PLC OUTPUT 8 Electrical Schematic 22 HIGH VOLTAGE OUTPUT 1 Electrical Schematic 23 HIGH VOLTAGE OUTPUT 2 Electrical Schematic 24 TOP HEATER OUTPUT 1 Electrical Sc...

Page 36: ...Manual Formech IMD508 36 Electrical Schematic 1 2 ...

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Page 53: ...32mm Bottom Heater B M32 90 1 63A Isolator Switch 3Pole CTRL KN 3P 63A 3 MCB 20A CTRL 20A TYPE B 6 MCB 10A CTRL 10A TYPE B 2 MCB 16A CTRL 16A TYPE B 1 MCB 10A 3Pole Type C pump CTRL 10A Triple C 11 20mm Fuse Holder CTRL 37181 4 Fuse 1A Cab Fan 240v OP CTRL PYRO CTRL 20mm fuse 1A 2 Fuse 4A 24vdc CTRL PLC CTRL 20mm fuse 4A 1 Fuse 500mA 24vdc Cab Fan CTRL 20mm fuse 500mA 1 24V SMPSU 10A Din Mounted C...

Page 54: ... 308 1844 5 Reed Switch Pnumo REED FL2 1 Blue Illum Pushbutton POD ZB4 BW36 1 24V LAMP POD 105 102 1 Switch Body 1N O IILLUMINATED POD ZB4 BW061 1 Em Stop Button POD ZB4 BS54 1 Contact block 1N O 1N C POD ZB4 BZ105 1 Estop Legend POD ZBY 9330 1 1 2 to 12mm Push in straight AIR SUPPLY CDPC1204N 1 1 2 Lever ball valve AIR SUPPLY BV 2090 08 1 1 2 regulator filter AUTO DRAIN AIR SUPPLY M CFR60 4W 1 40...

Page 55: ...35500088 1 ISO 1 END PLATE MANIFOLD 35500087 3 ISO 1 5 2 VALVE E S MANIFOLD 54191023 2 ISO 1 5 3 VALVE W1 MANIFOLD 54191028 4 3 8 PLASTIC SILENCER MANIFOLD 34600408 7 Sol Pilots for 5 3 above MANIFOLD 18900001D2 8 Size 22 Connector MANIFOLD 88122405 24VDC 2 Cylinder 50bore x 600mm TH G453A5SK600A00 2 Speed Controller 1 4 to 8mm STRIGHT BH CDNSS0802 4 Speed Controller 1 4 to 8mm ELBOW TH clamp V CD...

Page 56: ...t 5 Silicone Seal Strip 20mm x 4mm MF SE515 20X4 5 Silicone Seal Strip 12mm x 8mm MF SE515 12X8 2 Door key catch 2 elect Elect 450 9955 1 Key catch Elect 341 0236 6 Hinge Elect 702 7831 4 FOOT M16 X 100 MF 4907 2 C IMD508 Major Component Parts Options 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 se...

Page 57: ... Number Date of Manufacture 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 Significant harmonised standards applied EN ISO 12100 2010 EN ISO13849 1 2006 EN 60204 1 2006 EN 12409 2008 ______________________________________________________ Signed Date Name Paul Vukovich Position Managin...

Page 58: ...0 1582 469 646 spares formech com For Parts Service Technical Assistance North and 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 ...

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