Formech 1372 Installation, Operating And Service Manual

1

1372

Installation, Operating and Service Manual

.

.

.

For Parts, Service & Technical Assistance

Telephone: [phone]

Fax: [phone]

Large Format Vacuum

Forming Machine

Table Of Content

Safety 3

Introduction 7

Specifications 9

Foreword 9
Noise emissions 9
Machine storage 9
Machine transportation, lifting and moving 9

Installation 10

Electrical connection 10
Phase Connections / Motor Rotation 10
Pneumatic connection 11
Heat Guard assembly and fitting of the stabiliser / support arrangement 11
Assembly of the control POD 11
Counterbalance arms and weights 12
Cooling System 12
Using the Cooling System 12

Operation Mode 13

Touch screen arrangement and operation 13

Job Editing Mode 17

Heater Settings 21

1372 - Zone Layout 21
1372 Heater element power arrangement 21
Heating Zone Control and Adjustment 21

Other Controls and user adjustments 22

Table Speed adjustment 22
Table Height Adjustment 22
Clamp Frame rear spring adjustment 23
Clamp Frame front clamp adjustment 23
Counterweight adjustment, loading and unloading 23
Touch screen control POD position 23
Fixing mould tools 24

Operating Procedure 25

Operating Techniques 26

Heaters 26
Bubble moulding 26

Mould Tools 27

Plastics 28

Post Forming Operations 28

After forming 28
Trimming 28

For ming Difficulties 29

Warranty 30

Clamp Seals 30
Heating elements 30
Vacuum system 30

Service & Repair 31

Electrical 31
Heater 31
Replacing a heating element 32
Auto-levelling system 32
Vacuum 33
Vacuum system 33
Pneumatics 34
Table Cylinder Maintenance 34
Clamp & table seals 35
Panel seals 35
Cleaning 36
Lubrication 36

Electrical Circuit information 37

Overview 37
Interlocking devices 37

EC Certificate 45

Manual - Formech 1372

3

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.

1) The electrical supply to the machine must be of adequate capacity. Wiring must be to local regulations
and carried out by a suitably qualifi ed technician. THIS MACHINE MUST BE EARTHED IN ACCORDANCE WITH
LOCAL REGULATIONS.

2) Ensure that the pneumatic air supply is regulated to 6 BAR or less and is properly fi ltered & lubricated using
a good quality airline oil. A competent person must make compressed air connections.

3) Do not operate the machine until you have been trained and are fully conversant with it. Read and
understand all of this User Manual. Users of this machine should complete regular competence tests.

4) Never remove any panels unless both the electrical and pneumatic supplies have been isolated.
Never remove any warning labels from the machine. It is important to understand that 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 correct lifting techniques in order to minimise these
effects.

6) When servicing the machine care must be taken to prop any heavy moving parts. This refers particularly
to the mould table, clamping frame and counter balance weights. Always restrict movement of these parts
before entering any part of the machine to prevent possible injury.

7) Always let the machine cool down before attempting to work on it. Some parts of the heater and heat
shield become extremely hot during operation.

8) Only use the machine for vacuum forming and blow moulding of plastic. It is not intended for any other
purpose.

9) Ensure that the area you are working in is properly ventilated and that you are aware of the potential
hazards from the plastics you are forming.

10) Ensure that the area surrounding the machine is clean and frequently cleared of fi nished product and any
waste.

11) This machine is fi tted with a dry running vacuum pump. Do not lubricate. Do not allow any liquid to enter
the vacuum system. Severe damage may be caused if the above is not observed.

Manual - Formech 1372

4

Safety

It is vital that any person using this machine and the person(s) responsible for the health & safety is
made fully aware of the potential hazards that could arise from the use and misuse.

These can be broadly categorised as: -

1. Electric Shock.

This machine uses Voltages up to 415V.

NEVER ATTEMPT ANY REPAIR UNLESS THE ELECTRICAL SUPPLY HAS BEEN LOCKED IN THE OFF POSITION.
ONLY SWITCH ON WHEN ALL COVERS & GUARDS HAVE BEEN REPLACED.

ONLY A QUALIFIED ELECTRICAL TECHNICIAN MAY WORK ON ANY PARTS CARRYING MAINS VOLTAGE
AND SHOULD BE RESPONSIBLE FOR ENSURING THAT THE MACHINE IS IN A SAFE CONDITION BEFORE
ALLOWING SERVICES TO BE RESTORED.

2. Burning.

Parts of this machine reach temperatures in excess of 300°C over large areas.

WAIT UNTIL THE MACHINE HAS COOLED DOWN BEFORE SERVICE WORK COMMENCES.

SPECIAL PRECAUTIONS MUST BE TAKEN TO ENSURE THAT ONLY THE MACHINE OPERATOR IS IN THE
OPERATING AREA DURING USE.

USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS GLOVES WHEN TESTING THE HEATED PLASTIC,
HANDLING HOT VACUUM FORMED PARTS, MANUALLY ASSISTING 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 RESIDUAL PRESSURE MAY STILL BE PRESENT WITHIN THE SYSTEM.

4. Toxic Fume Inhalation.

When large sheets of plastic are heated fumes will be given off.
ENSURE THAT THE MACHINE IS POSITIONED IN AN ADEQUATELY VENTILATED PLACE. ASSESS THE RISKS
OF THE MATERIALS TO BE FORMED PRIOR TO USE.

5. Injury from Moving Parts.

Where pneumatics components are used to power moving parts there is a risk of personal injury.
NEVER REMOVE ANY PANEL OR ATTEMPT ANY REPAIR UNLESS THE COMPRESSED AIR SUPPLY AND THE
ELECTRIC SUPPLY HAS BEEN DISCONNECTED.
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.

HEALTH & SAFETY - Hazards specifi c to this machine.

Manual - Formech 1372

5

HEALTH & SAFETY - Hazards specifi c to this machine.

Safety

6. Injury from Trapping.

There is a risk of trapping fi ngers and hands when loading mould tools. Ensure appropriate care is taken to
prevent trapping and use suitable personal protection. Care is required when operating the clamping frame to
ensure that fi ngers or hands are not trapped.
Keep hands clear of the heater rails when pulling the heater forwards.

7. Lifting, Reaching and Stretching.

TAKE CARE WITH LIFTING REACHING AND STRETCHING WHEN PERFORMING THE FOLLOWING ACTIVITIES:

-Operating the manual heater, the loading of materials and unloading of plastic formings.

-Applying manual assistance to formings during vacuum.

-Drilling holes and trimming of mouldings on the machine after forming.

-The fi tting and loading of mould tools.

-Loading and fi tting of reducing plates and frames.

-Fitting and adjustment of Fans.

-Replacement and maintenance of top frame and table seals.

ENSURE THAT LOCAL LIFTING AND HANDLING PROCEDURES ARE APPLIED AND MONITORED BY A PERSON
RESPONSIBLE FOR HEALTH AND SAFETY.

8. Fire.

The sheet auto-levelling system allows the level of heated plastic to be kept constant. There is a risk that
failure of the level sensors due to misuse of heaters OR the setting of the compressed air supply to a level that
exceeds the operating pressure of pneumatics valve and the machine specifi cation 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 AND PLASTICS PRESENTS AN EMERGENCY SITUATION. ENSURE FIRE
SAFETY TRAINING IS PERFORMED & CONTROLLED.

IT IS ESSENTIAL TO HAVE FIREFIGHTING EQUIPMENT AVAILABLE AT OR NEAR THE MACHINE. USE DRY
POWDER (BLUE) OR CARBON DIOXIDE (BLACK) FIRE EXTINGUISHERS.

9. Airborne Particles.

Particles present in the working area may become airborne during the use of the fan cooling system, when
using an airline to blow onto plastics and when the release function is operated without tooling fi tted.

ENSURE THAT THE DUST, PARTICLES AND DEBRIS IN THE WORKING AREA ARE KEPT TO A MINIMUM.
ENSURE THAT SUITABLE EYE PROTECTION IS WORN.

10. Working at Height.

When installing the fan cooling system, it is necessary to work at an appropriate height.
Ensure that adequate safety precautions are taken to prevent falling from height and that suitable, stable and
secure equipment is used to support your weight when working at height. 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 1372

6

HEALTH & SAFETY - Hazards specifi c to this machine.

Safety

11. Prohibited Uses

DO NOT USE THIS MACHINE FOR ANY PURPOSES OTHER THAN THE VACUUM FORMING AND BLOW
MOULDING OF PLASTICS SHEET.

DO NOT USE THE HEATER TO APPLY HEAT TO ANY MATERIAL OTHER THAN PLASTIC SHEET AS PART OF
THE VACUUM FORMING PROCESS SUCH AS: FOOD PRODUCTS, ALL TYPES OF PARTICLES, POWDER, DUST,
ALL TYPES OF LIQUID, WOOD, PAPER, METALS AND ANY FORMS OF COMBUSTABLE MATERIALS.

DO NOT USE THE TABLE MECHANISM TO CLAMP, COMPRESS, FOLD OR APPLY FORCE TO ANY ITEM UNDER
ANY CIRCUMSTANCES.

DO NOT USE THE CLAMPING FRAME TO CLAMP COMPRESS, FOLD OR APPLY FORCE TO ANY ITEM OTHER
THAN THE CLAMPING OF 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 ALLOW OTHER PERSONS WITHIN 1 METRE (39 INCHES) OF THE TABLE / APERTURE TRAP POINT
WHEN OPERATING THE TABLE USING THE TWO HANDED CONTROL TABLE LIFT FUNCTION.

DO NOT BLOCK THE PUMP EXHAUST PORT ON THE REAR OF THE MACHINE AND DO NOT USE THIS
PRESSURE OUTLET TO APPLY PRESSURE FOR ANY OTHER PURPOSE.

DO NOT USE THE TOP OF THE HEATER OR TOP OF THE HEATER GUARD TO STACK PLASTICS OR OTHER
MATERIALS.

DO NOT USE THE UNDERSIDE OF THE REAR OF THE MACHINE TO STORE ANY ITEM(S).

DO NOT USE THE MACHINE TO STACK OR LEAN ITEMS AGAINST THE SIDES.

DO NOT USE THE FAN OUTPUTS TO APPLY AIRFLOW FOR ANY OTHER PURPOSE OTHER THAN THE
COOLING OF VACUUM FORMINGS AS PART OF THE VACUUM FORMING OR BLOW MOULDING PROCESS.

DO NOT OBSTRUCT THE HEATER TRANSORT WITH ANY ITEM OR USE THE TRANSPORT WHEELS TO CUT
OR FORM ANY ITEM OR MATERIAL.

DO NOT USE ANY OTHER PART OF THE HEATER TO MOVE THE HEATER FORWARDS AND BACKWARDS
OTHER THAN THE HEATER HANDLE.

DO NOT USE THE FAN GANTRY TO HANG ANY ITEM.

DO NOT MOUNT THE FAN POSTS ON THE UNDER SIDE OF THE FAN GANTRY

DO NOT REMOVE THE SIDE PANELS OF THIS MACHINE TO USE THE PNEUMATIC CYLINDER TO CUT,
COMPRESS, BEND OR FORM ANY ITEM.

DO NOT USE OR MODIFY THE ELECTRICAL POWER IN THE CONTROL PANEL TO SUPPLY ANY OTHER
DEVICE OR TO APPLY MODIFICATIONS TO THE MACHINE OR ITS FUNCTIONS.

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 1372

7

Introduction

The Formech 1372 is a highly versatile, manually operated Vacuum Forming Machine that will produce
high definition mouldings in up to 6mm thick material. It is intended for use only for the Vacuum forming of
plastics components and for the blow moulding of heated plastics.

The Formech 1372 incorporates the following features:

• Easy to use graphical touch screen with single screen forming cycle operation and 10 job storage
facility.

• Powerful quartz heaters PLC controlled in 15 heating zones.

• Heater power level standby feature allowing energy saving when heater is in rear position.

• Heater safety shutoff after idle period

• A powerful ltered dry rotary vane vacuum pump.

• Reliable and robust PLC control system & touch screen.

• Vacuum gauge indication.

• The machine is tted with an auto-level facility, which detects a droop in the sheet of plastic

resulting from softening during its heat cycle. Air is blown into the chamber beneath the plastic
keeping the sheet level until it is ready to be formed.

• A powerful compressed air blow pre-stretch facility.

• A pneumatically powered scissor table incorporating 2 handed manual control allowing easy and

safe use of heavy moulds. Table speed can be adjusted by externally mounted table speed controls.

• An easily adjustable table height facility to assist performance with shallow mouldings.

• A powerful compressed air blow facility to release the moulding from the tool.

• The 1372 is ideal for prototype development work whilst also quite capable of small and large

production runs.

• The machine has been designed to be highly adaptable and functions such as changing a mould,

or fitting reducing windows (which allow smaller sheets to be used) can be carried out in the
minimum amount of time.

• Optional powerful fan cooling system.

This manual is the original user instructions for the Formech 1372. It informs the user on machine safety,
assembly, operation and maintenance. It also provides an introduction into vacuum forming with some
useful advice on mould making and post forming processes. If you would like a more comprehensive guide
to the vacuum forming process then please visit the ‘support’ and ‘about’ section of the Formech web page.

Manual - Formech 1372

8

Introduction

1- Heater
2- Clamp frame handle
3- Toggle clamps
4- Mitsubishi touch screen
5- ‘Table Up’ control buttons
6- Table adjustment (depth of draw)
7- Heater handle
8- Heater Guard
9- Counter balance weights
10- Self-adjusting clamp springs
11- Control box with main switch
12- Heater rear supports

1372

Manual - Formech 1372

9

Specifications

Foreword

Please read this manual thoroughly before attempting to install or use this 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.

Specifications

1372

Forming area: 1330mm x 620mm. Depth: 1820mm

Sheet Size: Nominal 1372mm x 660mm

Material thickness 0.25mm min. 6.0mm max

Electrical
Power - 17kW - Supply 380-415V, 5 wire, 3 phase + Neutral + earth, 50Hz
Power - 17kW - Supply 208-230V, 4 wire, 3 phase + earth, 60Hz (North America)

Width: 1820mm Length:2100mm Height:1200mm Weight: 600Kg

Noise emissions

Noise emissions on the Formech 1372 are less than 70dB(A).

Machine storage

The Formech 1372 must be stored in a dry environment.

Machine transportation, lifting and moving

The Formech 1372 is prepared for transportation with the heater secured forwards with counterweights and
accessories situated at the front of the machine where possible.

The weight of the packaged machine is towards the front.
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 machine must be lifted from the front taking particular care to avoid damage to the front clamping
frame and control pod.

The centre of gravity is at a point centre - rear of the main cabinet when viewed from the front.
Ensure lifting forks pass through to the rear of the main cabinet and to the rear frame.

Ensure that local lifting and handling procedures are applied and monitored

by a person responsible for health and safety.

Manual - Formech 1372

10

Installation

The machine should be sited on a level concrete fl oor. Dusty or draughty areas will compromise machine
performance but it is important to allow enough space (750mm) around the machine to allow access
into the various panels and to ensure a good airfl ow to prevent overheating. During all of the following
installation ensure that the power supply is properly isolated.

Electrical connection

An electric supply of correct voltage, current & frequency is required. An isolating switch with facility to be
locked in 'OFF' position and capable of handling full current should be wall mounted, within easy reach of
the operator.

380-415V Three phase supply
Using 3 phases, Neutral and Earth connection STAR confi guration. 3P, N & E

The major current consuming devices within this machine are 230V single phase. However, in order to
balance the load to electricity generator's requirements, each phase of a standard three-phase supply
should be connected to the L1 L2 & L3 of the machine. A neutral wire of full load capacity is required in this
case.

208-230V Three phase supply
Using 3 phases and earth connection – Delta confi guration. 3P & E

Again the major current consuming devices are 230V single phase. Therefore on 230V delta confi gurations
these devices are wired by using two 120V phases hence using alternate phases to balance the load across
three phases. It is therefore important to allow for this additional loading on the supply wiring.

Important notice on 3 phase & Neutral connections

To p revent damage of components it is highly important to check that the three phase and neutral
connections are correct. The machine colours for wiring are as follows:

Brown L1 - Phase 1
Black L2 - Phase 2
Grey L3 - Phase 3
Blue Neutral
Green/Yellow Earth or Ground

After making connections to the isolator switch in the rear cabinet it is essential to verify that the phases and
neutral connections are terminated correctly. The three phases must be connected to the connections L1, L2
& L3. The Blue neutral connections must be connected to the terminal labelled N.

Verify these connections using a volt-meter / multi-meter by measuring the voltage potential between the

Neutral and each phase in turn. The voltage between each phase and the neutral should measure 220 –
240V ac. Once this is confi rmed the Electrical box cover may be fi tted and the isolator switch turned on.

Phase Connections / Motor Rotation

For all electrical connections the pump rotation direction is important. After switching the machine
on press the Vacuum button on the operation screen and check that vacuum is present at the
hole in the centre of the table. If there is no vacuum or if pressure is present then reverse 2 of
the phase connections.

THIS MACHINE MUST BE EARTHED

For a

Manual - Formech 1372

11

Installation

The 1372 must be installed and commissioned by a Formech qualifi ed technician.

Pneumatic connection

If the air supply is insuffi cient the performance of the machine will be compromised.
The connection to the machine should be via a lockable shut off valve.

Ensure that the pneumatic air supply is regulated to 6 BAR or less and is properly fi ltered & lubricated using
good quality airline oil. A competent person must make compressed air connections.

If fl exible 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 size should be 12mm diameter.Threaded

fi ttings are BSP. Maximum airline pressure must not exceed 6BAR or 80 PSI.

Heat Guard assembly and fi tting of the stabiliser / support arrangement

The Heater Guard is attached to the rear rails and upper support bar. This machine may be supplied with
the heater stabiliser / support system fi tted. Where this is not the case assemble the support system and
heater guard as follows:

ENSURE THAT LOCAL LIFTING AND HANDLING PROCEDURES ARE APPLIED AND MONITORED BY
A PERSON RESPONSIBLE FOR HEALTH AND SAFETY.

Fit the bottom left and right support triangles with the angle returns facing inwards.

The heater guard assembly will be separate. The vertical support struts are fi tted to the upper support bar at
the back of the heater guard. The rear heater rails are also fi tted to the heater guard. The rear rails need to
be connected to the front rails using the rail link bar.

The rail link fi xings will be attached to the links. Remove these 2 screws from each side and retain ready for
the fi xing of the heater guard and rails. Mount the assembly, you may require up to 4 persons to lift the
assembly in place. Fit the rail link screws and nuts with washers. Do not fully tighten until the rails / guard
has been levelled.

Support the assembly until the support struts are attached to the bottom horizontal support bar.
Slide the bottom horizontal support bar through the bottom of the support struts and fi x the ends to the
back of the support triangles using the fi xings supplied. See item 8 & 12 – general arrangement.

The heater may need to be levelled although it is likely that the factory settings may be adequate.

To a djust the level so that the heater rails are completely straight remove the covers from the vertical
supports and adjust the height as required.

Adjust the rear triangle levelling screws as required. Fully tighten the rail link bar fi xings and check the level
again. Readjust as required.

Lift and position the heater shield in position on the rear heater rails and fi t the retaining bracket
Ensure that that all fi xings are tight.

Assembly of the control POD

Where the 1372 is delivered in a packaging crate, the control pod may be rotated or removed.

Remove the three fi xing screws from their fi xing point at the front RHS corner of the machine, rotate the POD
and refi t the 3 screws to allow the POD to be at a suitable angle.

Ensure the rubber seal is located in the POD stand and the fi xings are tight.

DO NOT LEAN ON THE POD.

If t

The connection to the machine should be via a lockable shut off valve.

Manual - Formech 1372

12

Counterbalance arms and weights

The counterbalance arm assembly is permanently attached to the clamp. Individual weights may be fitted
to each arm with a bar weight at the back end to be set in position to balance the clamp frame.

Weights are easily adjusted by loosening the screw with a 13mm spanner or socket. ENSURE SCREWS ARE
LOCKED TIGHT.

Adjustment may be required where a reducing window is fitted. Adjust the weights so that the clamp frame
is balance.

Set the weights so that the clamping frame is balanced at a suitable height.

COUNTERWEIGHTS ARE HEAVY ITEMS AND HENCE CARE MUST BE TAKEN TO PREVENT TRAPPING OF
FINGERS.

TAKE CARE WHEN ASSEMBLING, LOADING AND UNLOADING COUNTERWEIGHT. HEAVY ITEMS CAN
CAUSE CRUSHING IF MISSHANDLED, MISSUSED OR IF DROPPED.

WHEN LOADING AND UNLOADING COUNTERWEIGHTS ALWAYS ENSURE THE END STOP LOCKING SPLIT
PIN AND WASHER IS REPLACED AT THE END OF THE COUNTERWEIGHT ARM.

Cooling System

Attaching the Cooling System;

1 - Fit the gantry sides to the two heater rails at the boltholes on either side of the moulding area with the
four nuts and screws supplied.

2 - Fit the Gantry cross member to the top of the gantry sides with the four nuts and bolts supplied. The fan
mounting posts should be attached to the cross member so that the fan can be positioned behind the cross
member directing the fan draft forward and away from the heater.

3 - The swivel block should be supplied fitted to the fan unit. Slide this onto the cross member post and
tighten the grub screws and locking nuts. Never fit the fan posts on the underside of the cross member as
the fan may fall and cause injury. Mounting of the fans is a 2 person operation, precautions must be taken
when lifting and working at heights.

4 - Adjust the fan unit to the required position and tighten all the grub screws and lock nuts.

Using the Cooling System

The corresponding FAN button on the touch screen can operate the cooling fan at the appropriate time to
cool the moulding. The button changes colour when operated ON/OFF. It is worth considering the position
of the fan mounting to achieve good and consistent results with different mouldings.

Installation

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.

Operating procedures for this machine must be assessed, monitored and controlled

by the person responsible for health and safety.

Manual - Formech 1372

13

Operation Mode

Touch screen arrangement and operation

The main functions of the Formech 1372 are operated from the touch screen.

START:

START DEFAULT: Allows you to start

a vacuum forming process using the
default settings.

LOAD: Allows you to load a program
already saved in the memory.

HOME SCREEN

NEW/EDIT: Allows you to create a new

program. See section referring to Job
Editing Mode.

START: Allows you to start a vacuum
forming process, using the default
settings or one of your saved programs.

HEATERS: Turns the heaters ON. Button
Changes to Green when enabled.
Note that you have to press this button
to start a vacuum forming process.

Question mark: Shows the meaning of
all icons.

Manual - Formech 1372

14

Operation Mode

Operation mode

MAIN OPERATION SCREEN

Once you have chosen the
program you want to use, or
loaded the default settings, this
screen will open.
This gives you access to the
machine function of the
vacuum forming process.
(See page 15 dealing with Icon
descriptions)
The arrows guide the user
through the main 5 machine
functions of the forming cycle.
Remain on this screen when
performing continuous cycles.
Do not press fi nish unless you
wish to exit this screen.

LOAD

The LOAD button allows you to
choose a Job already saved in
the 10 memories available.

Press the screen for the Job that
is required to load the saved
settings.

The main operation screen will
load.

Manual - Formech 1372

15

Operation Mode

Heater timer

Shows the heater time. Press this to adjust the heater power & standby settings. Changes can
be saved or press to return to the main operation screen.

Pre-Stretch

This operation will turn on the compressed air valve to allow air to fl ow into the sealed
cabinet. This function does not latch. Press & hold to run.
The Icon will change colour when pressed.

Vacuum

This operation will latch the pump and the vacuum valve on to apply vacuum to the table
hole. The Icon will change colour when pressed.

Fan timer

This operation will latch the fan on for the time set for loaded settings. The fans will turn off
when the time has elapsed. Pressing again will restart the timer. The timer setting can be
changed in edit mode. The Icon will change colour when pressed. Press again at any time to
stop the fan.

Release

This operation will apply compressed air to the table hole. This function does not latch but
will unlatch the vacuum. Press & hold to run.
The Icon will change colour when pressed.

Table down

This operation will drive the table down. This function does not latch so it can be used to
lower the table in steps if required.
Also see section regarding the setting of table speed.

Save

When in the operation screen this allows the user to save the program or the times just used
onto the memory and store as a new job. This function opens the settings screen. Also used
on settings screens to save memory changes.

Finish

This operation will exit the main operation screen and open the Home screen.

Auto-level

This operation enables the beam sensor to provide automatic levelling of the sheet level
during heating. Compressed air is applied under the heated sheet when the beam is broken.
This button latches and may be unlatched at any time.









Manual - Formech 1372

16

Operation Mode

Note that when a feature is activated, the icon will go green , as shown below:

Vacuum activated

Auto-level activated

To bring the table up, press both ‘Table up’ buttons simultaneously.

These are located on the front panel of the machine:





Table buttons

Manual - Formech 1372

17

NEW/EDIT

This screen will open when you press
NEW/EDIT on the home screen.

Either press:

NEW: The settings screen will open.

Or

EDIT: The memory screen will open.

MEMORY

This screen will open if you press EDIT
above.
Select the stored job you wish to edit.
The settings screen will open

SETTINGS

There are six icons on this screen:

Zones
Standby
Autolevel
Heat time
Fan time
Save / Exit

Each setting function allows
editing of memory parameters.
Press the AUTO-LEVEL to enable.
The button will change to green.
See the following for other editing
functions

Job Editing Mode

Manual - Formech 1372

18

Job Editing Mode

ZONES

Pressing any zone will open the SET
ZONE HEAT LEVEL % screen to allow
adjustment in 5% steps.

Press the Back button to return to the
settings screen

SET ZONE HEAT LEVEL%

Press the required heat level button
to set the required heat level &
return to the ZONES screen.
Repeat with the remaining zones to
achieve the heat profi le required.

Manual - Formech 1372

19

Job Editing Mode

STANDBY HEAT %

Press set number to adjust using the
pop up keypad.

Press to return to the setting
screen.

The benefi t of quartz heaters is that they heat
up almost instantly compared to ceramic
heaters.
The standby feature is activated when the
heaters are in the rear position between cycles
and the power to the heaters is reduced to an
idling mode, which results in reduced power
consumption. As soon as the heaters are
brought forward they very quickly reach full
power for the next machine cycle.

SET HEAT TIMES IN SECONDS

Press set number to adjust using the
pop up keypad.

Press to return to the setting
screen

SET FAN RUN TIME IN SECONDS

Press set number to adjust using the
pop up keypad.

Press to return to the setting
screen

Manual - Formech 1372

20

Job Editing Mode

SAVE OR EXIT

Press this button when changes are
complete. The SAVE CHANGES window
will open
Press √ to open the select job memory
screen.
Press X to return to the main menu
without saving changes.

Saving to memory - Select Job memory
screen

Select the memory job name to save.
The parameter review screen will open

Saving to memory - parameter
review screen:

This fi nal screen will allow the user
to review the saved settings before
saving to memory.
The set values may be edited at this
stage by pressing on the parameter
value shown. Re-adjust as required
using the pop-up keypad.
The Job name may also be edited at
this stage by pressing on the name
box and using a pop up key pad.
Press the black button with Arrow to
save.
The Home menu will open & saving is
complete.

Manual - Formech 1372

21

Heater Settings

9 3 15

7 6 5 4 1 10 11 12 13

8 2 14

Front

1372 - Zone Layout

400W 300W 300W 300W 300W 300W 300W 300W 300W 300W 400W

300W 250W 250W 250W 250W 250W 250W 250W 250W 250W 300W

300W 250W 250W 250W 250W 250W 250W 250W 250W 250W 300W

300W 250W 250W 250W 250W 250W 250W 250W 250W 250W 300W

400W 300W 300W 300W 300W 300W 300W 300W 300W 300W 400W

Element power in Watts Front

1372 Heater element power arrangement

Heating Zone Control and Adjustment

The heating zone control is adjusted by the touch screen. When adjusted this will allow the heat of the
corresponding heater zone to be set. Reduce or increase the percentage to each zone to set the required
heater power level and review as necessary.

See also the section regarding Operating Techniques for heater settings.

Manual - Formech 1372

22

Other Controls and user adjustments

Table Speed adjustment

Two table speed adjustments are situated on the lower right hand side of the rear panel. (when viewed from
the rear of the machine).
These are fl ow regulators to adjust the air that is exhausted from the table pneumatic cylinder. Inserting a
6mm hexagon key in the centre and rotating clockwise or anti-clockwise will adjust them.
Adjust the regulator clockwise to reduce the air exhaust – to reduce the cylinder / table speed.
Adjust the regulator anti-clockwise to increase the air exhaust – to increase the cylinder / table speed.
The top fl ow regulator will adjust the table UP speed.
The lower fl ow regulator will adjust the table DOWN speed.

TAKE CARE WHEN REACHING TO THE BACK OF THE MACHINE. THERE MAY BE VERY HOT SURFACES IN
THIS AREA.

Table Height Adjustment

The lower stop point of the table may be adjusted easily from the outside of the machine.
The adjustment is performed by adjusting the table stop shaft situated below the left hand side panel.
For convenience the shaft has a 22mm hexagon end. A rotary handle is supplied with the machine to assist
with the manual adjustment. Always make adjustments with the table in the raised position.
Rotate the handle clockwise to lower the table height.
Rotate the handle anti-clockwise to raise the table height.



Compressed air

inlet

Manual - Formech 1372

23

Clamp Frame rear spring adjustment

The clamp frame is spring loaded at the rear. The spring are locked in place with 2 M10 nuts. The loading of
the springs may need to be adjusted, for example, when using thinner or thicker plastics materials to assist
clamping or when a reducing place is fitted.
To adjust the spring loading loosen the lower Nut for each spring and adjust the upper nut to suit. Tighten
the lower nut to lock against the upper nut.
TAKE CARE WHEN REACHING TO THE BACK OF THE MACHINE. THERE MAY BE VERY HOT SURFACES IN
THIS AREA.

Clamp Frame front clamp adjustment

The front material clamps are manually adjustable. Loosen the black thumb screw nut at the base to allow
appropriate adjustment of the top nut. Tighten the lower thumb screw and test that the setting is correct.
Readjust as required. Adjustment is required for varying material thickness and for reducing plates.

Counterweight adjustment, loading and unloading

Counterweights are fitted to the rear of the clamp frame.

There are 2 counterweight arms. Each arm has 2 counterweights. Additional weights are required for
machines fitted with reducing frames.

To adjust the position of the weight, hold the weight to be adjusted and loosen the retaining screw. The
weight will slide along the counterweight arm to the position required. Ensure the locking screw is tightened
after adjusting the counterweight position.

TAKE CARE WHEN REACHING TO THE BACK OF THE MACHINE. THERE MAY BE VERY HOT SURFACES IN
THIS AREA.

COUNTERWEIGHTS ARE HEAVY ITEMS AND HENCE CARE MUST BE TAKEN TO PREVENT TRAPPING OF
FINGERS.

TAKE CARE WHEN ASSEMBLING, LOADING AND UNLOADING COUNTERWEIGHT. HEAVY ITEMS CAN
CAUSE CRUSHING IF MISSHANDLED, MISSUSED OR IF DROPPED.

WHEN LOADING AND UNLOADING COUNTERWEIGHTS ALWAYS ENSURE THE LOCKING SPLIT PIN AND
WASHER IS REPLACED AT THE END OF THE COUNTERWEIGHT ARM.

Touch screen control POD position

The rotational angle of the touch screen POD is adjustable. Remove the 3 retaining screws, rotate to align
the adjacent holes and achieve the new angle required, refit the screws and tighten.

Other Controls and user adjustments

Manual - Formech 1372

24

Other Controls and user adjustments

Fixing mould tools

There are four mould tool fi xing points at each corner of the table to accept M6 Screws. Use these to fi t full
sized mould tool mounting boards, maximum thickness 10mm. Thicker tool mounting may be used if the
boards are reduced in size allowing a gap between the board and aperture or if the edges are chamfered.

Further holes may be drilled and tapped for M6 thread.
Avoid the centre 200mm section along the full left to right length in the centre of the table when positioning
mounting points.

Manual - Formech 1372

25

Operating Procedure

Operating Procedure

• Turn the isolator switch situated on the electrical box on the rear of the machine to the ‘ON’ position.

• Using the touch screen, on the Home screen, turn the heater ON to provide power to the heaters. It usually

takes between 15 and 20 minutes before the heaters have reached their operating temperature.

• Raise the table to top position and place your mould onto the table. See the section dealing with mould

design to ensure that your mould is suitable. A sheet of wire mesh is supplied with the machine. This is to
assist with air flow during the vacuum stage and is placed under the mould tool. Drive the table into the
lower position by pressing the TABLE DOWN icon on the operating screen.

• Open the material clamps (2) and raise the clamp frame. Position a sheet of plastic over the aperture. See

the section dealing with plastics to ensure that your material is suitable.

• Pull the clamp frame down and close the 3 material clamps. The plastic should completely cover the

white seals around the aperture. Use the adjusting screws at the front of the material toggle clamps to
properly grip the plastic. The rear of the clamp is spring loaded. The pre-load spring tension at the rear of
the clamping frame can be adjusted by moving the position of the two lock nuts – see section dealing with
adjustment.

• After the heater has reached operating temperature, pull it forward over the plastic using the handle at the

front of the heater unit.

• Activate the auto-level by touching the corresponding button on the screen. This enables the auto-level

feature. If the plastic is sagging and not being heated evenly then the auto-level feature may be used to
keep the plastic level while the heater is forward and until ready to form a mould.

• As the plastic heats up it may begin to rise slightly. It will then soften and begin to drop back.

• If the heating cycle time is known then the timer can be set in edit mode prior to starting.

• If not using the timer push the heater back slightly to test the softness of the plastic manually or to

observe its state. Continue heating until it is soft enough to form. At this point, push back the heater all the
way.

• Touch the white pre-stretch icon to inate the plastic before moulding if required. This feature is

particularly useful if the mould is high because it keeps the plastic at a more even thickness throughout the
moulding. If the moulding is quite high it may be necessary to pre-stretch the plastic before moulding takes
place.

• Press the two TABLE up buttons simultaneously and hold until the table is fully raised. Then press the

vacuum icon.

• The vacuum icon is used to apply vacuum to the table. The moulding will form around the tooling.

• At the appropriate time when the plastic has formed around the mould tool the fans may be turned on to

start the plastic cooling process – press icon. When the moulding is adequately cooled, press the fan icon
again to turn it off.

• Once the plastic has cooled sufciently the release icon may be pressed to blow the moulding off the

mould. Too long or too soon a release may distort the moulding.

• Once released the moulding is now complete and the table may be lowered. Press the TABLE DOWN icon

and ensure the moulding has released from the mould tool. Ensure the table has reached its lower position.
Release the clamp frame to remove the moulding for inspection.

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

OPERATING. OPERATING PROCEDURES FOR THIS MACHINE MUST BE ASSESSED, MONITORED

AND CONTROLLED BY THE PERSON RESPONSIBLE FOR HEALTH AND SAFETY.

Manual - Formech 1372

26

Operating Techniques

Heaters

The powerful quartz heaters are designed to heat the plastic rapidly without burning the surface. The time
required to heat the plastic sheet remains fairly constant once the heaters have reached their operating
temperature.

The movement of the heater is manually controlled. The operator is able to send the heater partially back to
check the condition of the plastic and then bring it forward to continue the heating process. This action will
not interrupt and restart a timed heating cycle unless the time has elapsed and the alarm already sounded.
Always use the blue handle to move the heater.

The heater control system is controlled by the PLC to vary the output of individual zones as displayed on the
heater zone screen. There are 15 controllable heating zones which allow the operator to either switch off
zones not required or adjust the individual zone temperatures for different material requirements. Heating
zones may be adjusted in increments of 5%. The specified level of heat will remain constant after setting

The individual zones may be set up to provide an even spread of heat. To achieve the best results set the
inner zones lower than the outer zones and remember that the rear of the heater will always run hotter than
the front. Having set the heaters, slight adjustments may have to be made depending on the mould design,
plastic type / thickness / colour and the machine & environment temperature / conditions.

When using the full forming area it is advisable to keep the central zones 1, 4, 5, 10 & 11 turned down
slightly. These areas retain the heat the most and the outer zones lose the heat the fastest. When using
reducing frames the zones not in use should be turned down or OFF. Always push heaters over rear heat
shield when not heating plastic.

Heating cycle times vary according to a number of factors. With a little experience, timings may be easily
estimated. Some plastics such as styrene have a wide tolerance to heating times giving consistently good
mouldings. Care must be taken with materials, which are Hygroscopic (retain moisture) such as ABS, as the
surface will blister if the material has not been pre-dried in an oven before vacuum forming.

The moulding should be formed when the plastic is sufficiently ‘relaxed’ or at its ‘plastic transition’
temperature. A properly heated sheet will give an excellently defined moulding. If the sheet is not hot
enough while forming the moulding will not pick up all the detail from the tool.

The sheet heating times below were recorded using high impact styrene.

Please note that these times are a guide only.

Various factors will affect the heating time including the colour and surface finish of the material.

1.5mm Thick = 45 seconds

2.0mm Thick = 95 seconds

4.0mm Thick = 170 seconds

Bubble moulding

With the 1372 it is possible to produce bubble mouldings without using a tool. To form a bubble the plastic
sheet should be heated with the drape table in the lowered position. When the plastic sheet has heated right
through, push back the heater, touch the pre-stretch button and hold. The plastic will start to inflate.

Manual - Formech 1372

27

Mould Tools

Tools for vacuum forming should always be solidly constructed as the operating air pressure reaches
approximately 100 kg over an area 100mm x 100mm (one ton per square foot)

All tools should be mounted on a baseboard. They cannot have undercuts and must be produced with
slightly angular sides ('draft angle') to aid release. Vent holes are needed to allow the air to be evacuated
from pockets and sharp angles on the tool. Providing these holes are kept small they will not leave marks on
the surface of the finished moulding.

Tools made from wood or medium density fibreboard (MDF) are easily constructed and can give short runs
of good quality mouldings at a low cost. (See note below)

The use of close-grained wood will avoid grain patterns appearing on the mouldings.

Plaster of Paris may be used for one-offs but the plaster must be allowed to properly dry out.
(See note below)

Metal tools have the advantages of carrying fine detail and being more resistant to both distortion and
surface damage. Metal tools should be pre-heated before use. A cool metal mould will absorb some of the
heat from the plastic sheet before it can take up the full definition.

Resin tools combine most of the advantages of metal moulds with relative ease of manufacture. Various
resinous materials are commercially available especially for vacuum forming tool production.

NOTE: Porous mould materials such as wood and plaster should be properly sealed to prevent the vacuum
pump from sucking out any moisture or sawdust, loose plaster etc. The vacuum circuit may quickly become
choked with dust or slurry if moulds are not properly sealed.

Repairs to the vacuum circuit can be costly. A drain filter option is available and strongly
recommended if forming plaster moulds. The vacuum filter is not designed to prevent moisture
getting into the vacuum pump.

As the plastic cools after forming it will contract, gripping the tool tightly. If the tool has been made with
sloping sides and has a good surface finish it will release more easily. Where the draft angle must be kept to
a minimum a release agent may be used to assist release.

Sealed moulds will usually release more easily. Silicone based release agents may be used on more difficult
moulds. Silicon based release agents are rapidly absorbed by porous (unsealed) moulds, rendering them
ineffective.

The use of talc as a release agent is not recommended. It may clog the vacuum circuit.

Manual - Formech 1250/1500

28

Plastics

Plastic sheet is commercially available in a wide variety of grades, thickness and colours. Materials such as
styrene and PVC are most suited to vacuum forming. Other materials such as acrylic, polypropylene and
polycarbonate will mould but difficulties may be encountered.

It is not within the scope of this manual to attempt to list all the potential problems and their solutions. It is
recommended that the newcomer to vacuum forming gains experience and confidence with easily formed
materials before moving onto the more difficult materials.

Post Forming Operations

After forming

After forming, most plastics can be subsequently heat formed to add such details as folds or clips. Although
many plastics can be printed, and in some cases painted, the presence of release agent used to help free a
tight moulding may make the surface resistant to further decoration.

Trimming

An ideal moulding will be ready for use when removed from the machine and requires no finishing. However,
most mouldings do require trimming before they can be used.
There are numerous methods available for this process.

Thin materials can be trimmed with a sharp knife. Shaped cutting dies can be used to cut out intricate
shapes. If no flange is required on the finished product then a trimming saw mounted in a pillar drill will cut
the moulding in a horizontal plane to free it from the surrounding material. Trim or Spindle saw are available
from Formech. Please contact our sales department for further information.

In mass production environments the range of equipment available for this requirement encompasses
clicking presses, roller presses, routers, horizontal band saws, water jet cutters, laser cutters and many others.

Manual - Formech 1372

29

Forming Difficulties

PROBLEM CAUSE REMEDY

Lack of definition Material too cold Increase heating time/temp.

Mould too cold Warm mould

Insufficient vacuum Adjust vacuum timings

Check vent holes on mould

Is mould restricting vacuum

flow? Are vacuum tracks in mould

adequate?

Webbing (small pleats at corners of

mouldings)

Incorrect pre-stretch height

Adjust pre-stretch flow and/or time.

Check panels for leaks

Incorrect heater zoning Adjust problem zones

Material overheated Reduce heating time

Vacuum speed too fast Regulate to suit

Mould design/position

Increase tapers or radii. Use plug

assist. Move cavities further apart

(Multiple moulds)

Webbing Excess material

Reduce material size or use

'dummy' moulds

Shrinkage of moulding (after

removal from mould)

Product removed from mould too

quickly

Increase timings to allow longer

mould contact

Increase cooling time

Moulding too thin in areas Incorrect heater zoning

Decrease temperature in problem

zones

Too much pre-stretch Decrease flow or timing

Cold spots

Check elements are working. Are

there any draughts?

Mould too cold Warm mould

Material not consistent Consult supplier

Creased or distorted formings

Excessive mould release pressure or

timing

Adjust to suit

Material too hot at release Increase cooling time

Material thinning Adjust heater zoning

Thick tops on finished mouldings.

(Chill marks)

Mould too cold causing rapid

cooling on contact

Increase mould temperature.

Adjust flow on water cooled

moulds

Design of mould

Use plug tool to assist material

flow

Insufficient pre-stretch Increase pressure, flow or time

Material too hot or too cold Increase heating time/temp.

Marks on finished mouldings Damaged or dirty mould

Repair or clean mould. Use

blowgun between formings.

Manual - Formech 1372

30

Warranty

Reliability and a long service life are synonymous with the Formech brand. However, as with any machinery,
certain parts will require periodic replacement and regular maintenance and care will prolong machinery life.

Clamp Seals

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.
The table and clamp seals are not covered by our warranty.

Heating elements

The Quartz infrared heating elements supplied with this machine are manufactured using quartz tube and
therefore may break or crack with impact or physical shock.

The Quartz heating elements contain internal fi laments, which become extremely hot when power 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 10 years or more. Because of this we are unable to apply our standard warranty to
Quartz heating elements. However our experience is that this form of infrared heating is durable, reliable and
more resilient to shock and impact than similar ceramic products

The heating elements are not covered by our warranty.

Vacuum system

The vacuum system on this machine is fairly simple but uses high quality components throughout. The life
expectancy of the vacuum system will be compromised by the ingress of dirt, shavings, dust, liquid etc. A
cartridge fi lter is fi tted to the vacuum pump inlet to prevent particle being drawn into the vacuum chamber.
Monitoring of the condition of the fi ltering system will prolong vacuum performance. Replace the fi lter if it
becomes degraded with dirt and particulate.

THE VACUUM CIRCUIT INCLUDING THE VACUUM PUMP WILL NOT BE COVERED BY OUR WARRANTY IF
THEY ARE FOUND TO BE BLOCKED WITH FOREIGN MATTER OR CORRODED BY THE INGRESS OF LIQUID.

Manual - Formech 1372

31

Service & Repair

Apart from the table and clamp seals, which are considered to be consumable items, the service and
repair of your machine is likely to be minimal. This is providing that you have noted the sections regarding
the vacuum system and heating elements. However, depending on usage, performance monitoring and
subsequent preventative maintenance may be required to ensure that the machines performance is
maintained.

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 PERFORMING SERVICING AND REPAIRS.

MAINTENANCE ACTIVITIES FOR THIS MACHINE MUST BE ASSESSED, MONITORED AND
CONTROLLED BY THE PERSON RESPONSIBLE FOR HEALTH AND SAFETY.

Electrical

Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF
position. Only a qualifi ed electrical technician may work on any parts carrying mains voltage and should be
responsible for ensuring that the machine is in a safe condition before allowing services to be restored.
Faults on electrical & electronic modules are rare but loose plugs and terminals are responsible for most
electrically based failures. A logical approach to detecting the fault begins with an exact appraisal of the
fault scenario.
Much time can be wasted looking in the wrong areas for a problem that, when found, was obvious.
See also section dealing with Electrical circuit information.

Heater

The fl exible conduits between the heaters and the control cabinet contain a number of heatproof power
cables. Due to the continual motion of the heater these may eventually suffer from fatigue and require
replacement.
Only the correct grade of cable should be used, and the work carried out by a skilled technician.
The Quartz heating elements should be periodically inspected particular¬ly for hairline cracks. There is
usually no specifi c reason for this occurring other than through age due to the expansion & contraction. If an
element fails to heat and the terminations are correct then it will require replacement. The element terminal
connections on the element tray require periodic tightening as result of continued expansion, contraction &
vibration. Remove the heater cover. Remove every terminal block cover and systematically check & tighten
every terminal block screw ensuring that every wire is securely in place. This procedure may be repeated
every 4-8 months depending on usage.
For the reasons stated, the elements, associated cables, connectors, fuses and triac controllers are specifi cally
excluded from our standard warranty

MANUAL RELATING TO SAFETY AND THE SAFETY HAZARDS SPECIFIC TO THIS MACHINE

BEFORE PERFORMING SERVICING AND REPAIRS.

Manual - Formech 1372

32

Service & Repair

Replacing a heating element

• If the plastic is not being heated evenly and there is an obvious cold spot then follow the below procedure.
This procedure is simplified if the checks are performed from ‘cold’

• Switch off machine and let heater cool completely, this will take at least 45 minutes.

• Bring the heater half way forward, place hand near but not on elements to see if they are still hot. If they

are, let machine cool for a further 15 minutes.

• When elements are completely cool, turn on each zone individually and very carefully feel each element

connected to that specific zone. The difference in temperature will quickly become noticeable. If one or
more elements fail to heat then follow below.
Service\Repair

• Disconnect the electrical mains supply.

• Bring the heater completely forward.

• Remove the self tapping screws securing the slotted heater cover and place to one side with the cover.

• Remove the cap from the terminal block associated with the faulty element, loosen the terminal block

screws and remove the element leads and insulation sleeves.

• Remove the 4 M4 nuts securing the element to the tray placing a hand underneath the element to prevent

it from falling. Remove the element.

• Fit the new element, feeding the connection leads through the tray and secure it in place with the

retaining nuts.

• Slide on the insulation sleeves, replacing with new if perished or damaged. Ensure that the connections are

fully tightened and correctly wired.

• Replace the terminal block cover and check that no cabling is touching any metal parts.

• Replace the slotted heater cover and t the self tapping screws.

Auto-levelling system

This machine is fitted with an automatic sheet levelling system. An optical sensor directs a beam of infrared
light across the machine. The system comprises of a transmitter and receiver. If the beam is broken air is
pumped into the machine cabinet under the plastic lifting it until beam transmission is re-established.

When the plastic is heated it begins to sag and cuts the beam, the compressed air lifts the plastic until it has
cleared the beam. The air is then shut off until the plastic sags again. The intervals between the air turning
on & off may be very short. The optical sensors are located under the top-frame at the sides.

The alignment between the optical sensor and the reflector is finely adjusted. It may require re-adjusting if
the machine has been transported or used roughly.

If the heater is left for any time over the forming area (without plastic clamped in) sensors may become
distorted. The sensor may fail if it is exposed to high temperatures.

Adjustment may be carried out by slightly bending the sensor mounting plate. The sensor has two small
adjusting screws that alter sensitivity and range. These have been set at the factory and are unlikely to have
moved. Only adjust these if you cannot make the sensor work properly by any other means.

If no LEDS are visible at any time then the sensor may have lost its power connection or become faulty.

The Auto-Level may be working properly but blows the plastic up higher than the top-frame level. If this is
the case adjust both sensor mounting plates slightly downward

Manual - Formech 1372

33

Service & Repair

Vacuum

Warning: never oil any part of the vacuum pump. It is designed to run dry and could be severely
damaged by lubrication.

The vacuum circuit requires very little maintenance. The inlet filter is mounted on top of the vacuum pump
situated under the table on the RHS of the machine. Unclip the top cover of the filter box. The paper
cartridge filter will prevent small particles and dust from entering the vacuum pump. This filter should be
inspected periodically and blown out if dirty or replaced if in poor condition. Do not run the machine without
this filter.

Worn or damaged seals around the perimeter of the table may cause loss of vacuum. These are classed as a
consumable part and require replacement after some time. To replace seals follow the procedure relating of
Clamp & Table seals in this section.
Other causes of vacuum loss are loose or damaged flexible pipes or fittings, blocked filters or build up of
contamination in the vacuum valves. The valves should be dismantled and cleaned with paraffin or diesel
fuel. Be sure to remove all traces of the solvent used before re-assembling.
Lubricants or other liquid may cause irreparable damage to the pump if introduced into the vacuum circuit.

Vacuum system

If the vacuum appears to be weak or non-existent check the following.

• The mould baseboard is not restricting the vacuum inlet in the drape table.

• NOTE: If the mould baseboard is too soft it may pull down under vacuum and block the vacuum inlet.

• The mould is adequately vented to allow trapped air to be evacuated.

• The table and clamp seals are in good order and the table is locking properly at the top of its travel.

• There are no open holes in the drape table.

• The lter box cover is correctly tted.

• The vacuum valve is operated by a pilot valve using compressed air, this may not operate if the pressure is

too low.

If all the above points are OK and you can hear the pump running when you switch it on then one of the
following points will be the cause of the problem. If the pump does not run, refer to the Electrical trouble
shooting section above.

• A pipe is loose, damaged or blocked.

• The pump lter is blocked.

• The vacuum valve is blocked or corroded.

• The vacuum pump is blocked or corroded.

If the heater has been left in the forward position, with no plastic in the clamp frame, the table will start
to overheat. The pipe attached to the back of the table will shrink and constrict the passage of air. Pipes
become less flexible over time and may loosen or crack.

Manual - Formech 1372

34

Service & Repair

Pneumatics

Check oil in lubricator daily.
Providing there is a good fi ltered regulated and lubricated air supply, using good quality airline oil,
maintenance will be minimal. However, a thorough inspection of the machine is neces¬sary from time to
time. Any mechanical damage of pipes and fi t¬tings should be dealt with before re using the machine.
Always lock air supply OFF and bleed out system air before attempting any maintenance of air system.
Other problems that cylinders and solenoid valves may suffer from are: -

• Lack of electrical supply - Check appropriate circuitry.

• Solenoid has become open circuit - Replace with new solenoid.

• Return mechanism jammed or broken - Dismantle valve to investigate. Replace if required.

• Wet or dirty air supply - Check condition of air compressor and condensate management system.

• Internal leaks within valves & cylinder.

Please specify cylinder/ valve number & model when ordering any pneumatic spare parts.

It is important to maintain the lubricator oil level. Adjust the lubricator so that a very small amount of oil is
applied – too much may cause damage to the pump.

Many problems can be caused by water in the pneumatic system.

Table Cylinder Maintenance

The pneumatic table lift assembly is a potentially hazardous area of the machine to perform

repairs, maintenance and adjustments. The following guidelines must be followed when performing

maintenance on this area. It is recommended that maintenance of this are is conducted by

qualifi ed and competent persons.

Lift the table using the 2 handed control system to a point just below the top frame. Remove all air supply
from the machine and switch off the power. Remove both side panels and fi t supports on both sides between
the scissor base and the underside of the table and fi x in place. The prop must be of suitable strength to take
the weight of the table. Remove both the outlet 10mm air pipes that feed the cylinder from the table valve.
He table will rest on the fi tted props. Check that the table and props are secure. Remove the 2 front panels.
Full access is now available to the table cylinder and table mechanism.
For general maintenance and cylinder removal:

• Check all scissor pivot fi xings, guides and bearings for wear, tighten and / or replace as required.

• To remove the cylinder, remove the 4 cylinder base  xings, loosen the rod end lock nut, rotate the cylinder

rod and unscrew from the rod end post.

• Disassemble the cylinder and replace seals as required, reassemble and re t the cylinder. Check

adjustments and set as required.

• Fit the front panels, reconnect all air pipes, and connect the air and power. Drive the table up and remove

the 2 table props. Check operation and fi t side panels.

Manual - Formech 1372

35

Service & Repair

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.
Formech supply a kit comprising the necessary seals and sealant for the Formech 1372. We recommend
that only the correct silicone seals and sealant are used to give an effective seal.

DUE TO THE NATURE OF THE POSITION AND SIZE OF THE SEALING AREA, THIS PROCEDURE REQUIRES
REACHING AND STRETCHING. ENSURE PRECAUTIONS ARE TAKEN TO MINIMISE EFFECTS OF REACHING
AND STRETCHING AND THAT WHERE A PLATFORM OF ANY TYPE IS USED, THAT IT IS STABLE AND SECURE.
ENSURE THAT SUITABLE GLOVES ARE USED IF USING SHARP TOOLS TO REMOVE EXISTING SEALS AND
ADHESIVES.

To replace a damaged or worn seal

• Remove the all traces of the existing seal and sealant.

• Using masking tape, make a frame inside where the seal will go (table) or outside (top frame). Gain a good

‘key’ to the sealing surface using an abrasive cloth or paper.

• Degrease the area and remove all dust.

• Cut the seal strip to the lengths required allowing for 25mm overlap at the corners.

• Apply a bead of sealant to the masked area where the seal is to be placed and spread to achieve a thin

and even coating. Ensure a generous layer covers all of the sealing area.

• Bed down the strips of silicon seal until it is rmly seated in to the sealant. Do not attempt to stretch the

seal strip it will contract back to its original size before the sealant sets.

• Ensure the strips are straight along the sides and perpendicular at the corners. Cut through the strips at 45°

where they meet at the corners with a sharp blade. Continue this process for all 4 corners.

• Apply a small amount of sealant to the mitred joints and rm together to achieve a clean, square and

close joint. Place masking tape over the mitred corners to help keep them firmly positioned until the sealant
sets.

• Carefully remove the masking tape and leave overnight

Panel seals

The rubber seals fitted to the side panels should be periodically inspected and replaced where necessary.
Failure of these seals will prevent the correct functioning of the auto-level and pre-stretch functions.

DUE TO THE FACT THAT REPLACEMENT OF THE PANEL SEALS REQUIRES THE PANELS TO BE
REMOVED, THE MACHINE MUST BE COMPLETELY ISOLATED FROM BOTH ELECTRICAL AND AIR
SUPPLIES WHEN SUCH WORK IS PERFORMED.

To replace the seals, isolate power and air supplies, remove the panel that requires service and remove the
damaged seal. Apply silicone sealant to the sealing area and replace with new seal strip. Only use original
parts. Allow to dry for minimum of 2 hours before refitting the panel.

If you are unable to cure any problem relating to your machine, or if you wish to order spare parts please
contact us at the contact number on the front of this manual stating the model, 1372, the serial no. (on
specification plate), and a full description of the fault or parts you need.

Manual - Formech 1372

36

Service & Repair

Cleaning

Ensure the inside of the machine and the heater tray is cleared of dust , dirt and debris. Do not allow dirt
and loose particles to build up, particularly on the heater tray.

Lubrication

The 1372 requires minimum lubrication. The main lubrication area is the table guide bars situated on either
side of the table. Apply a general purpose grease when required to assist with table movement.
Apply grease to the scissor pivot points when this area is undergoing general / cylinder servicing.

Manual - Formech 1372

37

Electrical Circuit information

Overview

The following is an overview of the 1372 control circuit showing the safety related parts of the control
system.

Circuit wiring information consists of the following:

P1. Power distribution.
P2. Inputs and safety related parts on the control system.
P3. Outputs.
P4. Heater Outputs.
P5. Heater tray wiring
P6-7. Major components parts listing

Interlocking devices

Rear heater limit switch, SW4 – Prohibits Auto-level when closed. Prohibits pre-stretch, release, vacuum and
‘table up’ command when open.

Manual - Formech 1372

38

Electrical wiring diagram P1

Manual - Formech 1372

39

Electrical wiring diagram P2

Manual - Formech 1372

40

Electrical wiring diagram P3

Manual - Formech 1372

41

Electrical wiring diagram P4

Manual - Formech 1372

42

Electrical wiring diagram P5

Manual - Formech 1372

43

P6 Major Parts Listing

Qty Description Reference

27 250W SQE Quartz Element 250W SQE

24 300W SQE Quartz Element 300W SQE

4 400W SQE Quartz Element 300W SQE

11 Sleeving HTGL Sleeve 710

48 30A Ceramic Terminal Block 30A Ceramic Block

14 1.6mm Solid Blue & Brown 1.63mm GG Bl / Br

60 SIAFGL Red 1.0mm 1.0mm SiFGL Br

15 SIAFGL Blue 2.5mm 2.5mm SiFGL Bl

6 SIF G/Yell 4mm 4.0mm SiF G/Y

1 50mm Cable chain with 60mm radius SR300-1372

1 Cable Chain bracket A300A-1372

2 Heater Limit switch Switch Long lever roller

4 Wheel Bearing 1/2" KLNJ

3 MCB 32A - B MCB 32A - B

1 MCB 10A – B triple MCB 10A - Btriple

3 20mm Fuse holder 20mm fuse holder

3 fuse 20mm, 1A,2A,3.15A

6 DIN Terminal Block std 2.5mm Std terminal block

3 Din Rail Neutral Terminal 2.5mm N terminal block

1 4P Isolator, 63A KN 63A 4 Pole

4 Triac output pcb 4 Triac AG PCB

1 PLC PLC FX3G

1 User I/F GT1055

1 Lead Comms, 3M GT01-C30

1 fx3u Battery backup FX3U32BL

1 24vdcpsu 24Vdc PSU 1.7A

3 Relay single pole 6A, 24V 38SPCO24

1 24VDC DPCO Relay 24V 97DPCO24

1 Buzzer 12-24V FK84F

1 Contactor, Pump EM-10G

1 Contactor over load for above ZE6

1 Beam Sensor CX 411-P

1 2 Handed ctrl module Cat I BA5120

2 Grey Button BA8

2 N.O / N.C. Switch body BZ105

1 conduit 32mm htr SP32

2 Conduit end connector SP32 SP32/M32A

6 Scissor bearing 25mm 6205

0.25 Lead screw 1320-1372

1 Lead screw nut 1336-1372

1 Thrust bearing 51207

Manual - Formech 1372

44

P7 Major Parts Listing (continued)

1 Cylinder 100 bore- 400mm Cyl 100A400

1 5/3 Closed centre 3\8 Valve 541 91 028

1 5/3 valve sub base 3\8 355-382

2 Sol. Pilots 189-01

2 Exhaust flow restrictor 711-3/8

1 Limit switch, Table down C50ST-1372

2 2/2 Valve, 1/2" 210A15

1 2/2 Piston valve, 3/4" pilot operated 290A385

1 3/2 pilot Valve 189-32

1 3/4" wire reinforced suction pipe P-AM020-10

1 Vacuum Pump VT4.25 Three phase

1 Vacuum Filter Box F35

1 Vacuum Filter C111

1 Vacuum gauge 40mm 1/8 rear entry panel mount

3 Clamp Spring, 127 x 11.1ID 244040

3 Toggle Clamp - Blue sleeve 1892B

3 Toggle Clamp Knoblet M8 M8 Black Knoblet

3 Clamp Frame Grip 1372 Clamp sleeve

5 4mm x 20mm Silicone Seal Strip 4mm x 20mm Silicone Seal Strip

5 8mm x 12mm Silicone Seal Strip 8mm x 12mm Silicone Seal Strip

1 High Modulus Silicone Sealant 310ml Clear, HMA100

14 Natural rubber seal strip, 1M 12 x 8 Nat Rubber

1 1372 mesh coated 203 6201250

1 1372 User manual 1372 User manual

45

Manual - Formech 1250/1500

E C Machinery Directive

2006/42/EC

Declaration of conformity

We hereby certify that the machinery stipulated below complies with all the relevant provisions of the EC Machinery
Directive and the National Laws and regulations adopting this Directive. Modifications to this machinery without prior
approval from the undersigned will render this declaration null and void.

Machine Description: Vacuum Forming Machine

Machine Function: Thermoforming of Plastic Sheet

Model / Type: 1372

Serial Number: 224

Date of Manufacture: January 2015

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 LTD
Unit 4, Thrales End Business Park
Thrales End Lane
AL5 3NS Harpenden
Hertfordshire - UK

Significant harmonised standards applied:

EN ISO 12100 : 2010
EN ISO13849-1:2006
EN 60204 –1 : 2006
EN 12409: 2008
______________________________________________________

Signed
Date: 25 February 2015
Name: Paul Vukovich
Position: Managing Director
Being the responsible person appointed by the manufacturer

FORMECH INTERNATIONAL LTD
Unit 4 Thrales End Business Park,
Thrales End Lane,
Harpenden,
Hertfordshire,
AL5 3NS - UK

EC Certificate

46

For Parts, Service & Technical Assistance UK,

Europe and Rest of the World

Telephone: [phone]

Fax: [phone]

[e-mail]

For Parts, Service & Technical Assistance North

and South America

Telephone: [phone]

Fax: [phone]

[e-mail]

Formech International Limited
Unit 4, Thrales End Farm, Thrales End Lane, Harpenden, Hertfordshire, AL5 3NS U.K.
Tel: [phone] Fax: [phone]
Accounts: [phone] Email: [e-mail]

Registered office as above address. Registered in England Number 2999925 VAT no. GB 604 0796 55

Manual - Formech 1250/1500