Formech 508DT, 508FS Installation, Operating And Service Manual

1

For Parts, Service & Technical Assistance

Telephone: [phone]

Fax: [phone]

508DT/FS

Installation, Operating and Service Manual

.

.

.

Desktop / Floor-Standing

Vacuum Forming

Machines

Table Of Content

Safety 4

General arrangement 508DT 8

Electrical Specifications 8
Mechanical Specifications 8
Transportation / Positioning 8
Noise emissions 8
Machine storage 8

General Arrangement 508FS 9

Electrical Specifications 9
Mechanical Specifications 9
Transportation / Positioning 9
Noise emissions 9
Machine storage 9

General Arrangement 508DT & 508FS 10

Machine Footprint 508DT & 508FS
Machine arrangement

Installation and Inital assembly 508 12

Power Cable - 508DT 12
Power Cable - 508FS 12
Lifting and Handling - 508DT Only 13
Heater Guard - 508DT & 508FS 14
Air Outlet connection - 508DT 15

Installation and Initial assembly (508FS only) 16

Castor option 17
Fitting the Castors 17
Fitting the rear stabilisers 18
Cooling fan option 19

Compressed air connection - 508FS only 21

Optional extras 22

Heater Layout 23

Operating Procedures - Quick start guide default settings 24

Basic Operation Mode 508DT/FS 24
Operation Mode 508FS – Additional features 26

Operating Procedures - Using custom settings 27

Basic Operation Mode 508DT/FS - Editing the heater and time settings 27

Operating procedures – Other settings / loading programs 29

Warranty 30

Heating elements 30
Vacuum system 30

Manual - Formech 508DT/FS

3

Table Of Content

Service / Repair 31

Replacing seals 31
Replacing a heating element 32
Electrical Troubleshooting 34
Vacuum / Pressure Troubleshooting 34
Cleaning 35
Lubrication 35

Electrical Wiring 508DT 36

Vacuum Pump 2D351VM - 508DT only 37

Electrical Wiring 508FS 39

Becker Pump VT 4.10 - 508FS Only 40

EC Certificate 42

Manual - Formech 508DT/FS

4

Safety

Thank you for choosing Formech. Please read and follow the below safety instructions

before attempting to install or operate your machine.

>Do not operate the machine until you have been trained and are fully conversant with it.
>Read and understand all of this user manual.
>This is a ‘single person operating’ machine.
>Check your supply voltage and frequency. Make sure it is compatible with your machine. Your machine’s
electrical specifi cation is on the plate on the right hand side.
>You must ensure that the machine is properly earthed and fused.
>If your machine is not equipped with a moulded mains connector then note that:
The earth wire is GREEN with a YELLOW stripe.
The live wire is BROWN
The neutral wire is BLUE
>Only suitably qualifi ed personnel should make electrical connections.
>Turn off the machine and disconnect the power supply when the machine is not in use.
>The heater and pump on this model are not intended to be left running indefi nitely.
>Never remove any panels unless the electrical supply has been isolated.
>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.
>Note the safety warning labels situated on the front and rear panels. Never remove any warning labels from
the machine.
>Note the ‘HOT SURFACES’ safety labelling on the heater & heater guard. These areas can become VERY
HOT.
>Only use the machine for vacuum forming plastic. It is not intended for any other purpose.
>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. It is the responsibility of the owner or designated responsible
person to assess the risks associated with any dangerous fumes given off and to determine any necessary
precautions required such as fume extraction. Contact your plastics supplier to gain information regarding
hazardous fumes.
>The heater and pump on this model are not intended to be left running indefi nitely.
>There is a risk of being burnt when handling heated plastics. Always wear suitable personal protective
equipment such as gloves.
>Ensure that the area surrounding the machine is clean and frequently cleared of fi nished product and any
scrap.
>This machine is fi tted with a dry running vacuum pump. Do not lubricate. Do not allow any liquid to enter
the vacuum system. Ensure that moulds are properly sealed to prevent ingress of dust into the vacuum
circuit. Severe damage may be caused if the above is not observed.
>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.
>Users of this machine should complete regular competence tests.

Manual - Formech 508DT/FS

5

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 415Vac.

NEVER ATTEMPT ANY REPAIR UNLESS THE ELECTRICAL SUPPLY DISCONNECTED ONLY SWITCH ON WHEN
ALL COVERS 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 80 PSI (508FS) 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.

HEALTH & SAFETY - Hazards specifi c to this machine.

5. 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.

Manual - Formech 508DT/FS

6

HEALTH & SAFETY - Hazards specifi c to this machine.

Safety

6. 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.

7. 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.

8. 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.

9. 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 508DT/FS

7

HEALTH & SAFETY - Hazards specifi c to this machine.

Safety

10. 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 508DT/FS

8

General arrangement 508DT

1 2

3 5

4 6

7

Electrical Specifi cations

220/240V, 13 amps, 50Hz single phase
208/220V, 13 amps, 60Hz two phases (North America)
Power consumption: 3,2 kW

Mechanical Specifi cations

Sheet size: 457 x 508mm
Forming area: 482 x 432mm
Max depth of draw: 185mm
Overall width: 730mm
Overall height: 540mm (1250 with trolley)
Overall length: 1400mm (ASSEMBLED)
Weight: 100kg

Legend:

1- Touch screen
2- Vacuum gauge
3- Clamp frame
4- Material clamp
5- Heater box
6- Table lever
7- Specifi cation plate
Power inlet receptacle
Main fuse
Power switch ON/OFF
Air output

Transportation / Positioning - 508DT

The 508DT will be supplied strapped to a Pallet or in a crate. The machine may unpacked and placed on a
bench, table or 508DT trolley. Lift the machine using the clamp handles at the front of the machine and the
rear rail lifting handle extensions. Ensure that the structure, size and load bearing capacity of the bench or
table is suffi cient for the machine weight. A minimum of 2 persons are required to move the machine. In
the case of the 508DT trolley, ensure that the 2 machine retaining screws are fi tted to the under side of the
trolley / Machine. ALL MOVING AND LIFTING MUST BE SUPERVISED BY THE PERSON RESPONSIBLE FOR
HEALTH AND SAFETY.

Noise emissions

Noise emissions on the Formech 508DT are less than 70dB(A).

Machine storage

The Formech 508DT must be stored in a dry environment. If the machine is not used for a long period of
time, run the pump periodically (once a month).

Manual - Formech 508DT/FS

9

General Arrangement 508FS

Electrical Specifi cations

220/240V, 20 amps, 50Hz single phase
208/220V, 20 amps, 60Hz two phases
(North America)
Power consumption: 3,5 kW
Air supply requirement: 80PSI / 5 bar

Mechanical Specifi cations

Sheet size: 457 x 508mm
Forming area: 482 x 432mm
Max depth of draw: 290mm
Overall width: 597mm
Overall height: 1200mm (1950mm with cooling fan system)
Overall length: 1100mm (ASSEMBLED)
Weight: 100kg

Legend:

1- Touch screen
2- Vacuum gauge
3- Clamp frame
4- Material clamp
5- Heater box
6- Table lever
7- Specifi cation plate
Power inlet receptacle
Main fuse
Power switch ON/OFF
Air output

Transportation / Positioning - 508FS

The 508FS will be supplied strapped to a Pallet or in a crate. The Machine may be carefully moved from
the transportation pallet and situated directly on a fi rm fl oor before installation. Ensure that the structure
and load bearing capacity of its position is suffi cient for the machine weight. A minimum of 2 persons are
required to move the machine. Do not attempt to lift this machine without a mechanical aid. ALL MOVING
AND LIFTING MUST BE SUPERVISED BY THE PERSON RESPONSIBLE FOR HEALTH AND SAFETY.

Noise emissions

Noise emissions on the Formech 508FS are less than 70dB(A).

Machine storage

The Formech 508FS must be stored in a dry environment. If the machine is not used for a long period of
time, run the pump periodically (once a month).

1 2

3 5

6

7

Manual - Formech 508DT/FS

10

Machine footprint - 508DT & 508FS

Machine arrangement

1. Touch screen.

Touch sensitive user screen to control the process with the ability to store programs in the memory.

2. Vacuum Gauge.

To indicate the vacuum level achieved during moulding.

3. Clamp Frame.

This holds the plastic material in position during the forming and release processes.

4. Material Clamps.

These clamps fix the Clamp Frame firmly down. After placing the plastic under the clamp frame the material
clamps are adjusted by tightening or loosening the orange nutlets. The levers are pulled up until they are
fully over-centre. Adjustment may only be carried out while not under pressure. The rear of the
clamp frame is self adjusting.

General Arrangement 508DT & 508FS

730mm

1400mm

Manual - Formech 508DT/FS

11

General arrangement 508

5. Heater.

This carries the heating elements and is drawn forward by pulling the centrally mounted handle.

6. Table Lever.

When pulled towards you the table will rise to the upper limit. A further application of pressure will lock the
table in this position. During forming the table complete with mould is lifted into the hot plastic and locked
in place to ensure a good vacuum seal. At the end of the cycle the table is returned to the lower position by
pushing the handle back and away.

7. Air pressure outlet.

The air pressure outlet allows you to supply other equipment that requires air pressure. Air is produced from
the exhaust of the vacuum pump. Do not connect compressed air to this outlet. (508DT only)

7. Specifi cation Plate.

This states the model type, electrical supply needed to power the machine & other essential data.

7. Power connection.

508FS – supplied with 2.5mm cable fi tted to connect to a single phase 20amp socket. See Safety section
at the beginning of this manual. 508DT – Supplied with C19 plug or C201 receptacle. Note the safety
labelling.

7. Mains fuse.

This fuse protects the machine and should only be replaced by another of same type and rating. See Image
below – 508DT Only. 508FS – Circuit breakers are fi tted to Live and neutral feeds internally.

7. Power Switch ON/OFF.

508DT - See Image below. When OFF, power is cut to all functions. Before commencing any repair work
always remove the mains lead from the Power Inlet Receptacle. 508FS – Supplied with a rotary 2 pole switch
on the electrical cabinet.

The fuse is positioned
separately above the power
socket. 508DT.

Manual - Formech 508DT/FS

12

Installation and Inital assembly 508

12

For Parts, Service & Technical Assistance

Telephone: [phone]

Fax: [phone]

508DT/FS

Installation, Operating and Service Manual

.

.

.

Desktop / Floor-Standing

Vacuum Forming

Machines

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.
Modifi cations 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: 508DT/FS
Serial 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: A. Berry at address below.

…………………………………………………………………………………………………………

…………………………………………………………………………………………………………

Signifi cant harmonised standards applied:

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

______________________________________________________

Signed

Date: 15 October 2012
Name: Paul Vukovich
Position: Managing Director
Being the responsible person appointed by the manufacturer

User manual EC Certifi cate

of conformity

Your Formech Machine is supplied with:

Counter balance
weights (508FS)

Heater shed Table mesh

Power Cable - 508DT

C19 to BS 1363 Plug (UK & Ireland)
C19 to CEE 7/4 Plug -Schuko Plug (EU)
C19 to Nema 6/15 Plug (North America)

Power Cable - 508FS

2.5mm, 3 Core – 3m

+ Power lead (508DT)

Manual - Formech 508DT/FS

13

Installation and Inital assembly 508

Lifting and Handling - 508DT only

The machine is shipped with two lifting bars
fi xed to the rear of the heater rails. Once the
machine has been positioned on either the
trolley or the table top, remove the lifting bars
before the heater guard can be fi xed in place.

Remove the 2 screws on both sides
and remove the lifting bars.
Store the lifting bars for future use.



Slide the heater guard onto the
front rail link bars.

Manual - Formech 508DT/FS

14

Installation and Inital assembly 508

Heater Guard - 508DT & 508FS

Slide the heater guard rails onto the front rail link bars
as shown. Take care to fi t evenly so that the front and
rear rails meet and the fi xing holes are aligned.

Fit the 4 screws – 2 each side – using an 8mm spanner.
Ensure all screws are tight and that heater rails are
aligned.

The heaters are kept in the front position for transit
by a screw that is positioned mid way along the front
heater rail.

Remove the screw from the side to allow the heaters to
be moved backwards.

1

2

3



Manual - Formech 508DT/FS

15

Air Outlet connection - 508DT only



Fitted with an 8mm tube Air outlet
connector for dome blowing.

Installation and Initial assembly 508

Manual - Formech 508DT/FS

16

Installation and Initial assembly (508FS only)

Remove the nuts and washers from the counterweight
arms.

Lift the Counterweight arm with the screws and insert in
corresponding holes of the clamp frame.

Ensure the counterweight arm is fi tted to the outside of the
clamp frame.

& Fit and tighten the washers and nuts removed in

Repeat for both sides of the clamp frame

1

2

3

4

5

6

1

2

3

4 5 1

6

Counterweights

Manual - Formech 508DT/FS

17

Installation and Initial assembly (508FS only)

Castor option

The 508FS is designed to be fitted with castors.
If the castors are ordered with the machine then the unit will be supplied as follows:

• 2 Braked castor wheels pre-tted to the rear stabiliser.

• 2 castor wheels with xings to be tted to the underside of the main unit.

ALL MOVING AND LIFTING MUST BE SUPERVISED BY THE PERSON RESPONSIBLE FOR HEALTH
AND SAFETY. ENSURE THAT THE MACHINE IS FULLY SUPPORTED AND IS STABLE BEFORE
WORKING UNDER PARTS THAT MAY TRAP OR CRUSH.

It is best to fit the front wheels when the unit is on the delivery pallet or slide the unit onto suitable sized
blocks to raise the main body off the ground. The castor wheels are fitted to the front corners of the
machine.

Fitting the Castors

• Move the machine so that the front overhangs the pallet / blocks and locate the xing holes.

• Fix each of the castor wheels with the M10 screw, split washer and washer. Ensure the screws are tight.

• Assemble the rear stabiliser with tted locking castors – refer to next section.

• Carefully remove from pallet / supporting blocks.

ALWAYS ENSURE THE REAR WHEEL CASTORS ARE LOCKED WHEN LOCATED AT THE WORK AREA.

If the castors are supplied as a retrofit item then the front fixing holes will be blocked with screws fitted
internally. These screws will need to be removed before fitting the wheels.

• Remove the crank handle.

• Remove both side panels by removing the 2 M6 screws holding the top of the panel accessible form the

forming area. Loosen the panel lower retaining screws and lift off the panels.

• Remove the screws and ret the side panels and the crank handle ensuring the xings are retted correctly.

• Fit the front castor wheels as above and t the rear locking castor wheels to the rear stabiliser using the

fixings supplied.

If the unit is supplied with the castor wheel option and the machine is to be used before fitting the wheel
castors then the auto-level and pre-stretch air will escape through the wheel mounting holes until the wheels
are fitted or the fixing holes are blocked.

Manual - Formech 508DT/FS

18

Installation and Initial assembly (508FS only)

Fitting the rear stabilisers

The triangular supports and the
connecting crossbar at the rear of the
machine need to be assembled before
being attached to the rear of the main
body of the machine.

The triangular supports are

interchangeable between the left and
right hand side. The white crossbar
needs to be bolted to the supports
from the underneath and then the
four bolts tightened to create a rigid
framework.

This is then bolted to the rear of the
main body using four M6 cap head
screws.

Back Panel View

White Crossbar with returns upwards - Fit to triangles before fitting to machine

Triangular support stabaliser

Remove 4off

M6 Cap head

screw - Fit

complete
stabaliser

assembly &

replace screws

Manual - Formech 508DT/FS

19

The Cooling fan option consists of:

• FAN & Power lead

• L&R Fan Posts

• Fan Crossmember.

Remove the rear screw of the rail link Fan post .

Fix and tighten with the screw and a 2nd mounting
screw for both posts.

& Fix the crossmember to the fan posts using the
fi xings supplied. Position the fan grill towards the front
of the machine.

Installation and Initial assembly (508FS only)

Cooling fan option

1

2

3

4

5

6

1

2

3

4 5

6

Manual - Formech 508DT/FS

20

Installation and Initial assembly (508FS only)

Cooling fan option (continuation)

7

8

9

10

11

12

Position the fan unit on the crossmember.

Insert the mounting screws.

Fit the Fixing nut to the screw & tighten.

& Insert the IEC connector into the receptacle
located on the electrical box.

Secure the cable with the fi xings supplied.

7

8

9

10 11

12

Manual - Formech 508DT/FS

21

Installation and Initial assembly (508FS only)

Compressed air connection - 508FS only

8mm tube air supply outlet valve for
use with ancillary equipment (eg. Air
blow gun).

10mm tube air inlet connection.

Air requirements for the 508FS: 80PSI / 5 bar

Manual - Formech 508DT/FS

22

Optional extras

The following items can be purchased for your 508 vacuum forming machine

1. Service kit 2. Reducing windows 3. Blow mould windows

4. 508DT Machine trolley 5. 508FS cooling fan
& gantry

1. It is unlikely that you will need to service or repair your machine for many years provided you follow
the maintenance information contained in this manual. However, the table and clamp seals, which are
considered to be consumable items, will need to be replaced depending on the usage of the machine.
Therefore this kit contains the essential consumables (seals and pump fi lter) to ensure a good performance
of your machine year on year.

2. Formech has available 2 standard sizes of reducing windows for the 508, with apertures of 228 x 204mm
and 432 x 229 mm. Formech can also produce special size reducing windows. For more information please
contact our sales department.

3. You can use your vacuum forming machine to do blow moulding by fi tting a special circular reducing
window to your machine. The maximum diameter you will get on the 508FS is 430mm. For more
information please contact our sales department.

Manual - Formech 508DT/FS

23

Heater Layout

508DT

508FS

Zoning

Zoning

Front of machine

Front of machine

Front of machine

Front of machine

Manual - Formech 508DT/FS

24

Operating Procedures - Quick start guide default settings

Basic Operation Mode 508DT/FS

To warm up the heater, press the button followed by to return to the main menu. The
heater will turn on using the default values as follows.

Thermoforming materials and tooling will be required to perform the Vacuum Forming process. You will
need to have plastics materials cut to size and tooling to form your material around.

Place your tooling on the mould table. The steel mesh will allow good air fl ow to your mould tool. It may
be necessary to mount your tooling on a base board, it is important allow for good airfl ow through the
baseboard, to keep you base board to less than 6mm and to give the board a mitred edge with clearance
from the edge of the forming aperture.

The standby level is set to 50% so the heater will
be at half the set power when in the rear position.



<



RUN

DEFAULT SETTINGS:

ZONES: 70%

STANDBY: 50%

HEATING TIME: 50 seconds

The 508DT/FS has built-in default settings which allow
the operator to use the machine without entering values
for the heaters or heating time.

Main Menu: Allows you to create a new recipe, edit or
load an existing one, or start a vacuum forming process.
When the machine starts, the ‘DEFAULT’ settings are
automatically loaded.

To start the vacuum forming process, press the ‘RUN’
button to use the default settings.

A red screen will appear. Pull the heater forwards to
begin heating the material. Follow the instructions 1-28
to learn how to use all the operating features of the
508DT & 508FS.

The heater will reach operating temperature within 5mins. With the mould positioned on the table and
the table in the lowered position, place your plastic material on the aperture seals ensuring it is centrally
positioned to gain optimum clamping.

Depending on the material thickness and / or if a reducing window is fi tted the front clamps may need to be
adjusted to ensure an even clamping of the material. The Rear clamp hinges are spring loaded. Adjust the
lock nuts to adjust the loading.

Manual - Formech 508DT/FS

25

5. When the moulding is cooled press
to push air under the plastic to lift the mould
from the tool. The Release button will only
activate when pressed. When Release is
pressed the Vacuum will stop and the
button will appear.

Operating Procedures - Quick start guide default settings

Basic Operation Mode



FINISH



RELEASE



RUN



START

VACUUM



FINISH

1. Press to start the cycle

2. Pull the heater forwards using the handle

so the heater is covering the plastic.

3. The Heater timer will begin counting down.
It may be necessary to move the heater
back a little to check the plastic is suffi ciently
heated. When the plastic is soft enough
push the heater fully back and pull the crank
handle forwards to lift the table and mould
tool into the soft plastic. When the table is
sealed press the button.

4. The screen changes to show the Vacuum
latched ON. The vacuum can be turned
ON/OFF by pressing this button. Monitor
the forming to ensure you have achieved the
correct defi nition. The plastic will cool.

6. Press when the moulding is
complete and has been released from the
mould.

Manual - Formech 508DT/FS

26

10. The forming stage screen contains the Fan
ON/OFF button and shows the time set for
the fan timer. The Fan will run for the time set
when the is pressed.

7. There are 3 options:

•Press to return to the main menu.

•Pull the heater forwards and a new cycle will

begin from 3. above – ensure a new sheet of
plastic is clamped.

•Press to record the times just used –

see 26.

Operating Procedures - Quick start guide default settings

Basic Operation Mode (continuation)



MAIN



START

FAN



SAVE

TIMES

JUST
USED

8. The Main Menu allows you to create a new
record, edit or load an existing one, or start the
vacuum forming process.
The Formech 508FS has additional features
covered in the next section (9-10)
See 11-25 for editing, 26 for SAVE TIMES
JUST USED and 27-28 for loading previously
saved programs.

Operation Mode 508FS – Additional features

The 508FS has the Following additional features:

• Pre-stretch function that applies compressed air under the heated plastic before forming to stretch the

plastic more evenly.

• An auto-levelling system using the same air supply. Enabled in setting mode.

• Cooling system option.

9. The 508FS Pre-stretch button is positioned
on the heater timer screen. Apply pre-stretch
air after the heating stage before lifting the
mould tool into the plastic material.

Manual - Formech 508DT/FS

27

Heat settings (12)

14. The 4 heating zones may be set by

pressing the button.

15. The Heater standby level may be set by
pressing the button.

Operating Procedures - Using custom settings

Basic Operation Mode 508DT/FS - Editing the heater and time settings

11. Press the new edit button to

adjust and record the Heater and Time
settings. The settings screen will open.

12. Press to adjust the heater zone
power settings.

13. Press to adjust the heater timer and
fan timer (508FS).

Heat Zone Adjustment (14)

16. The heater zone layout is shown

displaying the zone number and the power
level set.

17. The auto level feature may be adjusted by
pressing the toggle ON / OFF button (508FS).

When forming clear polycarbonate, you may
need to fi t an additional cover to the auto­level sensor which has been developed for this
material.

18. To change the selected zone, press the
desired zone (16), and select the % of heat
required. The screen returns to the zone layout
screen. Repeat for the other zones as required.

Manual - Formech 508DT/FS

28

20. Press the time settings button (13) to
adjust the heater timer and Fan timer (508FS).

21. Press the Heat timer button to open the
heater time screen.

22. Press the FAN RUN button to open the
Fan time screen.

Operating Procedures - Using custom settings

Basic Operation Mode 508DT/FS - Editing the heater and time settings

Standby adjustment (15)

Time settings (13)

19. Press standby settings (15), and select the
required standby % level. The standby level powers
the heater to this proportion of the zone profi le set
when the heater is in the rear position. The purpose
is to provide an idle heat temperature and save
power. Press OK to return to the settings screen.

23. Press on the Heat timer value and adjust the
time in seconds using the POP UP keypad. Press OK
to fi nish.

24. Press on the FAN timer value and adjust the time
in seconds using the POP UP keypad. Press OK to
fi nish (508FS only).

Press OK to fi nish then OK again to return to the
settings screen. (12 & 13)

25. Press SAVE on the settings screen will open the
MEMORY SAVE screen, select an existing memory
slot to save changes or select any other slot to save
changes to a different name. Change the memory
#name using the POP UP keypad by pressing on the
title name box. Press when complete.

Return to the main menu.

Manual - Formech 508DT/FS

29

26. After forming test mouldings manually, if
the used times are required to be saved press
the button.

Operating procedures – Other settings / loading programs

Operation Mode 508DT / 508FS



SAVE

TIMES

JUST
USED

27. To load a program previously SAVED press
the button.

The LOAD screen will open.

28. Select the program number required to
Run, the program title will show in the title box.

Press for the required program and
the settings are loaded for use as in 2.

Manual - Formech 508DT/FS

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.

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 infrared heating elements supplied with this machine are manufactured from a ceramic material and
are very brittle. A shock to the machine may break an element.

An interlock system is built into the machine to prevent a mould being pushed up into the heater and
damaging 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.
Because of this we are unable to apply our standard warranty to ceramic heating elements.

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.

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 508DT/FS

31

Service / Repair

Replacing seals

Clean up completely,
mask the area and ‘key’
the surface.

Apply the sealant
evently.

Fit overlapping silicone
strips and ‘bed’ into
sealant.

Apply a 45 degree mitre
at the corners. Ensure
the joint is sealed.

1

2

3 4

1. Remove all the existing seal and adhesive with a sharp blade. Mask off the sealing area with masking tape

or similar (Mask the outside for top frames or reducing windows & the inside for table seals). Prepare the
sealing area with emery cloth or similar to achieve a good surface for the new adhesive to key with. Ensure
that the surface is clean from dust, dirt and grease.

2. Apply a generous bead of high modulus silicone sealant to the masked area and smooth down to give a
consistent layer.

3. Cut the silicone strip in lengths long enough to overlap the corners. Do not stretch the seal strip when
measuring or applying. Lay each strip on to the seal area overlapping at the corners. Ensure the seal strip is
bedded down well by pressing fi rmly along the full length.

4. With a sharp blade cut a 45° mitre joint at all corners. Fill gaps in the joints with sealant. Remove the
masking tape before the sealant has set. For best performance leave seal to set overnight.

Manual - Formech 508DT/FS

32

Service / Repair

Replacing a heating element

ELECTRICAL MAINTENANCE SHOULD ONLY BE ATTEMPTED BY SUITABLY QUALIFIED TECHNICIANS.

How to check a heating element

If you notice there is a cold area on heated plastics, it may be that a heating zone or heating element is not
working correctly. In either case the fi rst step is to check the wiring at the terminal block. It is not always
obvious that they are loose or disconnected.

1- First, check that the heating zones are set correctly, set all the zones to 70% and check for even heat and
softening plastic when the heater is held over the forming are with plastic sheet fi tted. Make a note of areas
where the plastic remains hard to determine if it is a single element of entire zone.

2- If an entire zone is not functioning then remove the top cover and check that the wiring is not loose or
has become disconnected for that particular zone. You will have to remove relevant terminal block covers
to determine this. If all appears OK then set the defective zone to 100% and check the voltage at the zone
using a suitable volt meter.

3- If no voltage is present then contact Formech for service and advice.

If a single element is found to be faulty then it will require replacement.

Unplug the machine from the mains

Bring the heater completely
forward and remove the 10
screws retaining the cover on top
of the heater.

The front 2 screws are retained with
an internal plate that will fall when the
screws are removed. Retain this plate
for fi tting during reassembly.

Manual - Formech 508DT/FS

33

Service / Repair

Replacing a heating element (continuation)

At this stage check that all the element
wires and interconnecting wires are fully
tightened and that the fault was not
merely a loose connection.

Remove the relevant terminal block
cover(s).

Loosen and remove the element wires
from the appropriate connector block.

Remove the nuts and washers holding the
faulty element.

Remove element and fi t the replacement
new heating element ensuring the fi xing
screws are secured.

Ensure that the connections are
correctly fi tted and the connector block
screws are fully tightened. Replace the
connector cover and test the heater.
Finally reassemble the heater top cover
and retaining plate for the front fi xings.

Manual - Formech 508DT/FS

34

Service / Repair

Electrical Troubleshooting

Before any maintenance work is carried out both electrical and air supplies must be locked in
the OFF position or the mains lead removed (508DT).

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 a complete appraisal of the
faults and symptoms.

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.

Vacuum / Pressure Troubleshooting (508DT & 508FS)

Raise and lock the mould
table in the up position

Turn the vacuum on and
place your fi nger over the
vacuum hole

Check the reading you
get on the vacuum gauge

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.

If the vacuum gauge reading of 25”Hg or higher is Normal. A lower reading indicates poor vacuum where
attention is required.

The possible causes of poor vacuum are:

a) mould or baseboard is blocking and covering the vacuum hole preventing air fl ow (*)
b) Top frame or table seals are worn or damaged and may need replacing.
c) The mould table, top frame or reducing plates are damaged or distorted.
d) Vacuum table pipe has been disconnected from underside of table.
e) Vacuum pump fi lter is blocked.
f) Vacuum circuit has loose or damaged pipes.
g) Vacuum valve is blocked.
h) Pump diaphragm is damaged.
i) Pump is faulty.

(*) Use the table mesh provided with the machine

Manual - Formech 508DT/FS

35

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 508DT & 508FS require minimum lubrication.
Apply general purpose grease to the table guide bars when required to assist with table movement.
Apply a small amount of fine silicone oil or fine oil to the heater slide bars when required to assist free
movement of the heater.

Manual - Formech 508DT/FS

36

Electrical Wiring - 508DT

Manual - Formech 508DT/FS

37

Vacuum Pump 2D351VM - 508DT only

Features

> Oil free with stainless steel valves
> Good quality, low noise
> Easily changed from pressure to vacuum and vice versa
> Accessory regulating valve and gauge available
> All models 240V single phase

Specifi cations

Model Typical Applications Typical Performance Max Pressure

2D351VM Vacuum fi ltration ult. vacuum 51mm Hg 30l/min at 30psi

Manual - Formech 508DT/FS

38

Typical arrangement

Vacuum Pump 2D351VM - 508DT only

Manual - Formech 508DT/FS

39

Electrical Wiring - 508FS

Manual - Formech 508DT/FS

40

Becker Pump VT 4.10 - 508FS only

SERVICE

Made in Germany

year

No

min

-1

kW

m /h

3

mbar

mbar

type

speed

power required

inlet capacity

vacuum

pressure

+

-

Hz

f

requenc

y

frequency

D-42279 Wuppertal

www.becker-international.com

XXXX

XXXX
XXXX
XXXX
XXXX

Index
Variante

XXXX

XXXX

Index (-)

(-)XXXXXXX

VT 4.10-XX

15

18 19

17

83

16

102 103

133

87

85

Spare parts list VT 4.10

Manual - Formech 508DT/FS

41

Becker Pump VT 4.10 - 508FS only

Position Identification No. Description

15 020000 16200 ROTOR

16 016800 05000 CLAMPING DISC

17 911001 00000 STAR-TOLERANCE-RING

18 949203 00000 TOOTHED SPRING WASHER

19 945320 00000 SOCKET HEAD SCREW

21 000100 16200 PUMP BODY

23 945319 00000 SOCKET HEAD SCREW
24 901327 00007 CARBON VANES (KIT)

28 000700 16200 LID

29 945364 00000 SOCKET HEAD SCREW

30 008901 16200 GASKET

61 004800 27300 FILTER COVER

67 009000 16300 BLADE SPRING

69 952009 00000 LOCATING PIN
72 909518 00000 FILTER CARTRIDGE (1x - necessary quantity)

76 945364 00000 SOCKET HEAD SCREW

77 948021 00000 SEALING RING

78 913161 00000 O-RING

83 006800 27300 PROTECTING HOOD

84 060901 16300 ELASTIC PAD

85 741310 50000 RUBBER BUFFER

86 949402 00000 WASHER

87 947001 00000 HEX.NUT

88 006801 27300 PROTECTING HOOD (FRONT)

89 741310 90000 RUBBER BUFFER

90 945318 00000 SOCKET HEAD SCREW

91 951922 00000 RUBBER ELEMENT

94 015100 27300 FOOT

95 951921 00000 RUBBER ELEMENT

96 068000 27600 SPACING COLLAR

97 945363 00000 SOCKET HEAD SCREW

98 949451 00000 WASHER

102 968104 00000 RUBBER SLEEVE

103 029600 16300 BOLT

124 736001 99613 VACUUM REGULATING VALVE

128 727502 06000 BLOW-OFF VALVE

132 951232 00000 SCREW PLUG

133 951224 00000 SCREW PLUG

Spare parts list VT 4.10 (continuation)

42

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: 508DT/FS
Serial 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: A. 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: Managing Director
Being the responsible person appointed by the manufacturer

EC Certificate

Formech International Limited, Unit 4, Thrales End Farm, Thrales End Lane, Harpenden

Hertfordshire AL5 3NS, United Kingdom

43

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]

Email: [e-mail]