Formech IMD508 Installation, Operating And Service Manual

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IMD508

Installation, Operating and Service Manual

.

.

.

For Parts, Service & Technical Assistance

North and South America

Telephone: [phone]

Fax: [phone]

High Performance

Thermoforming Machine

Manual - Formech IMD508

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Table Of Content

Table Of Content 2

Safety 4

Specifications 8

Foreword 8
Machine Specifications 8
Features 8
Noise emissions 9
Machine storage 9
Machine transportation, lifting and moving 9

Installation 10

Electrical connection 10
Three phase supply 10
Pneumatic connection 10

Introduction 11

Operation - Main Menu Fuctions 12

Powering up 12
Main Screen Control 12
Getting started 13
Control POD Functions 13
Operation Screen Safety Indicators 13

Operation - Manual Functions 14

Control POD Manual Operation Screen 14
Manual Setup - Heaters 16
Manual Setup - Table settings 17
Manual Cycle 18
Manual Plastic Clamping 18
Heating 18
Auto-Level 18
Moulding 18
Pre-Stretch 18
Cooling & Release 18

Operation - Setup functions for Semi-Automatic cycle 19

Semi-automatic screen & buttons 19
Process Timer Settings 21
Pyrometer Option 24
Heater Security Function 25

Machine Adjustments and Settings 26

Speed Adjusment 26
Clamp Frame rear spring adjustment 26
Cooling Fan Adjustment 26

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Table Of Content

Plug assist mechanical stop (Option) 26
Fixing mould tools 27
Pyrometer Air Pressure 27
Electrical 28
Typical fault scenarios 28
Heater 28
Replacement of Heating elements – Top Heater 29
Replacement of Heating elements – Bottom Heater 29
Auto-Levelling & Bottom Heater Safety Sensing. 29

Fault Diagnostics / Maintenance 30

Vacuum 30
Pneumatics 31
General lubrication 31
Clamp & Table Seals 31
Replace a damaged or worn seal 32
Cleaning 32
Service Support 32

Periodic Maintenance 33

Warranty 34

Heating Elements 34
Vacuum System 34

Electrical Schematics (Index) 35

Parts Listing 53

EC Certificate 57

Manual - Formech IMD508

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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 qualified 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 filtered & 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 finished product and any
waste.

11) This machine is fitted 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.

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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 230V.

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 500°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 specific to this machine.

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HEALTH & SAFETY - Hazards specific to this machine.

Safety

6. Injury from Trapping.

There is a risk of trapping fingers 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 fingers 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 fitting and loading of mould tools.

-Loading and fitting 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 specification may cause the plastic to be
blown into the heaters and to be ignited. Periodically monitor and check the condition of the infrared beam
sensors.

ENSURE THE COMPRESSED AIR SUPPLY IS SET TO THE RECOMMENDED LEVEL AND ONLY USE THE HEATER
FOR THE HEATING OF VACUUM FORMING PLASTIC MATERIALS.
RISK OF FIRE AS A RESULT OF HEAT 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 fitted.

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.

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HEALTH & SAFETY - Hazards specific 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 USE THE MACHINE TO STACK OR LEAN ITEMS AGINST THE SIDES.
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.

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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.

Machine Specifications

IMD508

Forming area: 470mm x 470mm

Sheet Size: Nominal 508mm x 508mm

Material thickness 0.25mm min. 6.0mm max

Electrical
Power - 12.6kW - Supply 380-415V, 5 wire, 3 phase + Neutral + earth, 50Hz, 32A (Europe)
Power - 12.6kW - Supply 208-220V, 4 wire, 3 phase + Earth, 60Hz, 40A (North America)

Air Supply: Approx. 10 cu. ft / min @ 100 psi (approx. 300l / min @ 6 bar.)

Width: 1200mm Depth: 2050mm Working height: 1430mm Height with Plug assist: 3080mm
Weight: 900Kg

Features

• Semi-automatic mode for sheet fed processes

• Manual Control for Sequence set up & sheet fed processes

• System control: PLC with Touch sensitive HMI

• Automatic sheet levelling

• Pre-stretch

• Mould release

• 21.5m3/hr (60Hz) Oil pump

• Air Fan Cooling

• Electrical actuator table drive with variable positioning and 5 speed settings

• Pneumatic clamping

• Real time user timing adjustment / setting by touch screen

• Pyrometer material temperature measurement integrated into semi-auto cycle

• Ceramic Heaters with full feedback heat level settings in Deg C & F

• Cooling Bolster (Option)

• 40 Job setting memory capability

• Plug Assist with mechanical dead stop (Option)

• Vacuum & Pressure gauge indication

• Safety light curtain guarding

• WAGO PLC

• Air flow regulation control

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Specifications

Noise emissions

Noise emissions on the Formech IMD508 are less than 70dB(A).

Machine storage

The Formech IMD508 must be stored in a dry environment. If the machine is not used for a long period of
time, run the pump periodically (once a month).

Machine transportation, lifting and moving.

The Formech IMD508 is prepared for transportation with the front stand assy.

Before lifting, remove all separate assemblies and leave the heater fixed in its position until positioning at its
operating site. Remove packaging where it assists with lifting and moving.

The centre of gravity is approximately at the machine centre.

Remove fixing blocks and the stand assembly from the crate base.

Ensure lifting forks pass through the main cabinet.

Fix the adjustable feet to the base of the machine before placing. The short foot is situated at the LHS REAR.

Ensure that local lifting and handling procedures are applied and monitored

by a person responsible for health and safety.

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Installation

The machine should be sited on a level concrete floor. 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 airflow 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.

Three phase supply

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.

THIS MACHINE MUST BE EARTHED

Pneumatic connection

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 filtered & lubricated using
good quality airline oil. A competent person must make compressed air connections
If flexible hoses are used it is strongly advised that they are of Nylon, canvas or wire reinforced rubber and
suitably rated for pressure and temperature. The connection hose size should be 12mm diameter or 1/2”
BSP. The unit is supplied with a length of pipe & BSP fitting.

Maximum airline pressure must not exceed 6 BAR or 80 PSI.

If the air supply is insufficient the performance of the machine will be compromised.

For this reason, an air reservoir should be sited as close to the machine as practical. If this is not possible then
large bore pipes can be used to prevent pressure drop when the above functions are used.

The IMD508 must be installed and commissioned by Formech.

It is essential to read and fully understand all the information in this manual relating to safety

and the Safety Hazards specific to this machine before installing and operating.

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

by the person responsible for health and safety.

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Introduction

The IMD508 is a large vacuum forming machine for sheet feed production suitable for forming a wide
variety of plastic materials. It has been designed with operating simplicity high on the list of priorities.

Operators who have previously used vacuum forming machines will quickly become familiar with the user­friendly controller programming.

Whether required for long or short production batches or for prototyping or sampling the IMD508 adapts
quickly to most needs.

The Formech IMD508 uses the reliable
and robust Wago PLC with Weintek 10”
Touch screen user interface.

Formech have produced high quality
functional graphic software to give
an easy to use, flexible and versatile
Thermoforming machine for all forms of
industrial and commercial use.

The IMD508 Software provides for both
manual and semi-automatic functionality
of the vacuum forming process.

The following section explains the IMD508 control functions:

1. Main menu functions.

2. Manual Operation, Heater Settings and the Vacuum Forming Process.

3. Set up and use of the Semi-Automatic Operation.

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Operation - Main Menu Fuctions

Powering up

Ensure the Emergency stop button is latched out.
Turn on the mains isolator at the control panel at the rear of the machine.
The main menu will be shown as below.

Main screen

The Main Menu shows the options.
Button descriptions are below.
On machine start up default settings are loaded for the

heater zones to allow for manual operation.
Familiarise yourself with the button icons.

Heater

Default heater settings are pre-programmed for manual operation. Press this button to
activate the heater. The heater must be ON to use the machine. The heater can also be
switched off during machine or tooling set up.

Pump

Press this to enable the pump. The vacuum pump can be switched off when not required e.g.
during machine or tooling set up.

Automatic Mode

Operate the machine using the semi-automatic cycle by selecting a stored program from the
memory.

Manual Mode

Operate the machine with each action of the machine being activated by the operator.

Language

Select the required language.

HELP Function

The question mark icon can be pressed at any time for an explanation of each of the icons.

Main Screen Control

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Operation - Main Menu Functions

Getting started

On the main menu screen
Turn the Heater ON
Ensure the Pump is ON
Press the Manual Button – The Manual Operation Screen will open

Control POD Functions

The following section describes the manual controls of the IMD508. Operate these controls independently
to ensure you are fully familiar with how the machine operates and how each action behaves.

Vacuum & Pressure

Gauges

Touch Screen

Emergency Stop

Emergency Stop

This momentary action latching button cuts the power to all outputs when pressed. The indi­cator shown will be displayed on the touch screen if pressed. The button will need to be ma­nually reset for normal operations to continue. Only use this button in emergency situations.

AIR

This indicator will show if the air supply to the machine is lost. The heaters will shut off until
air is restored. (Heating pyrometer option only)

Guard

When the Light guard is broken power is cut to all critical outputs. The Blue button on the
control POD will illuminate. Press this button to reset the Light guard. The indicator shown will
be displayed on the touch screen when the light guard is broken.

Bottom Heater Safety Detection

The bottom heater has a system to detect plastic material drooping onto the heaters. This
symbol will appear red if the sensing system is activated.

Operation Screen Safety Indicators

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AIR

Guard Reset

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Operation - Manual Functions

Press the Manual Button on the main
menu screen – The Manual Operation
Screen will open as shown.
The meaning and operation of the
buttons on this screen are shown below.
Following this is a full description of the
vacuum forming process.

The screen icons are designed to
be followed round in a clockwise
direction, starting with the clamp
(top left) and ending with the release
button.

Control POD Manual Operation Screen

Auto-level

This button enables the auto-level feature. If the plastic is sagging and not being heated
evenly then the autolevel feature may be used to keep the plastic level while the heater is
forward and until the heater is fully back.

Clamp

Allows movement of the material clamp UP & DOWN.

Heater Zone Settings

These buttons allows direct adjustment of the heater zones. This may only be performed
when the other functions are not in use.

Heater Drive

These buttons control the movement of the heater. There are separate buttons for the top
heater and the bottom heater. The direction of heater movement is reversed each time the
button is pressed. In manual mode the timer counts up.

Pre-Stretch

Press the Pre-stretch button to inflate the plastic before moulding.

Plug Assist

Press the plug UP & DOWN arrows on the button descend and retract the plug plate.

Mould Table

Press the Table UP & DOWN arrows on the button to raise and lower the table.

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Operation - Manual Functions

Vacuum

The vacuum icon is used to apply vacuum to the table by the vacuum pump.
In manual mode the timer counts up.
This button latches ON when pressed. Press again to turn OFF.

Fans

Pressing the fan icon will turn the cooling fans ON.
Press again to turn OFF.
In manual mode the timer counts up.

Release

The release icon is used to blow compressed air between the mould and the finished
moulding.
This is a momentary HOLD TO RUN button.

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Operation - Manual Functions

Manual Setup - Heaters

Select the Manual icon on the main screen.

The heaters are controlled by the PLC system to vary the output of individual zones as displayed on the
touch screen.

Allow 20 - 30 minutes for the heaters to reach operating temperature before attempting to run any
mouldings.

To change the heating zone settings press the heat zones settings button on the manual operation screen.

There are 49 heating zones on
the Top heater of the IMD508.
The heater must be set to ‘ON’
to operate.
Heating elements have
thermocouples fitted and the
element temperature is fed back
to the control system.
Set a target temperature for
each zone as required.

Temperatures can be set to Fahrenheit or Centigrade – press button to select.
The power of each 2½” square element is 125W.
The top value of each zone is the target temperature; the lower value is the actual zone temperature. All
adjustments are real time so a target value may be set and the actual temperature will respond and change.
To set, adjust the setting value using the + / - buttons or press on the value to open a keypad – press on any
zone to transfer the value to the zone. Repeat on all zones to set the required heat profile.

There are 28 heating zones
on the Bottom heater of the
IMD508.
The power of each 2½” x 5”
element is 125W.
Setting is the same as above.

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Operation - Manual Functions

Manual Setup – Table settings

Mould Table settings

The Mould table is driven by an electric actuator allowing variable height setting and 5 speed options.

Step 1 - Set the mould height value. This is the highest point of the mould measured from the cooling
bolster plate. Conditions apply as detailed below.

Step 2 - Set the table speed. There are 5 settings preset as a % of full speed (220mm/s).

Step 3 - Set the table start position. 450mm is the lower position. 10mm is the highest position. Conditions

apply to value setting which depend on the mould height and heater clearances. Details below:

• Settings are adjusted in table settings screen when cycle is stopped.

• Table height setting distances are measured from the underside of the aperture where material is
clamped to the table bolster top. All values in (mm).

• Condition 1. The Mould tool height value is a mandatory setting.

• Condition 2. The Mould height setting must be less than the Table Height setting to maintain the
mould below the aperture level.

• Condition 3. If Heater security function is turned OFF to allow the table to rise before the top
heater retracts, the Mould height must be less than 100mm.

• Condition 4. The Bottom heater may only be used when the Mould height is less than 150mm and
the table height setting must be greater than 300mm plus the mould height. Values outside these
limits will disable the bottom heater function

• A confirmation message will occur when a program is opened, including startup, showing the
mould height setting & requesting confirmation before starting a cycle.

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Operation - Manual Functions

Manual Cycle

Once the mould is correctly located on the mould table, a manual cycle may be attempted.

Manual Plastic Clamping

Place the plastic over the forming area and ensure the material covers the top frame seal completely. Once
the clamp frame is over the plastic correctly reset the guard. Press the Clamp down arrow.

Heating

Press the heater icons and the heaters will be driven forward over the plastic. Monitor the heating visually.

Auto-Level

If the plastic is sagging and not being heated evenly then switch the autolevel feature on, in the centre of
the touch screen. If the plastic sheet drops and breaks the sensor beam, short bursts of air will be blown in
to the chamber under the heated plastic ensuring the plastic remains level.

Moulding

Send the heater to the back position by pressing the heater button when the plastic is at the correct
temperature for moulding. When the heater has reached the back limit switch and stopped, press both table
buttons simultaneously to raise the mould into the plastic. Press the vacuum button to apply vacuum to the
table.

Pre-Stretch

If the moulding is quite high it may be necessary to prestretch the plastic before moulding takes place. To do
this, press the pre-stretch button when the heaters are back.

Cooling & Release

At the appropriate time the fans may be turned on to start the plastic cooling process. Once the plastic has
cooled sufficiently the release icon may be pressed to blow the moulding off of the mould. The moulding is
now complete and the table may be lowered and the clamp frame raised.

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Operation - Setup functions for Semi-Automatic Cycle

On the main menu press the Semi-auto button . The screen above will open and show
the stages and functions of the semi-auto cycle. The auto cycle stages follow the grey oval
beginning with the clamp. Parameter / timing settings for each stage are performed by
pressing the corresponding button. Changes are made immediately. Other buttons are
detailed below. When the semi-auto screen is opened, the parameter settings for the last
used job will show.

The purpose of the additional buttons is shown below:

RESET

Press this button to return all assemblies to the home position. The START button will show.

START

This button will start the auto cycle.
When pressed the STOP button will show.

STOP

This button will perform a controlled stop. A small rectangle will show when activated. The
machine will stop at the end of the cycle.

Semi-automatic screen & buttons

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Operation - Setup functions for Semi-Automatic Cycle

Timed Heater Cycle

When this button shows the auto cycle is set for the timed cycle and the heaters will operate
for the times set.
Press this toggle button to set to the pyrometer heat cycle

PROGRAM Select

Press this button to load a different program. The load program screen is opened.

SAVE Program

Press this button to save the changes made to the current program. The save screen shown
all the parameters for final check.

CYCLE Counter

This feature will count the quantity of automatic cycles. Press this to set the batch counter
and reset the counter. The number shown in the oval shows the batch counter setting. The
number shown at the top shows the actual count quantity.

BACK or RETURN

This button will return to the main menu.

PAUSE

This button is a manual over-ride to pause the heating stage timer. It is essential to monitor
this manual intervention to prevent material overheating.

JUMP / Advance

This button is a manual over-ride to end the heating stage timer before time-out or to end
the heating stage after Pause’ is applied.

Pyrometer timed cycle

When this button shows the auto cycle is set for the pyrometer control and the heaters will
operate for the target temperature set. The temperature of the pyrometer is shown above the
button and the target temperature is shown below the button.
Press this toggle button to set to the timed heat cycle.

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PAUSE

JUMP /
ADVANCE

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Operation - Setup functions for Semi-Automatic Cycle

Set the top heater time by pressing the heater button
at the top RH Corner on the Semi-Auto screen.

Press the number in the timer button and adjust the
time using the pop-up keypad.

Adjust the bottom heater time in the same way using
the Bottom heater button.

The Pyrometer values are set on the semi-automatic
operation screens

Set the pre-stretch parameters by pressing the pre­stretch button on the Semi-Auto screen.

Enable the pre-stretch by setting the toggle button to
‘ON’.

Set the pre-stretch time and the delay time (if
required) by pressing on the time value and using the
pop up keypad.

Set the Plug assist parameters by pressing the Plug
button on the Semi-Auto screen.
There are 2 plug stages: 1. Mould plug & 2. Release
plug
Enable the function by setting the toggle buttons to
‘ON’ or ‘OFF’ as required.
Set the Plug times and the delay times (if required)
by pressing on the time value and using the pop up
keypad.

Set the Table parameters by pressing the Table button
on the Semi-Auto screen.

Set the Table delay times (if required) by pressing on
the time value and using the pop up keypad.

Process Timer Settings

Manual - Formech IMD508

22

Operation - Setup functions for Semi-Automatic Cycle

Set the Vacuum parameters by pressing the Vacuum
button on the Semi-Auto screen.

Set the Vacuum time and delay times (if required)
by pressing on the time value and using the pop up
keypad.

Set the Cooling Fan parameters by pressing the FAN
button on the Semi-Auto screen.
Enable the Cooling function by setting the toggle
button to ‘ON’.
Set the fan time and the delay time (if required) by
pressing on the time value and using the pop up
keypad.

Set the Cycle Counter parameters by pressing the cycle
count button.
The RESET button will reset the count to zero.
Set the batch counter to set a required batch quantity.

Set the Release parameters by pressing the Release
button on the Semi-Auto screen.
Set the Release time and delay times (if required)
by pressing on the time value and using the pop up
keypad.

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Operation - Setup functions for Semi-Automatic Cycle



Press the PROGRAM button to open and load a saved
program.

Select the required program number to load in auto /
semi-auto mode.

Press the SAVE button to open and load a saved
program.

To save an existing program, select the required
program and press the SAVE button. To save as another
program select another program number and press the
SAVE button.
The Save Parameters screen will open showing the
parameters set. This allows final review and adjustment.
Press the SAVE button to complete.

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24

Operation - Setup functions for Semi-Automatic Cycle

When the pyrometer button shows the heater cycle will be completed when the material
reaches the target temperature.
The value is shown below the button. The Actual temperature is shown above the button

When the timer button shows the heat cycle will operate from the time shown on the heater
buttons.
The actual pyrometer temperature is shown above the button.





Pyrometer Option

When in Semi-Auto, the heat cycle may operate from the heater timers or the pyrometer.

Give consideration to the timings set for the semi-auto sequence. It may be necessary to run the

product in the manual mode first to establish the required time for settings.

The times for each stage of the process will affect the product produced. The time settings can

be adjusted while the machine is operating. Adjust the set times for optimum performance and

monitor the output. Simply press the button of a function, make the setting changes and return to

the operating screen. Remember to save any changes.





Ensure the table and mould height values are set.

Set appropriate timings for each function.

Choose to work from timer or pyrometer for the heat
cycle.

Select the Auto-Level feature if required.

Select the Heater Security if required.

Semi-automatic Operation

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25

Heater Security Function

When the Heater Security function is ON, interlocks provide protection against raising the table into the top
heater.

When the function is OFF, the top heater interlocks are removed allowing the table to be raised before the
top heater retracts.

Also when the function is OFF the pre-stretch and Plug function will be disabled.

The Mould height must be less than 100mm.

For the timed cycle the Mould table will be raised at the end time of the top heating stage and a ‘top heater
retract delay time’ will maintain the heater in position for a time set ; 1-5 seconds. Value is set in Top Heater

Settings screen. See Process Timer Settings.

For the pyrometer control cycle the Mould table is commanded UP when the pyrometer measurement
reaches the target temperature and a ‘top heater retract delay time’ will maintain the heater in position for
a time set ; 1-5 seconds. Value is also set in the Top Heater settings screen.

The timed bottom heater cycle may be used with this security function OFF but the bottom heater time
must be set to 5 second less than the Top heater time to allow the bottom heater to retract before the table
rises. If the bottom heater time is not set as such then the table will not rise as its command is prohibited by
the heater position (Bottom Heater must be retracted to allow table movement). Mould heights and table
positions will always apply.

The Pyrometer controlled cycle may be used with the bottom heater with the heater security function OFF
but the ‘Bottom Heater retract advance temperature setting’ must be set from 1-5 deg. This will retract the
bottom heater at the set value (1-5 deg) before the pyrometer target temperature and thus allow the table
to rise at the target temperature while the top heater remains forwards.

Operation - Setup functions for Semi-Automatic Cycle

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26

Machine Adjustments and Settings

Speed Adjusment

The Plug assist down speed, the table up speed and the table down speed are
controlled by the speed adjustments fitted to the front of the machine.

Adjust these to assist with synchronisation of the plug and release functions.

The Vacuum flow may be adjusted using the Vacuum lever valve. Other speed
adjustment is performed by using the speed controllers mounted on the cylinder
ends or valves.

Clamp Frame rear spring adjustment

The clamp frame is spring loaded at the rear.

The loading of the springs may need to be adjusted, for example, when using
thinner or thicker plastics materials to assist with correct clamping.

Panels will need to be removed when making this adjustment, isolate the machine power

before removing any cabinet panels

Cooling Fan Adjustment

The cooling fans may be adjusted to give the correct direction for cooling of the vacuum forming. Loosen the
nut and screws in the pivot block to rotate and position the fan on the fan post and fan plate.

Plug assist mechanical stop (Option)

The plug assist is guided by the external guide bars. Threaded screws on either side of the plug cylinder allow
adjustment of a mechanical lower stop. Ensure the plug is UP and adjust the 2 large nuts to the required
lower stop level. Ensure that the stop nuts at the same level on each side of the cylinder.

Manual - Formech IMD508

27

Machine Adjustments & Settings

Fixing mould tools

The aluminium mould cooling bolster has internal water channels and care must be taken to ensure holes
avoid the water channels shown. All dimensions in mm. The internal water channels are 10mm diameter.

Pyrometer Air Pressure

The pyrometer has air cooling to prevent over-heat, it is important that this air supply is always connected. A
pressure tank is provided to give the pyrometer air system a short term reserve supply if the main air supply
is disconnected. If the reserve air supply pressure falls then the heaters will turn off and the symbol will
show on the control screen. The pyrometer air supply may be adjusted using the regulator situated on top
of the reserve tank.

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28

Machine Adjustments & Settings

Electrical

The PLC relies on the limit switches continually reporting correct mechanical positioning information.
Although extremely robust, limit switches and cylinder sensors are frequently activated. The security and
operation of switches and sensors require checking during periodic maintenance.
If a limit switch is not operating properly nor will the PLC operating system. Limit switch faults will stop the
auto cycle and may prevent the machine functions completely.
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.
Assessment of the fault will entail understanding which interlocks operate to prevent further actions.

Typical fault scenarios

> Table will not rise

Check that the heaters are in the back position and that the heater-back limit switch has been operated.
Check that the clamp frame is properly engaged and the limit switch operated.

Heater will not come forward

Check that clamp and table are down and then plug is up and the carriage is to the right and the limit
switches operated.

Heater

The flexible cable chain between the heaters and the control cabinet contain a number of heatproof power
and thermocouple cables. Due to the continual motion of the heater these may 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 Ceramic heating elements should be periodically inspected for damage to the Ceramic elements and to
make sure that they are securely mounted and that the electrical connections are tight.
For the reasons stated the elements, associated cables, connectors, fuses and are specifically excluded from
our standard warranty.

Before any maintenance work is carried out both electrical and air supplies must be locked in the

OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage.

That person is responsible for ensuring that the machine is in a safe condition before allowing

services to be restored.

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Machine Adjustments & Settings

Replacement of Heating elements – Top Heater

Ensure the power is isolated and the air supply is switched off. Remove any side panels to allow access.
Remove the heater cover relating to the suspect problem element. Locate the problem element. Top heater
elements are rated at 230V & 125Watts. The element may be tested by measuring the resistance using an
electrical multi-meter set to resistance. One of the element terminals would need to be disconnected to do
this. When a faulty element is discovered, disconnect it and remove the clips. The fitting of the new element
is in reverse.
Elements on the IMD508 are fitted with thermocouples and hence they are required to be connected
correctly; 1.The 2 centre wires are the thermocouple wires, one of these is marked, take note when
disconnecting to ensure it is connected in the same way when reconnecting. Incorrect reconnection will
result in wrong readings. 2. Ensure the thermocouple and power wires are not crossed. Incorrect connections
will result in damage to control system components.
It is recommended that the heater tray electrical connections are periodically checked. This requires
systematic tightening every terminal screw. This procedure must be performed within the first 6 months of
use or sooner if usage is heavy. Repeat this procedure every 12 months thereafter.

Replacement of Heating elements – Bottom Heater

Bottom heater elements are rated at 230V & 125Watts. Test and replace in the same method as the top
heater. Access to the bottom heater is complex due to its position. The rear of the bottom heater box would
need to be removed and access to the rear of the machine may be required. It is recommended that bottom
heater servicing is carried out by Formech International.

Auto-Levelling & Bottom Heater Safety Sensing.

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.
Through beam sensors are reliable. The optical windows positioned in front of the sensors on the inside of
the mould box may need periodic cleaning.
Faulty auto-level sensing would cause the air to blow continuously in to the vacuum cabinet.
Faulty bottom heater safety sensing will prevent the bottom heater driving forwards.
Verify the signal at the PLC data input 11 & 12 of PLC module 1. Refer to electrical information page 8.

Before any maintenance work is carried out both electrical and air supplies must be locked in the

OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage.

That person is responsible for ensuring that the machine is in a safe condition before allowing

services to be restored.

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Fault Diagnostics / Maintenance

Before any maintenance work is carried out, both electrical and air supplies must be locked in the

OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage.

That person is responsible for ensuring that the machine is in a safe condition before allowing

services to be restored.

Vacuum

The vacuum circuit requires very little maintenance. The vacuum pump oil level needs to be checked
occasionally depending on use and the vacuum pump filter mounted on top of the pump should be
inspected occasionally and blown clean or replaced.

Loss of vacuum may be caused by worn or damaged seals around the perimeter of the table. These are
regarded as a consumable part and should be replaced when signs of wear become apparent. Other causes
of vacuum loss are loose or damaged flexible hoses and fittings.

The vacuum tank is fitted with a drain plug. Drain the tank if it is suspected that any moisture as been drawn
into the tank.

THE VACUUM TANK IS FITTED WITH A NON RETURN VALVE TO PREVENT IT FROM EVER

BECOMING PRESSURISED. UNDER NO CIRCUMSTANCES SHOULD THE MACHINE BE RETURNED

TO SERVICE (AFTER REPAIR) WITHOUT THIS DEVICE. IF ALLOWED TO PRESSURISE THE

VACUUM TANK MAY EXPLODE!

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Fault Diagnostics / Maintenance

Before any maintenance work is carried out, both electrical and air supplies must be locked in the

OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage.

That person is responsible for ensuring that the machine is in a safe condition before allowing

services to be restored.

Pneumatics

Providing there is a good filtered regulated lubricated air supply, using good quality airline oil, maintenance
will be minimal. However, a thorough inspection of the machine is necessary from time to time. Any
mechanical damage of pipes and fittings 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.

Excessive oil dripping or air escaping from a cylinder nose bush usually suggests that the seals require
replacement. Seal kits are available for cylinders. Internal leaks within cylinders and valves are usually
detected when a cylinder creeps into the wrong position or air continually seeps out of the valve exhaust
port. Again seal kits can be provided - please specify cylinder / valve number & model when ordering.

Other problems that solenoid valves may suffer from are:

1) Lack of electrical supply - Check appropriate circuitry

2) Solenoid has become open circuit - Replace with new solenoid

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

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

If the machine is to be not used for more than a few hours the compressed air system should be
de-pressurised.

We strongly recommend fitting a lubricator to the main air supply if the machine is intended to be used for
daily production. This will extend the working life of the pneumatic cylinders and valves.

Adjust the lubricator such that the oil level drop can be noticed over the course of one days full use. Do not
allow excessive amounts of oil to enter the pneumatic system.

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

General lubrication

Bearing housings, slide and rails should be checked periodically, and lubricated when necessary using high
temperature lithium grease.

Clamp & Table Seals

These are regarded as a consumable part and should be replaced when signs of wear become apparent.
(See section dealing with Vacuum)

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Fault Diagnostics / Maintenance

Before any maintenance work is carried out, both electrical and air supplies must be locked in the

OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage.

That person is responsible for ensuring that the machine is in a safe condition before allowing

services to be restored.

Replace a damaged or worn seal

Remove the existing seal with a sharp knife. Remove as much of the original sealant as possible. Using
masking tape, make a frame inside where the seal will go (table) or outside (clamp) squeeze some glue
around the area where the seal is to be placed. Do not be too economical with the glue. Bed down a strip of
silicon seal until it is firmly seated in the glue.

Do not attempt to stretch the rubber seal, it will contract back to its original size before the glue is dry. Cut
the ends at 45 degrees. Continue this process for all 4 sides of the seal. Fill up any gaps in the mitred joints
with glue. Place masking tape over the mitred corners to help keep them firmly positioned until the glue is
dry.

Leave overnight, then remove masking tape and trim any excess glue off with a sharp knife.

We supply a kit comprising the necessary seal and glue for the IMD508

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.

Service Support

If you are unable to cure any problem relating to your machine, or if you wish to order spare parts please
contact us on the numbers and emails shown on the back cover of this manual stating the model IMD508,
the serial number (on the specification plate), and a full description of the fault or parts you need.

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33

Periodic Maintenance

Ongoing routine ‘In Process’ checks & work area housekeeping may be performed during normal operation.
Monitoring and reporting of machine performance may allow maintenance requirements to be dealt with
before wear, damage or when process problems occur. The following schedule indicates such checks /
activities.

Inspection / Check Daily Weekly Monthly Annually
Air Pressure set at 6 Bar X
Monitor for air leaks X
Check integrity of all mould table and clamp frame seals X
Test Emergency stop operation X
Perform Safety Light Curtain check before 1st operation X
Visible condition of clamp, table & heater sensors / switches X

General safety & housekeeping of overall working
environment around equipment

X

Clamp frame adjustment depending upon material

As required

Monitor Pyrometer consistence (Option)

As required

Check Clamping and Table silicone seals X
Clean Bottom heater glass (if fitted) X
Inspect heating elements for damage and hairline cracks X X
Replace / clean vacuum pump filtering X X
Drain vacuum tank X
Lubricate major mechanical assemblies X X
Inspect Pneumatics system X
Clean Auto-level & bottom heater safety sensor optics X
Check Security of Fan units X X X
Full Formech major service routine – dependant on utilisation X

Areas to be monitored

Effectiveness of process functionality

Observation of sensor functionality

Observation of heating element functionality

Fault / event logging

Job data housekeeping

General work method housekeeping and safety of self and others

Monitoring for Hazardous & Dangerous situations

The following Periodic Maintenance Schedule summarises the regular maintenance required by the IMD508.

Owners, designated responsible people and persons required to perform any level of maintenance / servicing
must read the Formech IMD508 manual thoroughly. Particular attention must be paid to references and
notices regarding safety.

The maintenance requirements will very depending on the level of machine utilisation.

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34

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 infra-red heating elements supplied with this machine are manufactured from Quartz material and are
brittle. A shock to the machine may break an element.

Interlocking systems are 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 Quartz & Ceramic heating elements.

THE HEATING ELEMENTS ARE NOT COVERED BY OUR WARRANTY.

Vacuum System

The vacuum system on this machine is relatively uncomplicated but uses high quality components
throughout. The life expectancy of the vacuum system will be compromised by the ingress of dirt, 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 IMD508

35

Electrical Schematics (Index)

Electrical Schematic 1 BLOCK
Electrical Schematic 2 SAFETY RELATED PARTS
Electrical Schematic 3 POWER DISTRIBUTION
Electrical Schematic 4 LOW VOLTAGE PROTECTION
Electrical Schematic 5 EMERGENCY STOP SYSTEM
Electrical Schematic 6 SAFETY GUARDING SYSTEM
Electrical Schematic 7 PLC / HMI
Electrical Schematic 8 PLC INPUT 1
Electrical Schematic 9 PLC INPUT 2
Electrical Schematic 10 PLC INPUT 3
Electrical Schematic 11 PLC THERMOCOUPLE INPUT 1
Electrical Schematic 12 PLC THERMOCOUPLE INPUT 2
Electrical Schematic 13 PLC THERMOCOUPLE INPUT 3
Electrical Schematic 14 PLC OUTPUT 1
Electrical Schematic 15 PLC OUTPUT 2
Electrical Schematic 16 PLC OUTPUT 3
Electrical Schematic 17 PLC OUTPUT 4
Electrical Schematic 18 PLC OUTPUT 5
Electrical Schematic 19 PLC OUTPUT 6
Electrical Schematic 20 PLC OUTPUT 7
Electrical Schematic 21 PLC OUTPUT 8
Electrical Schematic 22 HIGH VOLTAGE OUTPUT 1
Electrical Schematic 23 HIGH VOLTAGE OUTPUT 2
Electrical Schematic 24 TOP HEATER OUTPUT 1
Electrical Schematic 25 TOP HEATER OUTPUT 2
Electrical Schematic 26 TOP HEATER OUTPUT 3
Electrical Schematic 27 TOP HEATER OUTPUT 4
Electrical Schematic 28 BOTTOM HEATER OUTPUT 1
Electrical Schematic 29 BOTTOM HEATER OUTPUT 2
Electrical Schematic 30 BOTTOM HEATER OUTPUT 3
Electrical Schematic 31 TOP HEATER LAYOUT
Electrical Schematic 32 BOTTOM HEATER LAYOUT
Electrical Schematic 33 PNEUMATICS DRAWING 1
Electrical Schematic 34 PNEUMATICS DRAWING 2

Manual - Formech IMD508

36

Electrical Schematic 1 & 2

Manual - Formech IMD508

37

Electrical Schematic 3 & 4

Manual - Formech IMD508

38

Electrical Schematic 5 & 6

Manual - Formech IMD508

39

Electrical Schematic 7 & 8

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40

Electrical Schematic 9 & 10

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41

Electrical Schematic 11 & 12

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42

Electrical Schematic 13 & 14

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43

Electrical Schematic 15 & 16

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Electrical Schematic 17 & 18

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45

Electrical Schematic 19 & 20

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Electrical Schematic 21 & 22

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47

Electrical Schematic 23 & 24

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48

Electrical Schematic 25 & 26

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49

Electrical Schematic 27 & 28

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Electrical Schematic 29 & 30

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Electrical Schematic 31 & 32

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Electrical Schematic 33 & 34

Manual - Formech IMD508

53

Parts Listing

49 Heating Element, 125W QSF TCK Top Heater 125W QSF TCK

28 Heating Element, 125W HSF TCK Bottom Heater 125W HSF TCK

110 3 Pole Ceramic Block Heater 703-3855

20 Cable 1.63mm Solid Heater DG 1.63mm

350 Cable1mm Silicone Glass Heater Sifgl 1

15 Cable 2.5Mmm, Silicone Glass, White, Blue Heater Sifgl 2.5

30 Glass Fibre Sleeving Heater Marflex S10

400 Thermocouple Cable K Heater KF7212

2 50mm Cable Chain with 60mm Radius Top Heater SR300-A050-120

2 Set of Cable Chain Brackets Top Htr Top Heater AN300-A050 K00

1 Pyro Unit & Jacket Top Heater RAYMI3 10L TH CB15

2 SB32 Adaftaflex Galv Braided Bottom Heater SB32

4 Conduit end Swivel connector SP32 Bottom Heater SP32/M32A

4 Adaptaflex Elbow. 32mm Bottom Heater B\M32\90

1 63A Isolator Switch 3Pole CTRL KN 3P 63A

3 MCB 20A CTRL 20A TYPE B

6 MCB 10A CTRL 10A TYPE B

2 MCB 16A CTRL 16A TYPE B

1 MCB 10A 3Pole Type C pump CTRL 10A Triple C

11 20mm Fuse Holder CTRL 37181

4 Fuse 1A Cab Fan, 240v OP CTRL, PYRO CTRL 20mm fuse 1A

2 Fuse 4A 24vdc CTRL, PLC CTRL 20mm fuse 4A

1 Fuse 500mA 24vdc Cab Fan CTRL 20mm fuse 500mA

1 24V SMPSU, 10A Din Mounted CTRL 514-659

1 1000 lightguard 630mm CTRL 012-104

1 Controller MFU for above CTRL 011-149

1 E stop controller CTRL XPSAC5121

1 PLC CTRL 750-881

1 4 Ch IP Module CTRL 750-402

1 16 Ch IP Module CTRL 750-1405

1 2 Ch IP Analog 0-10vdc Module CTRL 750-467

40 2 Ch T/C Module CTRL 750-469

1 2 Ch OP Analog 0-10vdc Module CTRL 750-550

1 4 Ch OP Module CTRL 750-504

2 8 Ch OP Module CTRL 750-530

5 16 Ch OP Module CTRL 750-1504

1 End Block Module CTRL 750-600

1 Supply System Module CTRL 750-613

IMD508 Major Component Parts & Options

Manual - Formech IMD508

54

Parts Listing

2 Supply Module inc Fuse Holder CTRL 750-601

1 HMI MT-8100i Weintek 10" CTRL MT-8100i

1 RJ45 lead 10m GREY CTRL 556-354

2 Cabinet Fan CTRL 37-0668

2 Cabinet Grill CTRL 37-0878

1 Contactor DIL-EM10 G 24VPump CTRL DILEM-10-G 24V

1 Contactor Overload, 4-6A CTRL ZE6

3 Relay, Single Pole 6A, 24V CTRL 38.51.7.024.0050

4 Relay, 2 Pole. CTRL 95.05

4 Control Relay 24VDC Coil 2pole CTRL 50.12.9.024.1000

2 Control Relay, 3NO, 2NC CTRL CAD 32 BL

1 550W FAN Single Phase LH CTRL VBW6-00115

20 Triac output pcb CTRL AG 4CH-6A

1 SERVO MOTOR SIO SERVO TM2M075-1802-GMA-

HD-238-40-230

1 PROGRAMMING CABLE SERVO CBL-T2USB-485-M8-006

2 Beam Sensor A/L B/H CX 411-P

1 Limit Switch, Plug PLUG 308-1844

5 Reed Switch Pnumo REED FL2

1 Blue Illum.Pushbutton POD ZB4 BW36

1 24V LAMP POD 105-102

1 Switch Body 1N.O. IILLUMINATED POD ZB4 BW061

1 Em. Stop Button POD ZB4 BS54

1 Contact block 1N.O. & 1N.C. POD ZB4 BZ105

1 Estop Legend POD ZBY 9330

1 1/2" to 12mm Push in straight AIR SUPPLY CDPC1204N

1 1/2" Lever ball valve AIR SUPPLY BV-2090-08

1 1/2" regulator/filter AUTO DRAIN AIR SUPPLY M-CFR60-4W

1 40mm Pressure gauge 1/8 bsp POD B001F146A

1 40mm Vacuum gauge 1/8 bsp POD B001F139A

1 1/4" Regulator TH pyro M-R55M-2W

1 8mm tube to 1\4" CHECK VALVE TH pyro CDCVPC0802N

1 1/8" guage pyro 0-30psi PYRO YY003040B2D

1 1/4" Relief valve 9 bar PYRO W60006-9.0

1 Tank Pressure switch PYRO 398-7045

1 Tank Pressure 24L PYRO BPB0471

2 3/8" Lever valve (water in) Bolster B/V 2378-06

4 10-3/8 compression fitting Bolster A9480-1038

2 10-3/8 elbow compression fitting Bolster A13280-1038

IMD508 Major Component Parts & Options

Manual - Formech IMD508

55

Parts Listing

2 10mm Equal Elbow compression fitting Bolster A13260-10

8 10mm Olive Bolster A9740-10

8 10mm Internal support bush 7mm ID, 8mm OD Bolster A10770-1008

2 10mm Bulkhead compression 26mm od Bolster A360-3/8

1 10mm PTFE Tube, 5m Bolster PTFE10-8

1 10mm tube copper, 10M Bolster CT210/10ML

1 FLOW REG PANEL MOUNT 10mm PS CDNSFB10N

1 FLOW REG PANEL MOUNT 10mm REL CDNSFB10N

1 FLOW REG PANEL MOUNT 8mm PLUG DOWN REG CDNSFB08N

1 1/2" lever BV Panel Mounted VAC REG VAPB-1/2-F40-F03

1 1/2" lever VALVE HANDLE VAC REG VAOH-9-H9

1 1/2" Valve, 2/2 PS AL SCE 210A15 240v

1 1/2" Valve, 2/2 REL SCE 210A15 240v

1 1/2" Air silencer PS AL A780 1/2"

1 1/2" Piston valve, 2/2 pilot operated VAC E290A384

1 3/2 Valve for above Pilot VAC 18900032 24VDC

5 ISO 1 SUBBASE MANIFOLD 35500088

1 ISO 1 END PLATE MANIFOLD 35500087

3 ISO 1 5/2 VALVE E/S MANIFOLD 54191023

2 ISO 1 5/3 VALVE W1 MANIFOLD 54191028

4 3/8" PLASTIC SILENCER MANIFOLD 34600408

7 Sol. Pilots for 5/3 above MANIFOLD 18900001D2

8 Size 22 Connector MANIFOLD 88122405 24VDC

2 Cylinder 50bore x 600mm TH G453A5SK600A00

2 Speed Controller 1/4 to 8mm STRIGHT BH CDNSS0802

4 Speed Controller 1/4 to 8mm ELBOW TH, clamp V CDNSC0802

1 Cylinder 50bore x 700mm PLUG G453A5SK-700-A00

2 Cylinder 63bore x 430mm CLP G453A63SK-430-A00

2 Rear Trunnion MP2, Female 63Bore CLP 434 00 133

2 Rear Trunnion MP4, Male 63Bore CLP 434 00 128

1 Cylinder 50bore x 70mm EXHST G453A5SK-70-A00

1 Rear Trunnion MP2, Female 50Bore EXHST 43400132

1 Rear Trunnion MP4, Male 50Bore EXHST 43400127

2 3/8" Cylinder Blocking Valve CLP 34602451

1 1/4" Cylinder Blocking Valve PLUG 34602450

1 1/4" Valve 3/2 24vdc ctrl safety SCG551A005MS 24VDC

3 1/2" Rubber PIPE 1m Vac H-GP1-13-15 13ID

1 Vacuum Pump Vac U4.20

IMD508 Major Component Parts & Options

Manual - Formech IMD508

56

Parts Listing

10 Metric Bush, 16mm Bore x 20mm CLP MB 1620DU

8 Spring, RED, clamp CLP 9-1212-260

8 Guide Bearing, KLNJ 1/2" CLP 1/2" KLNJ

2 Plug spring MF SP1258

4 Linear bearing MF LBE20 IKO

4 20MM LINEAR HARDENED SHAFT MF 20mm table guide shaft

5 Silicone Seal Strip, 20mm x 4mm MF SE515 20X4

5 Silicone Seal Strip, 12mm x 8mm MF SE515 12X8

2 Door key catch, 2 elect. Elect 450-9955

1 Key, catch Elect 341-0236

6 Hinge Elect 702-7831

4 FOOT M16 X 100 MF 4907/2/C

IMD508 Major Component Parts & Options

If you are unable to cure any problem relating to your machine, or if you wish to order spare parts please
contact us, stating the model (IMD508), the serial No. (on specification plate) and a full description of the
fault.

Manual - Formech IMD508

57

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: IMD508
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: Andrew Berry at address below.

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

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

Significant harmonised standards applied:

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

Signed
Date:
Name: Paul Vukovich
Position: 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

EC Certificate

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

Hertfordshire AL5 3NS, United Kingdom

Manual - Formech IMD508

58

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]