formech line bender flb1000...power is supplied at the c14 inlet receptacle (skt1). both power feeds...

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For Parts, Service & Technical AssistanceTelephone: +44 (0) 1582 469 797

Fax: +44 (0) 1582 469 646

Installation, Operating and Service Manual

Formech Line Bender

FLB1000...FLB1000

Manual - Formech FLB10002

Table of Content

Safety 3

Introduction 4Installation of Quartz Heating Element 4Machine storage 4

Control Functions 5A. General arrangement & Control panel 5

Operating Procedure 6B. Basic Operation 6C. Heater 8

Accessories 9A. Cooling Jig (Optional Extra) 9B. Adjustable Back Gauge (Optional Extra) 9

Digital Timer 10

Warranty 11

Service / Repair 12Electrical Troubleshooting 12

Parts Identification 13

Technical Data 14Electrical Specifications 14Mechanical 14Functions 14Electrical Schematic and Major Components Parts Listing 15

EC Directive 16


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 the user manual.• Check your supply voltage and frequency. Make sure it is compatible with your machine. Your machine's electrical specifi cation is on the plate at the rear of the machine. • You must ensure that the machine is properly earthed and fused.If your machine is not equipped with a moulded mains connector then note the below:• 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 on this model is not intended to be left running indefi nitely.• Never remove any panels unless the electrical supply has been isolated. • Note the safety warnings situated on the top panels. • Only use the machine for bending plastic sheet. 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.• Always let the machine cool down before attempting to remove any panels. Some parts of the heater and heat shield become extremely hot during operation.• 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.• Users of this machine should complete regular competence tests.


Introduction

The FLB1000 is a manually operated line bending machine that is capable of producing high quality bends in plastic sheet from standard materials up to 1000mm wide.

Operating from a normal domestic electrical supply the FLB1000 Line Bender is easy to use with simple controls.

The machine is ideal for training applications where students are able to produce items in a range of materials and thicknesses.

It is robust enough to find uses in industry, particularly for display purposes e.g. menu holders, price holders and machine guards.

It is small enough to be stored away when not in use or to be transported for demonstration purposes etc.

Installation of Quartz Heating Element

The Quartz Heating lamp is packaged securely inside the appliance during transit.

To install the heating lamp follow the procedure below:1. Remove the 8 screws from the base of the unit and the 2 countersunk screws from each side to remove the base of the unit and gain access to the internal of the unit.2. Remove the packaged lamp from inside the unit.3. Inspect the lamp and report any breakages.4. The lamp fits between the 2 lamp holders at each end of the heater strip. The lamp holders are spring loaded.5. Place a lamp end in to a lamp holder and carefully push the other end of the lamp into the other end. Do not apply excessive force. Ensure there are no other obstructions.6. Check the lamp is securely in place.7. Ensure all packaging is removed from inside the unit.8. Replace the base retaining screws.9. The product is ready for normal use.

Machine storage

The Formech FLB1000 must be stored in a dry environment.


Control Functions

Refer to the pages titled ‘Parts Identifi cation’ at the back of this manual for identifi cation of controls.

A. General arrangement & Control panel

1. Power Isolation Switch. Power is disconnected when this switch is turned OFF. Always remove the mains power lead from the power inlet receptacle before commencing any repair work.

2. Temperature regulator. This allows the temperature of the heating element to be regulated from a very low setting right up to the maximum for very quick cycle times.

3. Power Inlet and mains fuse receptacle. The machine is supplied complete with a power cable that plugs into this receptacle and then into a suitable power socket. The fuse protects the machine and should only be replaced by another of same type and rating. See Safety section at the beginning of this manual. Note the safety labelling. If your machine is a special voltage or frequency then it may be supplied with a lead not terminated into a mains plug.

4. Measurement guides. To help create accurate bends on a repeat basis.

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

6. Material Clamp. This holds the plastic material in position during the heating process.

7. Digital timer.

8. Gap adjusters.

Safety NoticeIt is advisable to monitor the heating stage by making frequent observations.

Never leave the machine unattended when actively heating plastic.


Operating Procedure

Refer to the pages titled ‘Parts Identification’ at the back of this manual for identification of controls.

B. Basic Operation

1. Start with the temperature regulator set to position 5 and raise the material clamp to the rear position. Leave a gap between the reflectors of approx. 8 or 10mm. (see the gap we recommend depending on the temperature regulator position)

Reflector gap Regulator positionMax (18mm) Up to position 6 (Full)

Approx. 10mm Up to 5Approx. 5mm Up to 3

2. Decide where you would like to bend the piece of plastic in order to position the material on the grid.

3. Place the material on the machine top over the element and lined up on the grid, and then bring down the material clamp. The clamp helps to keep the material flat over the element during the heating process to produce an even heating band all the way along the bend.

4. You can use the digital timer counting up to find out how long you need to heat the sheet of plastic for if it is a job that will be repeated. Please see how to operate the timer on page 8.

5. If you are unsure of the heating time for the material, then all you have to do is to lift the clamp, and then try to bend the material carefully in situ to see if it is ready for bending. If it still needs a bit more heat, then bring the clamp down and resume the heating cycle.

6. Once the material has been heated to the correct temperature, lift the material clamp and remove the material. The material is then placed into the cooling jig (you can build your own or purchase our cooling jig in the accessories section) to cool down to a predetermined angle, while the next sheet of material is placed on the line bender.


Operating Procedure

B. Basic Operation (continuation)

Line bender with optional Adjustable Back Gauge in extended position.The fence allows you to accurately position your material for production runs.

Line Bender with Optional Adjustable Back Gauge in standard position.


C. Heater

The powerful 1000mm quartz heater is designed to heat the plastic rapidly without burning the surface. The time that is required to heat the plastic sheet remains fairly constant once the heaters have reached their operating temperature.

The temperature regulator will need to be set to suit the reflector gap setting. Refer to the table below for guidance on heat setting with respect to reflector gap setting.

Reflector gap Regulator positionMax (18mm) Up to position 6 (Full)

Approx. 10mm Up to 5Approx. 5mm Up to 3

Heating cycle times vary according to a number of factors. With a little experience, timings may be easily estimated.

Some plastics such as polystyrene have a wide tolerance to heating times giving consistently good mouldings. Care must be taken with other materials such as ABS, which is hygroscopic and absorbs moisture, which can result in blistering along the bend.

The sheet should be formed when the plastic is sufficiently relaxed to bend to the desired angle.

Operating Procedure


Accessories

A. Cooling Jig (Optional Extra)

Cooling jig with adjustment from 0 - 180 degrees.

B. Adjustable Back Gauge (Optional Extra)

This allows the material to be placed in the exact position each time.


Digital Timer

When ‘at standby’ the unit displays the ‘Time Settings’ in seconds.

The Time Setting can be changed, while at standby with the up/down pushbuttons.

There is a short delay on pressing a button to prevent inadvertent operation and to allow for two button selections.

Pressing the ‘START’ button starts the timer count down.

At the end of the time a sounder sounds for 2 seconds and the display fl ashes ‘000’ for 4 seconds. The unit then returns to standby.

Pressing and holding ‘START’ for 2 seconds during a timed run cancels the run and returns the unit to standby.

Pressing the ‘+’ and ‘START’ pushbuttons together starts the unit timing up from 0, when the ‘START’ button is pressed again the unit stops counting and the display slowly fl ashes the time measured.

Pressing ‘START’ restores the Time Setting before the time measurement.

Or…

Pressing all three buttons transfers the time measured to the Time Setting, which then can be adjusted in the normal manner.

The ‘Time Setting’ is stored and is shown after the power has been restored when the unit has been turned off.


Warranty

Reliability and a long service life are synonymous with the Formech brand and we offer a 12 month warranty with the machine.


Service / Repair

It is unlikely that you will need to service or repair your machine for many years. In the event that you need to replace either the temperature regulator or the heating element, it is a very simple procedure to open the machine and replace the relevant parts.

ELECTRICAL DIAGNOSTICS AND REPAIR MUST BE PERFORMED BY A SUITABLY QUALIFIED PERSON.

Electrical Troubleshooting

The suitably qualified person must refer to the wiring schematic section before attempting diagnostics or repair.

The following is a functional summary of the electrical control circuit.

Power is supplied at the C14 Inlet receptacle (SKT1). Both power feeds (L&N or L1&L2) pass through the 2 pole power switch (S1), this switch is illuminated when power is present. Power is fed from the switch to the heat power regulator (R1) and process timer (T1). The process timer is a standalone function. The heat power regulator provides a rotary variable output to the quartz heating element (QE1) and the power indicator (IN1). The Quartz Element is fitted into the 2 lamp sockets (SKT2).

There are several possible fault scenarios. Apply a methodical approach when diagnosing.

For power problems there are basic indicators that will assist with diagnostics; if the switch indicator is on then this confirms there is power to the machine. If the Power switch indicator is OFF then the problems lies before the switch (power lead or input fuse). Also if the timer shows ON then there is power to the machine.

If there is no heat output then inspect the heat element and filament. Check if the output indicator is ON or OFF etc.. To gain access to the element and electrical components remove the button screws from the bottom panel and the small countersunk screws from the side panels.

Fault scenarios may also be caused by poor connections. Check all the connections. Also check the heating element is inserted correctly into the lamp holders (SKT2).

Use a multi-meter to check the lamp continuity if required. The correct resistance reading for the Quartz heating element is 65 Ohms.

AFTER ANY MAINTENANCE WORK ALWAYS CHECK AND VERIFY THAT THE EARTH CONNECTION IS CORRECT.

If you are unable to resolve any problem relating to your machine, or if you wish to order spare parts please contact us at the below address, stating the model (FLB1000) the serial No. (on specification plate) and a full description of the fault or parts required.


Parts Identifi cation

1280(50“)

12

300(13“)

175(7“)

6 5 4 3

1- Power Switch ON/OFF2- Temperature Regulator3- Power Inlet Receptacle + Fuse4- Measurement Guides5- Specifi cation plate6- Material Clamp7- Digital Timer

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Technical Data

Electrical Specifications

- 220-240V, 50-60Hz, Single phase- 208-220v, 60Hz , Twin Phase - N America- 800 watts- Fuses 5 amp on machine

Mechanical

- Width: 1280mm- Depth: 330mm- Height: 175mm- Weight: 15Kg- Life of element: many years depending on usage

Functions

- Bending width – 1000mm - Sheet thickness – up to 10mm


Technical Data

Electrical Schematic and Major Components Parts Listing


EC Directive

E C Machinery Directive2006/42/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: Line Bending MachineMachine Function: Linear Heat Assisted Bending of Plastic SheetModel / Type: FLB1000Serial 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: Martin Smith

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Significant harmonised standards applied:

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

______________________________________________________

Signed

Date: Name: Paul VukovichPosition: Managing DirectorBeing the responsible person appointed by the manufacturer

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

Hertfordshire AL5 3NS, United Kingdom


For Parts, Service & Technical Assistance UK, Europe and Rest of the World

Telephone: +44 (0) 1582 469 797Fax: +44 (0) 1582 469 646

[email protected]

For Parts, Service & Technical Assistance North and South America

Telephone: 312.396.4072Fax: 312.396.4073

[email protected]

Formech International LimitedUnit 4, Thrales End Farm, Thrales End Lane, Harpenden, Hertfordshire, AL5 3NS U.K.Tel: +44 (0)1582 469 797 Fax: +44 (0)1582 469 646Email: [email protected]

formech line bender flb1000...power is supplied at the c14 inlet receptacle (skt1). both power feeds...

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