Formech Line Bender FLB1000 · 2020. 10. 27. · 5 Manual - Formech FLB1000 Introduction The FLB1000 is a manually operated line bending machine that is capable of producing high

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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...

Manual - Formech FLB10002

Table of Content

Safety 3

General Arrangement 4

Introduction 5Installation of Quartz Heating Element 5Machine storage 6

Control Functions 7

Operating Procedure 8

Digital timer 9

Heat gap width adjustment 9

Accessories 10Cooling jig with adjustment from 0 - 180 degrees 10Optional adjustable back gauge 10

Service / Repair 11

Warranty 11

Technical Data 12Electrical Specifications 12Mechanical 12Functions 12Electrical Schematic and Major Components Parts Listing 12

EC Directive 13


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 appliance until you have been trained and are fully conversant with it.• Read and understand all of this 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.


General Arrangement

1- Power switch ON/OFF2- Temperature Regulator3- Power Inlet Receptacle + Fuse4- Measurement Guides5- Material Clamp6- Digital Timer7- Gap Adjusters


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 fi nd 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 10 screws in the top cover and remove the cover.

2. Remove the two aluminium width adjustment sections.

3. Remove the packaged lamp from inside the unit.

5. The lamp fi ts between the 2 lamp holders at each end of the

heater strip. The lamp holders are spring loaded.

6. 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.

4. Inspect the lamp and report any breakages.


8. Ensure all packaging is removed from inside the unit and replace

the top cover and fi t the 10 retaining screws.

9. The product is ready for normal use.

Introduction

Installation of Quartz Heating Element (continuation)

Machine storage

The Formech FLB1000 must be stored in a dry environment.

7. Check the lamp is securely in place. Reposition the two aluminium width adjustment

sections by slotting into the end blocks.


Control Functions

Refer to the page ‘General arrangement’ on page 4 of this manual for identifi cation of controls.

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 assist with accurate and repeatable bending of plastics.

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

6. Digital timer.

7. Heat gap width adjusters for thin materials and sharp bends.

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 ‘General Arrangement’ on page 4 of this manual for identification of controls.

Basic Operation

1. Turn the power ON, set the temperature regulator to position 4 ½ and raise the material clamp to the rear position.

2. The FLB1000 has the facility to adjust the heating area gap width from 2mm to 16mm to control the bend radius for different thicknesses. Thinner materials will require a smaller bend radius and a lower heat setting. Thicker materials will require a larger bend radius and may also require a lower heat setting and a longer time to allow the heat to penetrate the material. Higher regulator setting may burn or distort the material so it is essential to perform testing on materials to find the optimal power setting to achieve a good quality bend. Refer to the table below for an indication of settings during testing and set up.

Gap Width Material Thickness Regulator positionApprox 12mm 6mm Up to position 5Approx. 8mm 2 - 4mm Up to position 4Approx. 4mm 1- 2mm Up to position 3

3. Decide where you would like to bend the piece of plastic and place the material on the machine top over the element and lined up on the grid. Bring the material clamp down over the plastic. 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. Test the material by lifting the clamp and try to bend the material carefully to determine if it is ready for bending. If it needs a more heat, place back over the heater in the same position to resume heating.

5. 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 to cool down to a predetermined angle while the next sheet of material is placed on the line bender.

6. Review the results and determine the correct gap width, power setting and heat time to achieve the desired bend. Note the heating time for setting of the timer.

7. 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 that can result in blistering along the bend.

8. The sheet should be formed when the plastic is sufficiently relaxed to bend to the desired angle. Effective use of the line bender will require experimentation with your plastic using optimal heater settings for the material thickness and appropriate gap settings for the thickness and radius required.

9. The FLB1000 has a powerful Quartz Element therefore it is likely power control only ever need to be set up to level 4 to5.


Digital timer

The Timer is simple to use. The display shows the time in seconds.

Adjust the required time using the + & - buttons to show the required time and press START to initiate the countdown. A sounder operates for 2 seconds at end of the time count down.

Press and hold the START button at any time to cancel the run time and reset.

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

Press START again and the timer shown will reset to the original setting.

Pressing all three buttons will transfer 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.

Heat gap width adjustment

The two aluminium Tee sections over the quartz lamp are adjustable to allow for the user to vary the width of the heating area.

Simply rotate both adjusting controls located at each end of the unit to set the desired heating width and check that gap remains the same over the full length of the heat area.

A narrower gap would be required for thinner plastics to achieve a smaller fold radius. A wider gap for thicker materials will provide a larger fold radius.

See image on the right.


Accessories

Cooling jig with adjustment from 0 - 180 degrees

Optional adjustable back gauge

Optional Adjustable Back Gauge in standard position allowing the material to be

positioned consistently.


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 Troubleshooting

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

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 10 screws in the top cover and lift out the width adjustment sections.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.

Warranty

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


Technical Data

Electrical Specifications

- 220-240V, 50-60Hz, Single phase- 208-220v, 60Hz , Twin Phase - N America- 700 watts- Fuses 5 amp on machine

Mechanical

- Width: 1310mm- Depth: 375mm- Height: 150mm- Weight: 22Kg

Functions

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

Electrical Schematic and Major Components Parts Listing


EC Directive

2006/95/EC

We hereby certify that the machinery stipulated below complies with all the relevant provisions of the EC Low Voltage Directive and the National Laws and regulations adopting this Directive. Modifications to this equipment 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: LB1000Serial Number: Date of Manufacture: Is in conformity with the provisions of the following other EC Directives:

2004 / 108/ EC – EMC

Technical File Compiled by: Andrew Berry

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

Significant harmonised standards applied:

EN ISO 12100 : 2010 EN 60204 –1 : 2006

______________________________________________________

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]

Documents

Formech Line Bender FLB1000 · 2020. 10. 27. · 5 Manual - Formech FLB1000 Introduction The FLB1000 is a manually operated line bending machine that is capable of producing high