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com

HFTF-70T
Automatic Tilt Thermoforming Machine

OPERATING
INSTRUCTION
MANUAL

RUIAN HENGFENG MACHINERY CO., LTD (V3.0)

Tel: 0086-577-65575608 Fax: 0086-577-65575628
Web: www.cn-hfjx.com E-mail: [email protected]

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CONTENTS
PROLOGUES................................................................................................................ 3
Chapter 1 Safety Caution.........................................................................................4
I.Safety Operating Procedures........................................................................... 4
II.Environmental Requirements.......................................................................... 5
III.Cautions before and after start machine...................................................... 6
IV.Cautions during operation...............................................................................7
V.Cautions of Maintenance................................................................................. 7
VI.Others.................................................................................................................7
Chapter 2 Machine Installation.............................................................................. 9
I.Environmental Requirements........................................................................... 9
II.Space Requirements........................................................................................ 9
III.Specification of Electric and Air Pressure.................................................... 9
IV.Installation Steps............................................................................................ 10
Chapter 3 Technical Specification.........................................................................12
Chapter 4 Operating Instruction.......................................................................... 13
I.Operating Instruction of Control Panel..........................................................13
II.Human Machine Interface Operating Instruction....................................... 19
Chapter 5 Debugging Operation...........................................................................49
Chapter 6 Maintenance..........................................................................................55
I.Machine Maintenance......................................................................................55
II.Molds Maintenance......................................................................................... 56
Chapter 7 Alarm and Treatment...........................................................................59
Chapter 8 Trouble Shooting.................................................................................. 66
Chapter 9 Appendixes............................................................................................ 70
1.Machine Layout................................................................................................70
2.Upper Mould Size Drawing............................................................................ 71
3.Lower Mould Size Drawing............................................................................ 72

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PROLOGUES
HFTF-70T Automatic Tilt Thermoforming Machine is the new light duty plastic
thermoforming machine for plastic container,with the character of advanced design,
excellent performance,advanced control and wide application. It can produce different
kinds of plastic cups,box and another container.For example,jelly cup,milk cup,ice cream
cup,disposable water cup,noodle bowl,fast food tray and so on.It also can produce
decorative sheet,ceiling board and packing material like toy,hardware.

Please read this operating instruction manual in detail in order to use this machine safe
and correct. It is good for the production,operation and daily maintain.

This instruction manual include basic technology and debugging method.The practical
experience is very important in the production process and it is only obtained from
practice and observation.Combining advantages of this machine,operator can continue to
gain experience in the production process and improve the production efficiency.

Operator should absolutely obey safety operation rule,safety measure and ensure the
safety of people and equipments running in the production process.It will be better that
each operator and maintenance man have one operating manual and read it carefully and
know the safety device and warning label.In our opinion, operator himself should have
strong security awareness,good judgement and handling common sense.So the safety is
up to operator himself.

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Chapter 1 Safety Caution

I.Safety Operating Procedures

1.Safety Caution

①Safety Protection,Manufacturer should do as follows:

②Should point out using safety design equipment to all operator and maintenance staff.

③To train workers working on the condition of safety production and ensure safety.

④ In addition, must also regularly examine various functions of the equipment, especially

some functions relating to safety.

2.Danger

2.1The danger in the working area

Attention: The operators will not being guaranteed safety if do not operate in accord with this

manual or safety production rules.

Warning: Only qualified operator can examine and repair, and make the maintenance to the

equipment. This machine is in high temperature when working, operators should put on high

temperature protective clothing, and also take corresponding prevention measures to protect

the hand, arm, face, eyes.

This machine should be placed in an area with proper ventilation facilities to let the heat and

gas which comes from the equipment dispersing as soon as possible and keeping a good

production environment.

3.Perator and maintenance staff

Attention: Operator and maintenance staff is point to the people including carrying,

assembling, installing (setting), operating, maintenance, repairing, cleaning.

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4.This equipment can only handled by licensed people or the one who get through relevant

operation training.

5.Any repairing, maintenance, cleaning work should be in the condition of total power closing

II.Environmental Requirements

1.Choose a place with lower vibration and small impact to install the machine.

2.Don't install machine in the place with direct sunlight or moisture overweight.

3.Avoid to install machine in the place full of powder and corrosive liquid spray.

4.Environment Temperature: 0℃-45℃

5.Operator is not allowed to operate in the way that may damage the safety function of

equipment.

6.Operator has responsibility to protect the equipment from handling by any unauthorized

people.

7.Any abnormalities of the equipment, operator should reflect it to leader in time.

8.Closing process:Close the machine firstly, and then cut off total power, check whether each

circuit is completely cut off. Put the power warning sign on the power switch to express not

allowed to switch on the power in this period and ensure safety.

9.The special earth protective device must be firmly grounded after install machine.

10.There is an Emergency Stop switch in the electric control cabinet, operators can click this

button rapidly and cut off control power if any emergency appeared.

11.Operators should clean the workshop and check every part whether it is under the normal

condition before machine start.

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III.Cautions before and after start machine

1.Cautions before start:

1.1Operator should know every operation function program in the instruction manual before
operate this machine.
1.2Make sure all bolts, screws and connection is fixed and finished.
1.3Make sure the water, electricity, air line is already connected.Check every components
without loose, crack and oil, water pipeline without leakage.
1.4Check whether the phase position of voltage and power is correct.
1.5Check whether the lubricating oil is enough.
1.6Check the air pressure is 7 Bar.
1.7Check the whether the power voltage and rated capacity is enough.
1.8Check whether all safety guard and all mechanical parts and electric apparatus are
normal.
1.9Open factory power switch-- Open the main circuit switch device ON of machine-- Open
the power switch in the operation panel.

2.Running Cautions:
2.1Check whether leakage and make sure all indicating gauge are normal.
2.2Don't touch any operating key, any switch in the operating panel and any working object
during machine running.
2.3Check whether every motor, driving elements and other parts have any un-normal noisy,

3.Cautions before and after close machine.

3.1Operators should clean up machine everyday and make it clean after finish the work.
3.2Operators should close the machine power everyday after finish the work.
Sequence of close machine:Close power switch in the operating panel-- Close main
circuit power of machine -- Close factory power switch.

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IV.Cautions during operation

1.Operators should operate after special training.

2.Don't touch heating parts when machine running.Please be careful of personal safety and
don't put your hand at the mould, driving components and other dangerous place when no
protective measures.

V.Cautions of Maintenance

1.Daily Maintenance:
①Reading and knowing the safety protection method in the operating manual.
②Keep the machine and the place around machine clean.
③Keep the lubricating oil enough.
④Making maintenance record and make proper maintenance in the proper time.

2.Cautions before maintenance:

① Operators should cut off the main power and close the air source when machine start
maintenance.
②The maintenance of electric device should be operated by professional operators.
③Safety fuse, electric cable and so on should be produced by qualified producers.

VI.Others

1.Check no damage and scratch the mould cutter and the main double guide pillar and no
foreign-matters in the mould cavity and guide sleeve.

2.Make sure no water inleak in the electric components and air valve device.

3.Operators should jog and test the cooldown manually when change the mould.It is not
allowed to try driving mode to avoid mould damage.
Attention:Please note the position of the cam when jog and test the
cooldown.Prevent the machine falling inertance and keep your body safety !

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4.Please adjust the correct location when loosen the connecting shaft between cam
encoder and main cam. It means change the screen to "Parameter page". The location
indicating number of cam encoder should be "100" when cam turn to cutting point, ±2º error is
allowed.
5.When mould used for a long time or the cutter of mould is not very good, please do not force to
descend the cutter to get a good cutter effect, it will serious damage the mechanical parts of
machine.

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Chapter 2 Machine Installation

I.Environmental Requirements

1.Choose a place with lower vibration and small impact to install the machine.

2.Don't install machine in the place with direct sunlight or moisture overweight.

3.Avoid to install machine in the place full of powder and corrosive liquid spray.

4.Environment Temperature: 0℃-45℃

5.Environment Humidity: ＜90%RH

6.Make sure the solid of the floorboard according to the leveling device, the foundation

thickness should more than 100mm and it is enough to bear the weight of the complete line.

Adjust the vibration absober base and keep the main machine in level. (It is based on the

working surface of lower mould base)

II.Space Requirements

1.There are enough space for main machine, stacker, rewinder and unwinder to be moved,

operated and maintained easily.

2.Space Requirement: Length 17000mm, Width 5000mm, Height 3500mm.

III.Specification of Electric and Air Pressure

1.Specification of Electric:

Electric Phase Wire

Voltage Frequency Capacity
Current Position Diameter

228A 380V 50/60Hz 3+N+PE 150kw 50mm2

2.Specification of Air Pressure:

Pressure Setting Environment Relative

Air Supply
Source Pressure Temperature Humidity

≥0.7MPa 0.7MPa 0-45℃ ＜90%RH 4m3/min

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IV.Installation Steps

1.Machine should be put on a solid cement base which thickness is more than 100mm, adjust the

vibration absorber base and keep the main machine in level (On the base of working surface of

lower mould base).

2.The connection of power wire:

2.1The ligature of the electric control conbinet was already removed before shipment.
Please connect all wires correctly when machine arrived. Please check the wire
carefully,start the power only when all wires are connected correctly. inspect whether any
wrong connection after connect electrical circuit. Open the power until no error after
check.
2.2Power Line Connection: Connect the power wire with the air switch which is in the
electrical cambinet at the back of machine.
2.2.1Connect unwinder motor to the left side inseter of machine.
2.2.2Connect rewinder motor to the back right inserter of the machine, the inserter location
refer to the middle part inserter picture below.The right inserter connect to the line of
communication.

3.The air source connector below the left of machine should connect to the air source. The air
source should use the gas without humidity, without oil and without corrosivity. The pipe
diameter connect to air source should more than 1.5 inch.

4.The inlet and outlet of cooling water below left of machine should connect to the water source
separately. The pressure and flow of cooling water should ≥0.2Mpa, or there is no water can
cool in the pipeline in higher location.

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5.Open the power source and air source and then test.
5.1.Make sure whether the power phase is correct.
5.2.Check whether the direct of motor rotation is correct.For main machine, we should set it to
the lowest speed (the lowest speed is 200r/min) and choose jog forward in the manual
screen. The show value of encoder location in the touch screen is increasing if the
direction is correct. Generally, main motor is always contrarotate if see from the
operating side.
5.3Check whether each pressure gauge with correct indication.

6.Check the reducing gear box, the oil level of lubricators and lubricate each moving element.

Meanwhile, check each strong parts whether loose.

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Chapter 3 Technical Specification

1 Max. Forming Area 300×660mm

2 Max. Forming Depth 160mm
3 Sheet Thickness 0.3-2.0mm
4 Max. Roll Diameter 1200mm
5 Using Pressure ≥0.7mpa
6 Air Consumption ≥2500L/MIN
7 Water Consumption 50-100L/MIN
8 Heating Rated Power 120KW
9 Main Machine Rated Power 11KW
10 Pre-stretch Rated Power 11KW
11 Feeding Rated Power 5KW
12 Rewinder Motor Power 0.55KW
13 Unwinder Motor Power 0.37KW
14 Max. Manufacturing Speed 28 Cycles/Min
15 Power (Three Phase, Four Wires) 3×380V+N+PE（±10%）50HZ
16 Main Machine Dimension (LxWxH) 4500×3500×3300mm
17 Stacker Dimension (LxWxH) 3200×2100×1900mm
18 Rewinder Dimesion (LxWxH) 1200×1600×1300mm
19 Unwinder Dimesion (LxWxH) 2100×1300×1350mm
20 Machine Weight About 12500kg

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Chapter 4 Operating Instruction

I.Operating Instruction of Control Panel

1.Operation Panel Figure of Host

Fig.4.1

2.Directions of use of each button in host panel

2.1Feeding Start: The first time press "start" button (for more than 3 seconds) and start

feeding motor to feeding the sheet. Do not start the main motor, only perform the action

of feeding. Feeding speed and length perform the numerical value of "Feeding Speed"

and "Feeding Length" that set in the touch screen. The initial feeding cycles of feeding

motor was set according to the host running speed value. The feeding performing cycles

of feeding motor can be changed if change the host running speed value. Buzzer alarm

when feeding start and stop alarm till the host start or stop.

Fig.4.2

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2.2Host Start: The second time press "Start" button (for more than 1 seconds) after start

feeding can make the main machine start running. The initial running speed is set by the

main speed input value in touch screen. Changing the input value can change the speed

when host start, Changing the input value can accelerate or decelerate for adjustment

when normal running.

Note: Operators should move the pressed mould core up to the bottom of mould core

and at the same level with up mould, and the push-pull device should be zero (Zero On),

then operator can start host (this indicating lamp is in the Manual screen).

Fig.4.3

2.3Stop: Machine will stop running when click this button, and the indicating lamp of "Stop"

will turn on at the same time.

Note: Host will not stop immediately when click host stop button, it will stop when

running to the setting stop angle. Please click "Emergency Stop" button if anything

emergency happened.

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Fig.4.4
2.4Host Speed Governing: After host start, operator can click the button “+” or “—” to
change the host running speed, or input the number of running speed directly.

Fig.4.5
2.5Oven In/Out:Click this button, oven will turn into heating tunnel and the indicating lamp
turn on.Click this button again, the oven out of the heating tunnel.The order of the tunnel
in and out:
①Oven In:Click the button "In/Out", connect the direction of magnetic valve in and out,
oven turn into tunnel from the direction of "Y" axis, the signal of place proximity switch
XP4 connect, then start "X" axis and connect to magnetic valve, move to the correct
location by "X" direction and close to mould, and then finish the "in" action.(View drawing
as below

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Fig.4.6
② Oven Out: Click button "In/Out" and make "X" axis power off with magnetic valve,
backward to the right location by "X" direction. When the signal of proximity switch XP1,
XP2 connected, oven out with "Y" axis direction, then finish the out action.

Note: When start machine normally or fault stop and oven out, when "X" direction
finished moving, but the signal or receiving location of XP1, XP2 not correct, oven will
not out, sheet will melt by high temperature and even burn !

2.6Heater Switch: this switch control the working position of tunnel, when it in location "I",
the upper tunnel heating and lower tunnel stop: when it in location "II", both upper and
lower tunnel heating: when in middle position, heating stop.

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2.7Automatic/Manual: This function button control the working mode of press action,
forming action and blowing action. When switch in the "Automatic" location, all
actions work according to the parameter set in the screen, it should be in this location
when machine is in normal working. When switch in "Manual" location, the
interface will display manual operating screen, click action button in touch screen and
perform related action in middle location, every action closed.

2.8Emergency Stop Button: All working stop when click this button.

3.Cup Catch Control Panel

Fig.4.7
3.1Cup Catch Start/Stop: The first time click this button, cup catch start and running and
indicating lamp turn on. The second time click this button, it stop. The stop
location is up to the parameter of Stop Coordinate (Check red font parameter as
below)

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Fig.4.8
3.2Cup Eject Start/Stop: The first time click this button, eject motor running and indicating
lamp turn on, eject scattered cup from hopper. The second time click this button,
eject motor stop running.

3.3Traction Start/Stop: Click this button and traction action jog running and indicating lamp
turn on. The first time click this button, traction action start running and indicating
lamp turn on, it means traction motor and feeding motor running synchronous, the
running time is set by parameter. The second time click this button, traction action
stop running. Normally this function is applied in the initial stage of start machine or
the time when change sheet. Start this function when sheet out from oven but not
arrive rewinder and stop this function when sheet come into rewinder.

Fig.4.9
3.4Cup Delivery Start/Stop:Click this button, the delivery belt of delivery table jog running
and indicating lamp turn on.
3.5Alarm/Reset:This indicating lamp will twinkle if cup catch device has any fault or alarm
when running.Click this button can reset and make all action be the initial state after

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solve the problem.

3.6Emergency Stop:All working stop when click this button, but host will not stop running,
please pay attention to safety.

II.Human Machine Interface Operating Instruction

1.System Introduction
This system adopt human machine interface operating instead of traditional panel control
function. It can set numeral value and button switch convinent; The functions of numeral
value and indicating lamp will display at any times, direct dialogue between human and
machine; When incorrect operation and fault occur, it will display in touch screen and suggest
handling method, this is good for operator control machine running correctly and avoid fault
expend. This is easy for maintain. This interface operate simply, mark the functions of
each button switch, data input key, numeral value display and indicating lamp by words
directly.

2.Introduction of Operating Interface "Parameter"

Fig.4.10

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2.1Value Set: Some parameter should be set during production. For an example: set
temperature, feeding length, feeding speed and so on. The setting method is very simple, only
click the setting frame in touch screen and then one numeric keyboard occur automatic in this
system, operator can input the needed number by click the numeric keyboard and the input
number will show in touch screen, click button "ENT" if correct and numeric keyboard will
disappear at this moment; Click button "ESC" to cancel keyboard if no need to change the
original number; Click button "CLR" can delete the wrong number. The number can't be input if
the number exceed the set range. For an example: if set the stretch depth to be "122", please
click the stretch depth frame and input number "1" "2" "2" in the keyboard after keyboard occur,
then click "ENT" and click "YES" to confirm or click "NO" to input again.

Fig.4.11

Fig.4.12
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3.Host Forming Machine Interface Parameter Definte

Fig.4.13

3.1Stretch Depth: Set the stretch distance （0—200.0mm） of pre-stretch forming.

3.2Stretch Speed: Set the running speed (0—100%) of pre-stretch forming motor.
3.3Feeding Length: Set the feeding length of servo motor.
3.4Feeding Speed: Set the speed (0—100%) of feeding length.
3.5Host Speed Input: Adjust the speed （200—1500r/min） of main motor by change this
numeric value.
3.6Stretch Start Angle: The angle （ 2—40 ） when running after stretching down with
pre-stretch forming action.
3.7Stretch Stop Angle: The angle （ 50—150 ） when running after finish the pre-stretch
forming action and return to zero.
3.8Forming Start Angle: The angle （0—360） when forming magnetic valve start.
3.9Forming Stop Angle: The angle when forming magnetic valve stop.
3.10Demoulding Start Angle: The angle （0—360） when demoulding eject cylinder start.
3.11Demoulding Stop Angle: The angle（0—360） when demoulding eject cylinder stop.
3.12Vacuum Suction Start Angle: The angle（0—360） when the vacuum magnetic valve in
the bottom start.

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3.13Vacuum Suction Stop Angle: The angle（0—360） when the vacuum magnetic valve in
the bottom stop.
3.14Blowing Start Angle: The angle（0—360）when pressure demoulding blowing magnetic
valve start.
3.15Blowing Stop Angle: The angle(0—360 ） when pressure demoulding blowing magnetic
valve stop.
3.14Suction Start Angle: The angle (0-360) after demoulding and cup blowing out, cup catch
device and vacuum suction magnetic valve start.
3.15Suction Stop Angle: The angle (0-360) after demoulding and cup catch device finished
retainer cup, vacuum suction magnetic valve stop.
3.16Auxiliary 1, 2: The action that machine prepare for reservation.
3.17Feeding Start Angle: The angle when feeding action start, feeding action will stop
automatic after feeding for some length.
3.18Traction Time: The time of the action of traction motor.

4.The interface introduction of Cup Catch Device (Stacking Parameter)

Fig.4.14

4.1Cup Catch Action: This is the parameter when cup catch device go back and forth.

4.1.1Cup Catch Start Angle: The angle when cup catch mould start and return to

retainer cup. Must be adjust and return before host close its mould to prevent

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collision accident.

4.1.2Stop Coordinate: The location that cup catch mould stop after machine stop.

4.1.3Preparation Coordinate:The location that start cup catch mould to approach the

host open its mould, wait to enter host mould to catch cup.Ensure catch cup

mould not touch when host open its mould

Note:Operators should adjust this coordinate in manual mode before start machine to

prevent hit the host mould.

4.1.4Cup Catch Coordinate:The location that cup catch mould stretch to the host

mould when demoulding

Note:Operators should adjust this coordinate in manual mode before start machine to

prevent hit the host mould.

4.1.5Stacking Coordinate:The location of cup catch mould stretch to stacking device.

Note:Operators should adjust this coordinate in manual mode before start machine

4.1.6Current Coordinate:Location of which display cup catch mould running.

4.1.7Cup catch stay time:The cup catch mould reach to cup catch position point

staytime.

Note:Must set reasonable the stay time, cup catch mould must be return before the

host close its mould to prevent the collision accident.

4.1.8Stacking Stay Time: cup catch mould reach to sleeve cup position point stay

time

4.1.9Acceleration and DecelerationTime: Set the cup catch mould start running from

starting speed to running speed and from running speed deceleration to stop time.

In order to run more stable, operator should set high the data.

4.1.10Cup Catch Speed: Set the cup catch mould running speed, the running speed is

calculate the host speed change are synchronous run. namely host speed x catch

cup speed %, when the host running speed higher,the cup catch speed will

automatic increasing.
Note:Must set a reasonable value, made able to synchronous with running speed of
the host. Avoiding cup catch mould speed too slow out of synchronous with the
host, happen the host mould and cup catch mould hit accident.
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4.2The Parameter Area of Cup Push

System Design for stacked four rows of mold, when the count value reaches a preset
counting value, respectively, cups will be pushed from top to bottom to the conveyor belt
conveyor, then sent to the packing table. Operators should open the corresponding switch
according to the actual number of rows of the mold, height data of cup push coordinate,
preset value of counting and so on.

Fig.4.15

4.2.1Cup Push Positioning Speed: The relative running speed from the origin point to

the cup push coordinate.

4.2.2Cup Push Coordinate 1.cup push device move down from the original point to the

1st row of cup retainer mould.Setting the "Manual/Automatic" switch to manual

mode, operating interface change to "Manual"-"Cup Catch" page, move down

manually to the relative location of the 1st row of retainer mould, then get the data

of the current coordinate and input to the "Cup Push Coordinate 1".

4.2.3Cup Push Coordinate 2: cup push device move down from the original point to

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the 2nd row of cup retainer mould. Setting the "Manual/Automatic" switch to

manual mode, operating interface change to "Manual"-"Cup Catch" page, move

down manually to the relative location of the 2nd row of retainer mould, then get the

data of the current coordinate and input to the "Cup Push Coordinate 2".

4.2.4Cup Push Coordinate 3: cup push device move down from the original point to

the 3rd row of cup retainer mould. Setting the "Manual/Automatic" switch to

manual mode, operating interface change to "Manual"-"Cup Catch" page, move

down manually to the relative location of the 3rd row of retainer mould, then get the

data of the current coordinate and input to the "Cup Push Coordinate 3".

4.2.5Cup Push Coordinate 4: cup push device move down from the original point to

the 4th row of cup retainer mould. Setting the "Manual/Automatic" switch to

manual mode, operating interface change to "Manual"-"Cup Catch" page, move

down manually to the relative location of the 4th row of retainer mould, then get the

data of the current coordinate and input to the "Cup Push Coordinate 4".

Fig.4.15

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4.2.6Running/Stop Function Switch: Operators should click relative switch according to

the actual rows of the mould. When mould is three rows, click the relative switch

of coordinate 1, 2,3, do not click switch of coordinate

Fig.4.16

4.3Data of Cup Delivery Table

4.3.1Cup Table Positioning Speed ： The relative running speed that cup delivery table
move up from original point to the coordinate of cup table.
4.3.2Cup Table Coordinate 1: cup delivery table move up from the original point to the 1st
row of cup retainer mould. Setting the "Manual/Automatic" switch to manual mode,
operating interface change to "Manual"-"Cup Catch" page, move up manually to the
relative location of the 1st row of retainer mould, then get the data of the current
coordinate and input to the "Cup Table Coordinate 1".
4.3.3Cup Table Coordinate 2: cup delivery table move up from the original point to the
2nd row of cup retainer mould. Setting the "Manual/Automatic" switch to manual
mode, operating interface change to "Manual"-"Cup Catch" page, move up manually
to the relative location of the 2nd row of retainer mould, then get the data of the
current coordinate and input to the "Cup Table Coordinate 2".

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Fig.4.17

4.3.4Cup Table Coordinate 3: cup delivery table move up from the original point to the
3rd row of cup retainer mould. Setting the "Manual/Automatic" switch to manual
mode, operating interface change to "Manual"-"Cup Catch" page, move up
manually to the relative location of the 3rd row of retainer mould, then get the data
of the current coordinate and input to the "Cup Table Coordinate 3".
4.3.5Cup Table Coordinate 4: cup delivery table move up from the original point to the
4th row of cup retainer mould. Setting the "Manual/Automatic" switch to manual
mode, operating interface change to "Manual"-"Cup Catch" page, move up
manually to the relative location of the 4th row of retainer mould, then get the data
of the current coordinate and input to the "Cup Table Coordinate 4".

4.3.6Counting Preset: Preset the counting number, when it meet the preset number, cup

will be pushed out.

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4.3.7Counting Number Display: When machine running for one time (mould running

for one time), the counting add "1", when the display number more than (≥)the

counting preset number, cup push action start, then counting number to be zero.

4.4Parameter Page of Cam

Fig.4.18

4.4.1Cam Speed Change 1, 2, 3 is provide for user and user need 6 grade operating
secret to modify.The cam speed change 4,5 is used by producer, user can't modify.
4.4.2Cam Speed Change: Set the speed of the host running "1000PRM, start angle of"
10 " and stop angle of " 102 ", , deceleration rate of 30%, then the cam rotary angle
between" 102 "to" 10 " running with speed 1000PRM, but the cam is running slow
down to "1000PRM × 30% = 300PRM " with a low speed in the angle "10" to "102 ".
This function can be applied to some products need a long forming time in the mould,
in order to increase product performance.
4.5Introduction of Caterpillar, Die-base Adjust Page
In order to adjust sheet width convinent, this machine is equipped with the function of
displaying the sheet and caterpillar width. First of all, measure the width of front, middle,
back caterpillar and input to the input value box, then displayed value box will be
displayed the caterpillar width. The display value will increase and decrease in the

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display when click the forward and backward buttons, it display the caterpillar width.
Because of the accuracy, it has some error with the actual number, the current value need
to be amended.

Fig.4.18
4.5.1Front Caterpillar Forward:Front caterpillar motor forward running, the caterpillar
width become wide.
4.5.2Front Caterpillar Backward:Front caterpillar motor backward running, the caterpillar
width become narrow.
4.5.3Middle Caterpillar Forward:Middle caterpillar motor forward running, the caterpillar
width become wide.
4.5.4Middle Caterpillar Backward:Middle caterpillar motor backward running, the
caterpillar width become narrow.
4.5.5Back Caterpillar Forward:Back caterpillar motor forward running, the caterpillar
width become wide.
4.5.6Back Caterpillar Backward:Back caterpillar motor backward running, the caterpillar
width become narrow.
4.5.7Linkage Positive Adjustment:Front, middle, back caterpillar motor forward running
synchronously, caterpillar width become wide.
4.5.8Linkage Negative Adjustment:Front, middle, back caterpillar motor backward
running synchronously, caterpillar width become narrow.
4.5.9Die Base Up Start:The 1st time click this button, motor forward start (button turn
green and twinkle) the location of die base move up, and click this button again, die
base will stop move up.

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4.5.10Die Base Down Start:The 1st time click this button, motor backward start (button
turn green and twinkle) the location of die base move down, and click this button
again, die base will stop move down.
Note:When click the button to adjust the height of die base, it will not response rapidly,
it need to delay about 10 seconds to start motor after lock gasbag exhaust out
air pressure. When adjust to move down die base, pay attention to the cutter
depth of upper and lower mould to prevent cutter damage.

5.Introduction of Temperature Control Interface

This machine adopt advanced PID temperature control method, to ensure the stability of
temperature control, in order to produce various products

5.1Cavity is divided into four parts A, B, C, D, drying tunnel, meanwhile the front half part of
upper drying tunnel have 15 rows (A1-A15) independent of regulation and control area,
A1-A12 for vertical adjustment, A13,-A15 horizontal adjustmenthalf of the sub-12 road
(C1-C12) vertical adjustment. Lower drying tunnel have 11 rows, B1-B11, D1-D11 vertical
adjustment control region, B12-B14, control for horizontal adjustment. Electric heating
switch on the panel can be choosed separately control heating the upper oven, or heating
upper and lower oven at the same time.

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The electric layout

Feeding
The electric layout

Fig.4.19

5.2Temperature control interface

5.2.1Upper-Oven control interface(Temperature Units:℃)

Fig.4.20

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5.2.2Set Value (SV): Set needed oven control temperature for the production, the set

temperature will be different according to the different material, different

thickness,different producing speed. So the actual experience of the operator is

very important in the actual production operation and operators should keep a good

data recording habits.

5.2.3Measure Value (PV): System control temperature is maintained at the upper and

lower settings, generally, it fluctuate of the range of ± 1 ℃.

5.2.4Indicating Lamp: It turns green during temperature control working.

5.2.5Quick Setting: Operators can input any number here when it need to heat or cool

entirely, no need to input one by one.Heating: input positive number; Cooling:

input negative number.

5.2.6Screen Change: The key area that can change relative control screen.

5.2.7Lower Oven Control Interface（The unit of temperature is ℃）

Fig.4.21

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5.3Mould Chain Preheating Temperature Opertation Interface

Fig.4.22

5.3.1Setting Value(SV):set the needed control temperature for production.Temperature

of upper, lower mould: About 16∽20℃.Caterpillar Temperature: 200∽350℃,the

actual experience of the operator is very important in the actual production

operation and operators should keep a good data recording habits.

5.3.2Measure Value (PV):System control temperature is maintained at the setting

number, generally, it fluctuate of the range of ± 2 ℃.

5.3.3Indicating Lamp: It turns green during temperature control working.

5.3.4Pre-heat Switch: The control switch for caterpillar pre-heat.

5.3.5Error Warning:set machine will prompt that the temperature of mould with a big

error when the temperature of upper, lower mould exceed this number, but

machine will not stop.

5.3.6Deviation Stop:Set upper and lower mold temperature exceeds this value, in order

to prevent damage the cutter of upper and lower mould with a big temperature

difference, the machine will automatically stop and alarm, suggesting that the

mould temperature deviation is too large and stop, alarm;

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5.4Temperature PID Parameter Interface

The temperature control system uses advanced PID process control, with different

temperature control objects have their own different optimum ratio, differential time,

integration time parameter. Traditional PID parameter was identified by experts with rich

experience, or it may cause the whole system out of control, caused trouble for our users

if the parameters do not match. This control system with parameter self-tuning function, it

can control automatical according to the control object and simulate experts operation to

search automatically, judge the best parameter and to reach the optimal temperature

effect.

Fig.4.23

5.4.1All parameters have been self-tuning operation or adjustment is completed when

machine finished, unless the parameter is missing or found that the control of

unstable, if no necessary, the user do not self-executing self-tuning and do not

modify the PID parameters, or they may affect the temperature control effect.

5.4.2Start Self-tuning

Change the screen of "PID" button in the temperature control interface, enter

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parameter interface (need 6 grade operating password), click AT button to start

self-tuning, display "AT NO..." and start self-tuning. Operators can't change any

parameter after self-tuning start.

"AT" lamp close and display "AT On" after self-tuning finished. System calculate one
suitable parameter for heating system automatically, then system will control
according to the new "PID" parameter.New PID parameter will be displayed in the P,
I, D data area.

Fig.4.22

Fig.4.24
Note: In order to keep the accuracy of self-tuning parameter, we suggest to set in proper
order when self-tuning, do not set all parameter or different parameter together.

6.Introduction of Manual Operating Interface

6.1Manual Operating Interface of Host

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Fig.4.25

6.1.1Host

POS JOG: Host positive jog, the jog speed is up to host speed.

NEG JOG: Host negative jog, the jog speed is up to host speed.

6.1.2Feeding

POS JOG:Feeding chain positive running, the jog speed is fixed and can't be

adjusted.

NEG JOG:Feeding chain positive running, the jog speed is fixed and can't be

adjusted.

6.1.3Pre-stretch

POS JOG:Pre-stretch mould move down and jog, the jog speed is fixed, can't adjust.

NEG JOG:Pre-stretch mould move up and jog, the jog speed is fixed, can't adjust.

Home:Search the original point (home) of the pre-stretch mould, machine will

perform one action to original point automatically when the first time connect with

electric, zero point lamp will turn on when find the original point (home).

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6.1.4Host Action

Forming:connect air pressure magnetic valve and sheet in the mould formed by the

air.

Demoulding:connect demoulding magnetic valve and the air from air cylinder push

out the products from the mould.

Blowing:this function prepared for machine, some products need.

Vacuum:connect vacuum magnetic valve.

Demoulding Blowing:connect magnetic valve and air pressure demoulding and

blowing out cup.

Mould Locking:connect magnetic valve and air fill in the air-bag, then fix the mould

and make it can't move.

Auxiliary 1, 2: this action is prepared for machine.

Note：
①The selecting switch should be in "Manual Mode" when choose manual operation.
②If the pre-stretch mould do not search original location, or not in the original location,
under the state of zero indicating lamp not turn on, functions of host jog or host start
failure.
③ Operators should adjust the location of original point after change the mould, make
the original stop location of pre-stretch mould level with upper cutter.
④ The stroke of different pre-stretch mould is different, so the location of upper and
lower switch should be adjusted.
⑤ Operators should operate slowly when the host REV JOG to prevent mechanical
collisions, usually try not to be the reverse operation.

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Fig.4.26
Search for Original Point:
When across the origin location of the control, if the Homing direction is not limited to one
direction,
you can use the switch, the limit (-) switch from two directions Homing. The limit switch (+)
indicates lower limit of the limit switch (-) indicates the upper limit.

Fig.4.27

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Fig.4.28

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6.2Operating Instruction of Manual Interface for Cup Catching Part

Fig.4.29

6.2.1Cup Catch
POS-JOG: Cup catch mould move to the direction of host, the speed is fixed and can't
be adjusted.
NEG-JOG: Cup catch mould move to the direction of cup sleeve, the speed is fixed
and can't be adjusted.
Home:Searching the positioning origin location, machine will perform one homing
action automatically when machine connect with electricity. Indicating lamp turn on
when finished searching.

Note:

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① After start searching origin location, machine will alarm prompt and can't running

normally, machine can start only after solve the problems.

②Origin switch, the upper,lower limit switch of the machine is completed adjusted before

leaving the factory, do not easily change; change the origin location will affect the data of

cup catch coordinate and cup retainer coordinate, please adjust accordingly, the

possibility of mechanical collision will occur.

6.2.2Cup Push Device

Fig.4.30

POS- JOG: Cup push device jog move up, the speed is fixed and can't be adjusted.
NEG- JOG: Cup push device jog move up, the speed is fixed and can't be adjusted.
Home:Searching the positioning origin location, machine will perform one homing
action automatically when machine connect with electricity. Indicating lamp turn on
when finished searching.

Note:

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① After start searching origin location, machine will alarm prompt and can't running

normally, machine can start only after solve the problems.

②Origin switch, the upper,lower limit switch of the machine is completed adjusted before

leaving the factory, do not easily change; change the origin location will affect the data of

cup catch coordinate and cup retainer coordinate, please adjust accordingly, the possibility

of mechanical collision will occur.

6.2.3Cup Delivery Table

Fig.4.31

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FWD JOG: Cup delivery conveyor upward direction to jog and move, the speed is
adjustable and up to the cup table positioning speed.
REV JOG: Cup delivery conveyor upward direction to jog and move, the speed is

adjustable and up to the cup table positioning speed.

Home:Searching the positioning origin location, machine will perform one homing
action automatically when machine connect with electricity. Indicating lamp turn on
when finished searching.

6.2.4Cup Catch Action:

Cup Push Location: the location of cup push device change to left and right, this
function is used only when mould dislocation arrangement.

Vacuum Suction: Connect vacuum magnetic valve and cup catch mould start.

Cup Push Air Cylinder: connect left and right pushing linear magnetic valve of the
cup catch mould.

Baffle Valve Open/Close: connect the left baffle magnetic valve of conveying belt of
delivery table.

Delivery On/Off: The start, stop of the conveying belt of delivery table.

7.I/O Supervisory Signal

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Display the ON / OFF state of machine to control input / output signal, to facilitate the usual
machine maintenance or machine fault diagnosis. Displayed by screen switching function key
to change.

Fig.4.32

8.Alarm Information Screen:This device is set over 50 alarms, if an alarm occurs, the buzzer

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will sound, warning lamp turn on. Press the "Alarm" button, enter the "alarm screen", alarm
information will display on the alarm screen, operators can check the alarm reason according
to the relative prompts. Operators should clear the alarm after solve the problems, click the

"alarm reset" button, you can disarm the alarm. For details, please refer to the failure and
solutions (trouble shooting list).

Fig.4.33

9.Maintenance and Management Interface

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Fig.4.34

9.1Running Record
Running Counting: when machine start and running for one time, the counting number
add ‘1’, this counting number can be clear, to record the total running time of this machine.
Running Time: record the total running time of this machine and can't be cleared.
9.2Number counting
Counter 1: when machine start and running for one time, the counting number add ‘1’,click
RST (8 password) key to clear, it can be used for the production counting.
Counter 2: when machine start and running for one time, the counting number add ‘1’,
click RST (8 password) key to clear, it can be used for the production counting.
9.3Lubricating System
Lubrication parameters: If the machine lubrication system of oil pump is automatic
lubrication way, it is necessary to set the oil pump start lubricating time under actual
operating conditions. If add too much oil,it will overflow into the machine elsewhere,
affecting health, and waste oil; If too less oil, it will have mechanical transmission parts
damage, so it is necessary to set a reasonable lubricating method.
① Set the number of lubrication intervals: Enter the value (N), it means machine start

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lubricating after each "N" times that machine running (6 password).

② Set the lubrication time (in seconds): Enter a value (M), it means machine start
lubricating for "M" seconds after the machine running "N" times (6 password).

③Running Time after lubrication: this value increased by 1 when machine run a cycle,
when this value is equal to the lubrication interval times setting value "N", the machine
began to refuel, this value become 0 at the same time, it began to re-count.
④Manually start the lubrication: a manual lubrication refueling button, press and hold this
button, the pump started to refuel (8 password).

9.4Password

Considering for the operating safety, many features of the machine has operating

privileges,users can set different levels of operating passwords for different operator so

that it can not be excessive operated. Machine factory initial password is "11111111",

managers can be used the initial password set 2-9 grade operating passwords. Grade 2

is the highest authority, and grade 9 is the least privilege. The grade 1 password is special

for factory and users have no authorized to use.

Fig.4.35

9.5The System Directory:Switch into the user operating interface system menu, this

function is an advanced application, non-professionals do not enter (2 password).

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9.6The Time and Date Modified:Amendments to the top right of the display time of user

interface (6 password).

9.7Chinese and English switch key:Chinese,English Language change button.

9.8The without material feeding shutdown times: When setting a data is"X", the

machine running "X" times will automatic stop once the inlet detect no material feeding

into.This function will close when the data is "0".

9.9Parameter Storage(2 password)

Through Parameter Storage Interface, the mature parameter which is used at present can

be saved in the HMI or call previous data from HMI, which is convenient to record data by

manual after changing mould.

Fig.4.36

9.9.1SSE zone

9.9.2PLC--->HMI: Save present data into HMI. It is effective by pressing and holding the

button for 2 seconds after the button changing its color.

9.9.3HMI-->PLC: Read and write the previous mould data from HMI into PLC. It is

effective by pressing and holding the button for 2 seconds after the button changing

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its color.

Chapter 5 Debugging Operation

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I.Before and after starting Preparations

1.Before starting Preparations:

1.1Before used this equipment, operator should totally understand for each operation
function program.
1.2Make sure all bolts and connector have fixed completely.
1.3Make sure water,electric,air pipe wire are connected, check each parts without loosen
and split, oil,water pipe without leakage happened.
1.4Examine voltage or power phase is correct connection.
1.5Examine lubricate oil is enough.
1.6Examine air pressure is 7Bar
1.7Examine all safeguard protection device is normal, visually all mechanical and electrical
device abnormal or not, each emergency stop switches valid or invalid.
1.8As the order of open machine power : turn on workshop power switch- turn on machine
main circuit switch to ON- open machine main panel switch.
1.9Gloves, material cut cutter or scissors etc

2.Attention for running

2.1Examine the air,cooling water whether leakage, make sure all instructions table is
normal.
2.2When running, not touched the any operation key in the screen, operation panel switch
and work objects.
2.3Examine various part motors,transmission components or others pars whether have
abnormal noise.

3.Precautions before and after the shutdown:

3.1After the end of daily processing , should cleaning machine keep machine clear.
3.2After the end of daily processing, should shutdown machine power. As order of closed
machine: turn off control panel switch- turn off the machine main circuit power- closed
workshop power switch.

II.Mould installation and debugging

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Initial install or changed mould after, before starting, the mould cutter needs re-positioning
adjustment.

1.Mould installation,debugging steps:

a.machine upper mold base mounting surface, the upper mold surface with a clean rag
wipe clean and spray the right amount of anti-rust oil, transparent color food-grade
lubricants help die Sierra pole smear cream.
b.Using the upper mould special device installation upper molds loose fixed on upper
mould base, noticing pre-stretching whether accurate into mould ,in order more easy
check cutter pisition when clamping, don't lock bolts temporary.
c.Rising the assist pressure plug indentation to upper shears.
d.machine lower mold base mounting surface, the lower mold surface with a clean rag
wipe clean and spray the right amount of anti-rust oil, transparent color food-grade
lubricants help die Sierra pole smear cream.
e.Using special device install lower mould in the down mould base,besides fix the mould
by blots not fasten.
f.Use manual model slow jog machine clamping ,makes the lower mould base clamping
states,(notes upper,lower mould base new height),adjustment upper mould base by
adjust motor, the distance of upper and lower cutter plane is 0.5 -1 mm and parallel.
g.Falling upper mold base makes upper and lower cutter coincided(attend to the upper and
lower cutter mutual justify), makes the distance between upper cutter and lower cutter is
the sheet thickness1/3-1-5.( somes can be sleeving, it relevant with cutter and mould
structure)
h.Jog to cutting position,makes lower cutter into the shears.
i.Locked up and lower mold bolts:from up molds to lower molds, from inside to
outside,around the corners.Maker sure molds be balance force, suggestion used torque
wrench ,according the bolts size to choose properly torque.
j.Correct install cooling water pipe,air pipe.
k.As angle control program of thermoforming machine,it should setting
pre-drawing,forming air,blowing,ejection ,feeding etc start angle and stop angle to make
sure active program and using length of time.
l.Coarse adjustment according to the usual procedure control drawing, it is simulated a lot

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of practical production and processing program summary, and has a certain universality.
General is trimming,only for individual mould if necessary to adjustment.
m.Adjusting pre-stretch plug decreased depth,forming air pressure ,feeding sheet width,
feeding in sheet length,feeding out sheet width, heating temperature,cooling water flows
or rate,or setting cooling water temperature when use temperature controller.
n.General pre-stretching plug decreased depth determine (H):
Plug decreased depth (H) = forming products depth (H1)-h (h is usually taken 3-5 mm)
o.The lower mould that cutter,cavity,bottom roof ect each exhaust Holes should keep
patency.
p.Under the condition of equipment without material,low speed running or through
inching operation methods to check these settings is correct.
q.Loading test, fine-tuning machines,mould, processing parameters to normal production.

2.Mould cooling,maintenance in the production

a.In order to gain maximum possible productivity,try to keep mould temperature
lower.Surly, it relevant with the processing plastic sheet material, thickness.
b.When processing is commonly use material,such as PS,PVC,PP,ABS,the16——18℃ is
more typical of temperature.
c.Mould temperature can not lower 10℃, because it will have condensed water,affect
products quality,caused mould rusty.
d.High temperature mould will reduce production efficient,the positive pressure
thermoforming equipment general regular not exceed 30℃
e.A lots of cooling water flowing through mould, it is decide that the key of gain constant
temperature throughout the operation. Request per minutes average flowing about
50-100liter/min
f.It is quite important keep up mould temperature is same as lower mould.Otherwise,
different thermal inflate caused up shear plate,lower cutter edge part of brust, so the
upper shearing and lower cutter,guide premature tear and ware,reduce its life
g.Normally up shear plate with lower cutter temperature different not exceed 5℃.The
mould temperature control interface on machine,the up and down mouldtemperature
different error alarm, error shutdown alarm(Reference 4 chapter 5.3)
h.The eject bottom of mold have blowing holes,connected well air pipe and blowing
angle.Once found the sizes smaller ,providing another cooling way on cooling bottom.
i.General upper shearing the side of the mold near the heating box mold base, the next
blade mold base paste a layer of 3-8mm thick felt cloth. Mainly in order to prevent the

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heat of the heating box is passed to the mold, causing mold before and after the
temperature is inconsistent (so that the mold will not only easy to deform,but also affect
the cooling effectiveness and quality of the product).
j.Before starting, check the heating ceramic (especially upside) is fixed, reliable,Clean
the machine around the debris, tools, etc., to prevent the fear of falling with the sheet
into the mold during the production process, damage upper shears, lower cutter.
k.Shutdown to prevent foreign objects falling into the mold, the upper and lower mold in
the molding position in a closed state.

3.Initial startup or after replacement the new mould, setting the function knob to "automatic"
position, start the host running, the lower speed idling 1-2 hours, make sure no abnormal
phenomena, then stop for debugging. Note: after change mould to re-adjust the
pre-stretching up, down, origin switch position, generally speaking, origin position
adjustment to the pre-stretching mold core position higher than lower cutter up 2 mm, upper
and lower limit a corresponding pre-stretching mold core up and down stroke.

III.Installation the sheet

1.Put a roll sheet on the unwinder, adjust unwinding pressure 0.2-0.3Mpa,through sheet into
the between up and down roller by manual, Press unwinder jog switch to release sheet
about 1-2M for alternate
2.Manually adjust the entrance material of left and right guide plate, guiding sheet to
inlet,through touch screen "adjust chain width" and "adjust chain narrow" button adjust the
distance between of two chain, makes it proper sheet width.pressing"feeding start"
button ,the sheet feeding in to oven zone waitting heating.

IV.Turning heating switch on“II”to pre-heating oven, setted heating temperature value,the
temperature will different if the sheet material and the thickness different. The general
experience sheet thickness range 0.5-0.8mm should set temperature about 300-350℃,
increasing up 30-50℃ on two sides sheet temperature.
So the oven temperature automatic heated to set temperature. it is normal, it will a little
higher if the first time heated to set temperature, after later,the system will adjust the
temperature at the set temperature value. if heating thinner sheet only open up oven is fit to
the production requirement, but the heating switch should on “I”.

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V.Adjust Feeding length:through program adjust feeding length on screen which for
adjustment the sheet feed.

VI.Adjust feeding speed:combination of production speed, adjust an optimal feeding speed.

VII.Power on machine running

①Feeding start: pressing the panel "start" button ( 5 seconds or more), start the feeding

motor to feed, people guided the sheets into chain track, don't start main motor temporary ,

just execution feeding sheet action. Feeding speed and length executive in the screen

"feeding speed" and "feeding length" setted value. Feeding motor initial feeding cycle

according to host speed value to setting, change the running number data can change

feeding motor the feed execution cycle. When start Feeding motor the buzzer chirping to

warning until the host start or stop.

② Host start: after start feeding, and then pressing the "start"button (5 seconds or more),

which can be start host running, the host start the initial speed of the screen image by host

speed input value setting, change this value will change the start host speed, when the

normal running change this value will acceleration, deceleration as adjust;According to the

product forming condition and adjusting speed and temperature timely, the right temperature

is the main factor to guarantee the quality of the product, combined with the host running

speed change correspondingly to cooperate, through the many reasonable adjustment,

achieved the best effect, at this time the warning light green light shine.

VIII.When sheet processing excess material from caterpillar track, through the artificial traction,

pull to rolling machine.

IX.Through adjusted the program parameters, temperature, running speed etc the production

process adjustment, make the products can get the best forming effect and efficiency.

Detailed instructions please refer to chapter 4 parameters of the third quarter.

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X.Catching cups parts of machine: this part of the operation is matching the host running.

1.After the host start operation, pressing the panel the start / stop button, and then cup

catching machine running. If you want to adjust catching cup action successively, through

adjust the screen picture of the "cup catch start Angle" this parameter to change. Stop device,

click the operation panel on the "stop" button, and then cup will stop running. Boot can

choose whether to clear out cup in mould for cup.

2.catch cup parameters adjustment (detailed parameters refer to chapter 4 the fourth

quarter)

2.1catch cup coordinates: this coordinate position coarse adjustment should be in boot

before need to adjust well, it closing the host mould when turnover,but not collision,

after start catch cup according to actual operation situation for fine tuning, maked cups

very well sleeved on catching mould.

2.2Sleeving Cup coordinates: this coordinate position coarse adjustment should adjust well

before startup, makes the catching cup into sleeving cup suitable location, after start

the catching cup according to actual operation situation for fine tuning, makes the cup

very good transmission to stacking mould.

3.Cup stacking quantity Settings and already stacked the number of cup, according to the

following parameters can be adjusted, Meter numerical preset, meter numerical display.

4.pushing cup start / stop: after start the host forming,beginning the 3-5 cycles cup should not

start catching cup , the host forming finished cups will fall in the hopper of catching cup device,

should start pushing motor discharge cups.

5.Catching cup machine alarm:

It occurred motor alarm when operation, or during pushing cup process happend struck

phenomenon, the system will automatically alarm, the host will stop running

immediately.Detailed warning message will be displayed in the host touch screen,

according to the corresponding alarm code prompt do corresponding treatment.

Chapter 6 Maintenance
I.Machine Maintenance
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Reasonable lubrication and maintenance is make sure machine running normal and extend the
life of an important guarantee ,please strict implementation.
1.Lubricate
① Air components lubrication: using 20# engines oil,centralized automatic lubricator oil. To
keep the height of the normal oil surface.
② The moving parts lubrication:use 30 # engines oil, according to the actual situation
refueling to correct setting the inverter of numbers and times.
③Lubrication of rolling bearings: use calcium-based grease, replace it every six month.
④The surface of cam using 00# oil,each time refueling a day.
⑤It should change a time after reducer first using 500-1000hours, after change it 3000hours
per time.
⑥ Change engines oil should before the reducer stop, lubrication oil not cooled when
discharge lane

2.Maintenance
① After stop the machine,turn off electric,water,air on time,prevent from the foreign objects
into cavity,the status of up and lower molds is clamping position.
②Air tank needs often water draining,the components of a whole machine keep it clean, the
touched sheet and finished parts are pay attention to sanitary requirements.
③ Should always check the each fastener are loosen,the new machine after running
3-5times,should re-locked each fastener again, it needs centralized maintenance half an
year.
④ Frequently cleaning the surface of cam greaves and dusty,and keep the around
environments clean, increasing the cam using life.

II.Molds Maintenance

1.Positive pressure thermoforming mould structure features:

① Shearing,under the blade in addition to the since blanking role,and some under the
knife-edge but also played the role of the edge of the molded part.
②Upper and lower blades are generally fixed, flexible replacement of the cavity,a mold can
produce various specifications plastic cup. Only reduces the manufacturing cost of the
mold,but also to accelerate the retooling speed, while improving production efficiency.

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③Help die Sierra stretched, compressed air pressure molding.

④The shearing, under the knife-edge shearing 100-500 million.Blunt the shearing,under the
knife-edge after grinding sharp,can be used multiple times.Therefore,in the production of
‘disposal plastic cup’,the mould maintenance and repair of good or not directly impact on
production efficient and products quality,so efficient maintenance and repair is very
important.
Hence suggestion:forming mould best fixed installation in a model matching positive pressure
on thermoforming machine. Because mould frequent change not only reduce the production
efficiency, and mold in the disassembly, storage, installation, debugging process intangible
increased the possibility of damage, certainly will fit precision will reduce gradually, and then
affected the quality of our products and production efficiency.

2.Maintenance and Lubricate

To make the mold in the failure to produce a consistently good product quality status, and
must perform regular routine maintenance and repair work.
①All lubrication points on the mold, such as refueling nozzle or others similar, maintenance
eight hours at a time.
②Checking linear bearing guide sleeve have scratch traces or not. If yes, should determine
the scratch reason.
③Oriented linear bearings set each week and grease twice.
④Per 8 hours to help pressure the plug rod light coating of food-grade grease.
⑤Per 8 hours to the top of the pole light coating grease.
⑥Per 24 hours to check the top of the pole, pre-stretching rod locking nut loosen or not.
⑦Per 8 hours by the air gun clean the upper and lower mold, the mold at the turnover
position:
a.Clean out hiding in the sediment under the ejector plate;
b.Makes the pre-stretching plug low down, clean up the broken plastic mixed in the blank
holder.
①daily checked (visual) cooling system water pressure and water flow. When the pollution is
more serious water cooling ,should cleaning cooling system per three months . Once find
the stain accumulation , should add fit solvent into washing liquid , or replacement of the
cooling water regularly.
②Each week to check pre-stretch plug wear situation. Their appearance will change due to
abrasion and impact molded products. Therefore, we should reserve certain mold stopper
assist for alternate.

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③Check mold stopper assist degree of tightness per 8 hours(such as:Carefully tighten the
loose nuts) are the same level or not ( using level ruler).

3.Mould Storage
①The mold should be stored in a dry room with air conditioning. If the room have heavy air
humidity,should be all shiny surface coated with Vaseline, rust inhibitor to be protected.
②If the space allowed, the mold upper and lower halves motif separately placed. Note the
pressure stopper assist rod , plunger vertically upward. In this way to save, it can prevent
mold-oriented institutions tilt deformation, the shear cutter edge of the mold can be protected,
not damaged.
③If the two and a half mold can not separated placed, you can upright it on a dedicated mould
shelves, put a wood plate in between of upper cutter and lower cutter to prevent the upper
and lower cutter edge into deep mutual wear.
④Clearing up mould cooling water in cooling waterways,holes( such as adopt compressed air).
Especially in winter,when keep the mould under the without anti frost house,any water stay in
the cooling waterways will damage mould.

4.Maintenance
①Upper shearing cutter edge,down cutter edge and others movement parts of moulds are
easy suffered abrasion.
②Extending the blade life, generally the upper shearing,lower cutter edge parts that will
processing more longer, in order to later be able to grind several time.Machine cutting depth
(commonly know as cam high point ) should as low as possible, makes lower cutter not
inserted into upper cutter too much when cutting, reduce the abrasion.
③When using the filler metal (eg welding) practic repair avalanche crushed the cutter edge,the
cutter edge will be deformed or cracked. In order to more easy maintenance and ensure
products quality,processing the upper cutter hardness lower than down cutter. Basically, the
upper cutter hardness 55-58HRC,lower cutter hardness 60-65HRC.
④the extent of the material rubbed off from the shearing, mold upper mold blank holder of the
body's front-end may also need to re-processing (such as wear thinner).No matter how,must
be ensure that have enough space makes blank holder was pressured spring retracted on
upper shearing . Retracted on the upper shear distance at least equal to the cutting depth of
the machine (common 2.0 - 2.5mm, random slightly different).
⑤At most of moulds, lower cutter played forming parts of role.Remembered, unless the plastic
cups shape,dimension changed or others mold parts re-processing at same time,so lower
cutter can re-grind with precision tolerance.

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⑥Any impact of a high degree of grinding will probably force the cavity,the top end of such
re-processing, ensure that the size and shape has not changed.
⑦If the shear cutter edge need to re-grinding, and examining others mould components wear
situation also. If necessary, the worn,and unqualified to be replaced. This includes all moving
parts, the middle of the ring, plunger and pre-stretching plug rod guide sleeve,pre-stretching
plug and demolding the role of the cavity.
Note:When re-install a new upper shearings, generally advise to reinstall guider,positioning
parts. - Upper mode install new position pins,guide sleeve or guide post - lower the model
install position pin, guide post or guide sleeve.
⑧These operations must be allowed to competent, experienced personnel in
well-equipped,suitable for maintenance operations mold room operations.If not the condition
have maintenance personnel and tools facilities,it best send back to the original factory repair
double-check to prevent to damage mould.

Chapter 7 Alarm and Treatment

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Alarm Treatment
1.Main Motor Driver Alarm,check host Check the alarm code displayed in host

driver alarm code,confirm alarm reason! inverter,confirm alarm reason and solve the
problem according to host inverter instrument.

2.Pulling Servo alarm,check driver alarm Check the alarm code displayed in servo
code,confirm alarm reason! driver,confirm alarm reason and solve the
problem according to servo driver instrument.

3.Feeding servo alarm, check driver alarm Check the alarm code displayed in servo
code, confirm alarm reason! driver,confirm alarm reason and solve the
problem according to servo driver instrument.

4.Die-base adjust motor overload alarm! 1.Whether locking airbag venting;

2.Adjusting chain or mechanical drive jam or
dead;
3.Motor phase lock;
4.Motor reducer has problem.

5.Front caterpillar adjusting motor overload 1.Mechanical drive jam or dead;

alarm! 2.Motor phase lock;
3.Motor reducer has problem;
4.Front and back bellmouth is too big.

6. Middle caterpillar adjusting motor 1.Mechanical drive jam or dead;

overload alarm! 2.Motor phase lock;
3.Motor reducer has problem;
4.Front and back bellmouth is too big.

7. Back caterpillar adjusting motor overload

alarm!

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3.Motor reducer has problem;

1.Mechanical drive jam or dead; 4.Front and back bellmouth is too big
2.Motor phase lock;

8. Automatic lubricating system alarm! 1.Lock of oil;

2.Oil pump has problem.

9. Cup catch servo motor alarm,check Check the alarm code displayed in servo driver,
driver alarm code,confirm alarm reason! confirm alarm reason and solve the problem
according to servo driver instrument.

10. Cup push servo motor alarm,check Check the alarm code displayed in servo
driver alarm code,confirm alarm reason! driver,confirm alarm reason and solve the
problem according to servo driver instrument.

11. Cup Lifting table motor alarm,check Check the alarm code displayed in
driver alarm code,confirm alarm reason! inverter,confirm alarm reason and solve the
problem according to inverter instrument.

12. Cup catch frame lower limit alarm! 1.Initial origin reset is not finished when power
on;
2.Over stroking,lower strorking limited
connected.

13.Cup catch frame upper limit alarm! 1.Initial origin reset is not finished when power
on;
2.Over stroking,upper strorking limited
connected.

14.Cup catch frame to be zero alarm! 1.Origin reset not finished or reset time too
long;
2.Mechanical failure.

15.Cup push frame upper limit alarm! 1.Initial origin reset is not finished when power
on;
2.Over stroking,upper strorking limited
connected.
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16.Cup push frame lower limit alarm! 1.Initial origin reset is not finished when power
on;
2.Over stroking,lower strorking limited
connected.

17.Cup push frame to be zero alarm! 1.Origin reset is not finished or reset time is too
long;
2.Mechanical failure.

18.Cup out platform upper limit alarm! 1.Over stroking,upper strorking limited
connected.

19.Cup out platform lower limit alarm! 1.Over stroking,lower strorking limited
connected.

20.Cup out platform to be zero alarm! 1.origin reset not finished,or reset time too
loner;
2.mechanical failure.

21.Unwinder motor over alarm! 1.mechanical drive stuck;

2.lack of motor phase;
3.motor reducer failure;
4.material stuck.

22.Rewinder motor over alarm! 1.mechanical drive stuck;

2.lack of motor phase;
3.motor reducer failure;
4.stroking signal failure;
5.tension air pressure too high.

23.Traction motor overload alarm! 1.mechanical drive stuck;

2.lack of motor phase;
3.motor reducer failure;
4.material stuck;
5.traction pressure too high.

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24.Upper,lower mould temperature 1.measuring sensor failure or disconnected;

excessive different alarm! 2.mould temperature too high;
3.cooling water failure.

25.Upper,lower mould temperature 1.measuring sensor failure or disconnected;

excessive different alarm! 2.mould temperature too high;
3.cooling water failure.

26.Over high temperature,sheet drop down 1.oven temperature too high.

alarm!

27.Stretching limited wrong. 1.origin reset not finish;

2.upper,lower limited connected.

28.Stretching upper limited alarm! 1.Origin reset not finished when power on;
2.Over stroking,upper strorking limited
connected.

29.Stretching lower limited alarm! 1.Initial origin reset not finished When power
on;
2.Over stroking,lower strorking limited
connected.

30.Cup discharge motor alarm! 1.mechanical drive stuck;

2.lack of motor phase;
3.motor reducer failure;
4.material stuck.

31.Delivery platform motor alarm! 1.mechanical drive stuck;

2.lack of motor phase;
3.motor reducer failure.

32.Catching cup limited fault! 1.origin reset not finish;

2.upper,lower limited connected.

33.Pushing cup limited fault!

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1.origin reset not finish; 2.upper,lower limited connected.

34.Host ES fault! 1.host machine ES button was pressed;

2.major failure alarm occurs,automatic
shutdown.

35.Stacking ES fault! 1.catching cup ES button was pressed;

2.major failure alarm occurs,automatic
shutdown.

36.When host running mold 1.when host running from clamping to

opening,stretching position wrong alarm! opening,pre-stretching plug not on zero
position.
2.origin signal switch failure.

37.Pushing cup device no back zero 1.pushing cup origin reset not finish;
fault,pls back to zero! 2.after manual moving or failure alarm,no
execution back origin operation.

38.Vacuum pump motor alarm! 1.vacuum pump overload alarm;

2.lack of phases;
3vacuum pump damage.

39.Pushing cup not finish alarm! 1.pushing cup cylinder air source pressure
normal or not;
2.cup struck;
3pushing cup magnetic valve failure;
4pushing cup air cylinder failure;
5.sensor fault or position fault.

40.Pushing cup units position Not zero! 1.pushing cup origin not finish reset;
2.after manual moving or failure alarm,no
execution back origin operation;
3.sensor failure.

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41.Lubricate oil pump overload alarm! 1.motor lack phase;

2.oil-way full blocking;
3.lack of oil;
4.refueling time too long.

42.Pushing cup device to be zero position 1.when pushing cup return to origin alarm;
fault! 2.mechanical fault;
3.origin signal failure.

43.Stretching to be zero not finish fault! 1.when pre-stretching back to origin alarm;
2.mechanical failure;
3.origin signal failure.

44.Upper,lower mould temperature 1.Measuring temperature sensor failure or

excessive different outage alarm,examine disconnected;
mould cooling system! 2.mould temperature too high；
3.Water cooling failure.

45.Upper,lower mould temperature 1.Measuring temperature sensor failure or

excessive different outage alarm,examine break;
mould cooling system! 2.mould temperature too high;
3.Water cooling failure

46.Temperature measurement module 1 1.PLC system failure;

anomaly alarm! 2.temperature module damaged;
3.lack of temperature module.

47.Temperature measurement module 2 1.PLC system failure;

anomaly alarm! 2.temperature module damaged;
3.lack of temperature module.

48.Temperature measurement module 3

anomaly alarm!

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1.PLC system failure; 3.lack of temperature module.

2.temperature module damaged;

49.Temperature measurement module 4 1.PLC system failure;

anomaly alarm! 2.temperature module damaged;
3.lack of temperature module.

Chapter 8 Trouble Shooting

Machine is too noisy

1.Mould close too much 3.Bad vent

1.When correct the cutting,do not downward

the mould all the time if it can't cutting well,the
2.Sping broken when mould clamping and
blade overlap as possible as less,try to adopt
demoulding
other mothod.

2.Replace the spring for Φ6 × 380 × 22 (L ×

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rough × ring).Outer diameter of demoulding 3.Check forming magnetic valve and the
spring should less than 29.5mm.
exhaust muffl

Heater always damage

1. Over Voltage 1. Choose the normal voltage.
2. Bad wiring, connectors oxidation 2. Process connector and rewiring.
3. Exceed the lifetime 3. Change new heater.

Solid Relay always damage

1.Short Circuit

1.Check whether the fixed card of the heater

dropped into the oven, or other metal to make

2.Heat Dissipation is bad the copper shell short circuit.

2.Check whether cooling fan is normal

Feeding accurate is too low

1.Feeding speed is too high 1.Slow down the feeding speed, lower speed
with higher accurate.
2.The drive of machine is not smooth 2.The setting parameter of inverter is not
correct.
3.The chain is too loose. 3.The chain is too loose cause the
transimssion sliding.

Program running abnormal or not running

1.The connecting shaft of cam rotary is
breakdown.
2.The connect of encoder wire is bad or drop. 2.Change encoder or check the wiring.
1.Change encoder connecting shaft.

The temperature control is abnormal

1The display temperature is more higher than negative value.
setting temperature and become higher. 3.Actual temperature is very high but the
2.Temperature display abnormal,it is high or display temperature is very low.

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2.Check related temperature sensor and

4.Actual temperature and display temperature cables.
3.The polarity of temperature sensor is
are not displayed.
reverse,the temperature sensor is damaged
1.Replace the related solid relay or PLC output
or heater is damaged
point is damaged.
4.Solid relay is damaged or driver is damaged.

Bad Vent
1. Air source is too dirty. 1. Improve the quality of air source.
2.Fast venting valve is block. 2. Clean venting valve.
3.Forming valve is damaged. 3. Replace or repair the forming valve.

Cutting is not good

1.Mould corrector method is not correct. 1.Train the operator.
2.Mould itself has problem, cutter is not in the 2. Repair the mould.

same level or it is not accurate enough.

Host always tripping

1.Overload 1.Check whether the transmission part is
normal, whether the mold overlap is too tight,
or the mould core is stuck.
2.The wiring terminal screws loose, bad wiring. 2.Fix the screw
3. Transmission fault. 3.Check motor transmission and reducer.

Lower Mould core is always stuck

1.When test the mould, the left-right of mould 1.Re-adjust the mould ejector rod, the mould
ejector rod is out of level. core should lower than the excircle of cutter
core, keep the surface smooth.
2. Screw of mould core is dropped. 2.Clean the screw, Re-fix it by 504# glue
Note: check whether any burr in the fixed hole.

Products forming no good

1.Sheet temperature too cooled,increasing 2.Compressed air too later
heating temperature 3.Air pressure too lower

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4.Compressed air turn offer too early 7.Mould air exhaust port too small
5.Sheet touched mould 8.Sheet thickness uneven
6.Forming tools sealing no good 9.Sheet difficult forming

Products edge area Forming no good

1.Sheet temperature too lower, increase 3.Compressed air too later
heating temperature 4.Air pressure too lower
2.Compressed air too early

Not touched mould core

1.Sheet temperature too lower 4.Mould air exhaust port too small
2.Air pressure too lower 5.Sheet thickness uneven
3.Mould temperature too lower

Products have transverse mark

1.Sheet touched mould 3.Mould cutter too sharp or burr
2.Mould temperature too lower

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Chapter 9 Appendixes
1.Machine Layout

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2.Upper Mould Size Drawing

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3.Lower Mould Size Drawing

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