HFTF-2023 Operation Manual Modificado

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Tel: 0086-57 Ruian HengFeng Machinery Co.,Ltd Fax:0086-5777-65575628

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HFTF
FTF--2023
BOPS THERMOFORMING
MACHINE
OPERATI NG
OPERATING
INSTRUCTIONS
RUIAN HENGFENG MACHINERY CO., LTD
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PREFACE
The HFTF-2023 plastics pneumatic thermoforming machine is a forming
equipment with advanced design, excellent performances and wide uses. Training on the
spot is very necessary for operator as well as operating instructions. In order to operate
this machine safely and properly, please first read this operating instructions in detail.
Operator should know not only every components but also technics control unit.The
control system is composed of PLC and industrial grade man interface, you can adjust
the parameter during the machine running.
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Contents
Machine Working Condition ............................................................................. 03
Disassembly and Installation ..............................................................................03
Prior To Electric Connection ...............................................................................03
Function Control Instruction ...............................................................................05
Pre-operative Preparations ............................................................................... 07
Man Interface Operation ................................................................................... 08
1. Start Page ..................................................................................................... 08
2. Working Page................................................................................................ 09
3.Manual Working Page ....................................................................................12
4.Temperature PID Page ...................................................................................13
5. I/O Monitoring Page ......................................................................................15
6 . Manual Operation ........................................................................................ 16
.Selection Running Mode ..................................................................................... 21
.Adjust the Production ......................................................................................... 22
. Points for Attention for Safety.............................................................................. 25
Care and Maintenance ..................................................................................... 25
Troubleshooting ............................................................................................ 26
AppendixA:man- interface technicial parameters .................................................... 29
Appendix B: Feeding Motor Parameters Setting Table ............................................ 33
Electric Drawing ........................................................................................................40
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Machine Working Condition

The working condition of this machine:environment temperature should lower 40, elevation should
lower 2000M and air of environment shall not contain dust, salt and corrosive gases.When working
temperature is about 20, relative humidity can be 90%; when temperature is about 40, relative
humidity can't over 50%.
Disassembly and Installation

Disassembling: Handle the machine from the place with fork lift mark on the packing box.
Unpacking: Remove each parts of case, loosen four fastening screws between feet and packing
box. Owing to the cylinders in the center of the machine, please handle it with care.
Caution: Dont put the machine on the ground before installing the shock absorbing base.
Placing: Adjust the four shock absorbing feet, but the machine on the ground horizontally. Make sure
not to knock the main cylinder and driving chain during installation.
Installation of die table lifting system: Install the cylinder and cylinder supporting cross beam on
the top double-screw bolt, tighten the screws, and insert the air pipe.(Picture 1)
Connection of air source: There is a cut-off valve and pressure adjusting and drying dual valve at
the side face of the machine (beside the electric box), which are connected to users air source with a
3/4 inch flexible pipe. The pneumatic pressure should be kept at 0.7Mpa and above. The gas should
be of non-poisonous, non-wet, non-lubricant and non-corrosiveness. (Picture 2)
Connection of cooling water: There is two 1/2 cooling water interface ports at the right lower side of
the electric box. Connect the water source to the water coolant inlet, and connect the water coolant
exit to floor drain. (Picture 3)
Prior To Electric Connection
1. Main Technical Parameter
1- Max. Forming Area 510570mm

2- Max. Forming Depth 100mm
3- Sheet Thickness 0.09-1mm
4- Max. Dia. Of Sheet R olls 710mm
5- Max. Cutting Length 6350mm
6- Air Pressure 0.7MPa
7- Air Consumption 1200Liters/min
8- Water Consumption 10Liters/min
9- Produce Speed 600-1300cycles/hr
10- Power 3380V+N+PE 3220V+PE ,50/60Hz
11- Preheater Power 4Kw
12- MouldPlateHeatingPower 4Kw
13- Heating Plate Power 15Kw
14- Max. Sheet Width 580mm
15- Weight 2500Kg
16- Dimension (LWH) 275014102150(mm)
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2Dimension
Dimension & Drawing
3INSTALLATION
INSTALLATION POSITI
POSITIOON AND SPEC. OF WATER ELEC
WATERELEC TRI
ELECTRI
TRICC & AIR
Cooling water inlet:12mm TYPE2-Places

Electrical wire:5-pole 8mm2
Air inlet:3/4 6.9Bar(10PSI)
12mm 2
5- 8mm2
3/4 6.9Bar(10PSI)
Don not scale drawing

All dimensions are metric unless noted
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The equipment power adopt 380V, 50HZ, Three-phase AC. Input terminal is L1, L2, L3, N, PE. (N is
zero terminal, PE is safety ground). Power wire connect with terminal L1, L2, L3, N, PE from downside
power input holes of electrotechnical box. Power source connect with L1, L2, L3,N, PE is 410mm2,
wire N is 6mm2.Ground wire PE can't smaller than 6mm2. Operator should connect power plug of
rewinder with Sensor XP1 left of electrotechnical box before power on.
Raise the tension adjust oscillating rod of unwinding sheet, when it close the button switch and
receive signal, unwinding motor power on and running. Face to operating panel, the rotary direction of
motor shall be clockwise, or you should change the power phase sequence.
Close power QF1, open power switch of the control panel, meanwhile green indicating lamp turn on,
at this moment, the operating screen have buzzer sound and light, show the Theme Power Up Image.
Function Control Instructions
1.Material Lifting Valve

1.Material alve: Lift the conventional material roll under the action of pneumatic pressure
provided by the system.
2.Cl
2.Cl amping Pressure Val
Clamping alvve: It is used to control the main cylinder power pneumatic pressure and all
the pressure provided by air reservor. Also can adjust it to stop running.
3.Heating Pressure Regulator
3.Heating egulator: It is used to control the heating pneumatic pressure to force film to
contact the heating platen.
4.Forming Pressure Regulator
4.Forming egulator: It is used to control the forming pneumatic pressure to force film to
close to the die space to be formed.
5.Demoulding Pressure Regulator
5.Demoulding egulator: It is used to control the pressure for ejecting the finished products.
6.Feeding Press Roll Pressure Regulator
6.Feeding egulator: It is used to control the pressure for feeding material by the
press roll.
7.Mould Lifting Pressure Regulator
7.Mould egulator: It is used to control the pressure for lifting the die platen.
8.Heating Platen Poppet Valve
8.Heating alve: It is used to control to eject the heating platen out of the slide way so
as to change the mould.
9.Mould Lifting Valve
9.Mould alve: It is used to control the lifting of die platen.
10. Adjustment of Opening Speed
10.Adjustment peed: It is used to control the running speed for mould opening (Reduce
the speed by clockwise rotation, and increase it by anti-clockwise rotation).
11. Adjustment of Opening Position
11.Adjustment osition: Adjust the proximity switch (sp2) to control the falling distance of
the heating platen for mould opening.
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12. Mould Clamping Valve (YV

12.Mould 1)
YV1)
1): When it is switched on, open the air valve, connect the air source to
provide pneumatic pressure into upper of cylinder, enable the piston rod to drive the toggle to move
down, and enable the heating platen to lift and close the mould.
13. Mould Opening Valve (YV2)
YV2)
2): When it is switched on, open the air valve, connect the air source to
provide pneumatic pressure into lower of cylinder, enable the piston rod to drive the toggle to move up,
and enable the heating platen to fall and open the mould.
14. Cutting Valve (YV
14.Cutting 3)
YV3)
3): keep pneumatic pressure in the middle of cylinder, when it is switched on, the
air valve will be closed, the pneumatic pressure in the middle of cylinder will be exhausted forcibly, and
then starts cutting.
15. Heating Valve (YV4)
15.Heating V4): When it is switched on, the heating pneumatic pressure will be connected
and enter into the die space, press the sheet material on the heating platen to be heated.
16. Forming Valve (YV5)
16.Forming V5): When it is switched on, the forming pneumatic pressure will be connected to
close the sheet material to the die space to be formed.
17. Demoulding Valve (YV6)
17.Demoulding V6): When it is switched on, the ejecting pneumatic pressure will be
connected to eject the finished products.
18. Servicing Structure
(1) Material pre heater: If first preheat the sheet material before entering into the heating platen to be
(1)Material
heated, that will reduce the heating time and shorten the production cycle, also will increase the
heating performance. Especially, it can reduce the production cycle and increase the operating
efficiency for big batch material process.
Installation
Installation:The preheater is installed between the material leading roll and heating platen. First hang
the foam support on the heating plate, and put the back nylon wheel on the stand, then turn the
preheater on the blister pad, fix it with base by screws.
(2) Waste Twister: It used to rewind the material waste during production, which is fixed under the
(2)Waste
feeding pinch roll. The slitter edge out of the feeding pinch roll passes through the tension rod and
twist on the pole, control the stopping or driving of twisting pole by tension rod. The controlling
process are as follows: After every feeding, the controlling process are as follows: After every feeding,
the tension rod is just put on the ground, the proximity switch (SP4) receives the signal to start the
motor to drive the twisting pole, the twisting pole rewind the waste and drive the tension rod to
separate from ground, then the motor stops.
Adjustment: If adjust the upper and lower running speed of tension rod, only adjust the flow control
valve on the top of damping cylinder.
Care and Maintenance
aintenance: During operation, if it wont receive the signal due to too far distance between
the tension rod on the ground and the proximity switch (If receives, the red indicating lamps on the
proximity switch will be light ), only correct the distance between them within 2-3mm to restore.
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Pre-operative Preparations
Before production, first test run the machine about 12 hours without mould and material, and fit with
a fork lift with lifting device so as to move the heating platen and mould for replacing the mould.
1Test Running
(1)Adjust the closing pressure at 0.6Mpa, the other pressure should be closed temporarily.
(2)Set the controlling temperature of heating platen at 120C (thermocouple already connect).
(3)Select "automatic" running switch, press the "Clamping" button, the machine will run continuously
after starting and stop until turn the running select switch at "semi-auto" or "manual" position.
2Disassembly and Installation of the Heating Platen
(1)Select the manual operation, start mould closing with 0.35-0.45Mpa pressure.
(2)Switch off the main power, pull out the outlet of heating plate.
(3)Move the preheating unit, remove the organic glass frame.
(4)Move out the stainless steel tray.
(5)Pull out the thermocouples connecting wires (5 places) on the heating plate, and remove the air
inlet pipe.
(6)Lift the fork lift to the position as high as the bottom of heating platen, enter it from the feeding
surface.
(7)Open the mould lifting pressure regulator and ejecting valve to eject the heating platen out of the
track.
(8)Pull the heating platen by hand slowly until put it on the fork lift and move it to working table.
3Installation of gas hole hiding copper baffle on the heating platen
In order to avoid to loss too much air forming station and damage plastic material, so the gas
hole except on the mould must be sealed, do as follows:
(1) Loosen all fastening bolts (70 pieces in total), take off the heating platen on the top.
(2) Loosen two screws for fixing copper baffle, take off the copper baffle, then fit temporary
aluminum thin baffle or permanent copper baffle on it, also can use sheet aluminum of 2-
3mm for small batch production
(3) Its best to use the copper baffle of 2.5mm, drill same hole as well as main baffle in the
cutter range of mould. The copper baffle has fine heat conduction.
(4) If use the temporary aluminum-foil baffle, lay the aluminum foil on the copper main baffle,
then drill holes along with the gas holes of main baffle in the cutter range of mould, make
sure not to wrinkle.
(5) Clean the heating platen and put on it.
(6) Put on all the fastening bolts, dont tighten them at first, tighten them from center to external
in sequence after they are in their position.
(7) Put the heating platen on the machine, plug in thermocouple and power plug, connect with
air inlet pipe.
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4Installation of Mould
Before installing, it should install the heating platen according to the above mentioned method.
(1) Close the heating platen by manual operation with 0.35-0.45Mpa pressure.
(2) Remove the preheater and organic glass frame.
(3) Loosen four lock nuts on the die platen until there is enough height (concerned with the
height of mould).
(4) Open the mould lifting valve and adjust the lifting pressure, lift the die platen.
(5) Lift the mould to the height as same as the heating platen by fork lift, it should first pad with
boards of same width under the mould , ensure not to damage cutting of mould.
(6) Push the mould on the fork lift and boards to the heating platen.
(7) Adjust the mould to match the erection bolt holes on the die platen, then reduce the mould
lifting pressure slowly to fall the die platen.
(8) Tighten all bolts on mould.
(9) Readjust the mould lifting pressure to lift the die platen, take out the boards padded under
the mould, and slowly reduce the lifting pressure to 0, put the mould on the heating
platen horizontally.
(10) Tighten four lock nuts on the die platen.
Man Interface Operation
1.Start page After tested by itself, at first screen showing" start page",
if choose chinese mode,to press "chinese" button on lower right corner, the
system switch to chinese mode, if choose english mode,system switches to
english mode.Then press "running system" into operation page
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2Working
Working Page
2.1 Setting
Setting of Working Page Parameters
Closing delay time: When it setting automatic running, after closing wait interval closing again
Heating delay time: After receive closing signal to wait interval gas heating
Heating time: Controlled heating gas press sheet tighten and heating time.Adjust this
parameter, enable sheet forming to achieve good result on schedule time
Heating exhaust time: After heating gas discharge from cavity inside wait forming time
Forming Time: Control forming pressure, made sheet forming on cavity inside time
Cutting delay time: after shet forming, adjust this parameter, it can adjust the air
pressure discharge time of cavity inside
Cutting time: Controlling cutting time. It can't be cut down if too short time
Ejecting delay time: Adjust time difference between ejecting
and opening mould
Ejecting time
time: Control ejecting pressure the time of push out
product from cavity inside
Feeding delay time
time: When it automatic running,after ejecting
wait interval feeding
Feeding Length: refers to the step length of the feed material;
Feeding Speed: Refers to the step speed of the feed material
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2.2 Setting of Temperature Valve

Screen "PV" value of the heating plate corresponding to the measured temperature value
corresponding to the value of "SV" settings, depending on the material and environmental conditions,
the settings will be different.According to material and environment condition different, the setting
valve will different also.
Heating plate1Heating plate4 is use to heating sheet flat plate,each heating plates are
uniform distribution thermocouple. Heating part divides into four independence temperature control
zones,mainly is increase precise control and forming effect of product.
Pre-heater is use to preheating sheet on the heating plate front. Preheating is one process
which before sheet go into heating plate, it reduce heating time for shorten heating cycles.
Mould plate have cooling device that is used to heating mould. When mould point higher than
setting valve 2, cooling water will cooled to keep mould with steady temperature.
2.3 Counting Preset and Alarm

2.3Counting
Counting Valve Preset: Counter to counting cycles of each time:Counter is counting cycles of
each time ,when counting value equal to setting valve,the buzzer alarm, according to produce to
setting correspond value.
Speed Display: Indicating production speed, per minute cycles mould times
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2.3 Display Running S tate

2.3Display
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3Manual
Manual Working Page
Choosing manual mode of operation switch to manual working page, operate by manual or
testing on machine each action
3.1Function buttons
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3.2 Manual closing forbid function This two

units button is used for machine opening and closing
mould under manual mode to limit safe.Only choosing
release mode,user can operation machine closing and
opening mould by manual, otherwise it will alarm. Note:
When choosing forbid,the mode switch to semi or auto
on control plane, the forbid will be force release.
4Temperature
Temperature PID Page
The temperature PID data was modify or adjust needs profession people to operation.If the
temperature control not big problem, we not suggest user operate it.
The "static" and "dynamic" two units of P, I, D, data tuning the system to improve the accuracy of
temperature control required. Static means the machine is not running, dynamic refers to start the
machine is on automatic operation until the end of self-tuning.
Start Condition: to set the temperature of the SV value (reference value 130), P 0 0-D 0,
the machine is in non-production status.
Self-tuning Function: auto tuning: Press the Start tuning key, enter the self-tuning state, display
self-tuning status. Not allowed to modify the parameters are not allowed to operate the machines.
Since the end of the tuning, auto-tuning the lamp, and the system automatically calculate the
parameters of a set of suitable heating system
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Can be static or dynamic according to the "write static" or "write dynamic" button to save
the new PID parameters, the system will be controlled.
PV AT AT
AT

SV
O OFF ON O
N ON- F P
OFF I
F
In the parameter recovery: to restore the "initial PID parameters.
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5 I / O Monitoring Page
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6Options Page:
6.1State of Mould
Start : Mould electric heating turn on ;
Forbid: mould electric heating turn-off.
Open cooling water temperature:Setting mould cooling with water
temperature
6.2A
Automatic Oiling
a) Regular lubrication: equipment with lube oil pump, you can set this parameter to time to start
the pump, the oil lubrication of the machine refueling point, solve the inconvenience of manual
refueling. In order to better maintenance of equipment, according to the actual operation to develop a
reasonable refueling program.
b) the number of runs: to set the machine after the set number of times in the run to start
automatically pump fuel.
c) The fuel injection time: Set each pump refueling time.
d) has been in operation: the number of last oiling to running.
e) to move the oiling: Press and hold this button for the manual jog oiling.
6.3 Press roller control:Feeding rubber roller can

use"manual" or auto" controll
6.4Feeding
Feeding optimize: Programmer machine debugging, non-professionals do not operate.
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6.5 Unwinding delay time: to adjust the unwinding motor start-up delay in the receipt of the
unwinding signal; purpose is to make the rewinding tension rod to be able to maintain a certain dead
weight tension.
6.6 Advanced Settings: programmer machine debugging-specific, non-programmers do not
adjust.
6.7 Data Formula: convenience store mold production parameter set, the system design can
store 20 different data parameter set.
a) Data recipe "button to display:
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b) The library key the "n #" key to enter the parameters to read or save the page.
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6.6
6.6 Alarm Information
When the system detects a machine malfunction or incorrect operation, the screen
message, the operator can make the appropriate treatment according to the information. There are a
considerable number of the fault system is not automatically detected, and only continue to
accumulate experience in the actual production operations. Here are some common failure
phenomena:
a) the failure of the servo drive: such failures on the screen will pop up the following screen.
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b) The failure of the Security hood: the machine is running, you must close the security door,
otherwise the machine can not run. If your safety gate switch was damaged, please fixed it timely,
then run machine again to avoid accidents.
c)Temperature failure: the system will have failure phenomenon based on the detected display the
alarm page, the user can according to different prompted to make the appropriate checks,such as
thermocouple failures:
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Selection
Selection Running Mode
1. Manually: the mode selection switch on the control panel in the "manual" position, the user
interface will automatically switch to manual operation screen, in this state, you can press the
operator panel or on the screen "Closing" "Heating" "Forming" "Cutting" "Opeing" "ejecting"
"Feeding" the machine will make the appropriate action, while the button above the corresponding
indicator light.
2. Manual Mode: Semi-automatic way: the way selector switch on the control panel placed in the
Mode
semi-automatic "position, the user interface will automatically.Switch to the "page", press and hold the
"start" button for three seconds, the machine will start to run consecutive to run a cycle, namely:
Machine during operation, if you press "Stop" button to immediately stop the machine, only to
start again,the machine only to repeat the "heating" to "stop" the periodic motion. When the "start"
button press on the operation panel, the machine will beep, indicating that the machine began
running.
3.Automatic Operation Mode ode:: mode selection switch to "Auto" position on the operator panel,
the user interface will automatically switch to "work page", press "Start" button, the machine will
"mold" ... "to send the piece"continuous cyclical movement, until you press the "stop" button, the
machine will stop.If you want to end the work of the "automatic" run, the way you can also choose to
switch to "semi-automatic" machine in a cyclical action is completed, it will automatically stop.
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.. Adjust the production

After pre-production ready, also needs commissioning machine, which is the every function of
machine setting well control parameter and adjust the best state of every performance. After
debugging to mass production,avoiding the unnecesary material waste.
1. Setting of function control parameters
Set each parameters according to materials and thickness, mainly for operators experience
and grasped actual skill. Refer to the following data for the first test running.
(1) Setting Temperature
BOPS PVC
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Preheating Temperature 80 C 60 C
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Heating Plate (1) 135 C 110 C
o o
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o o
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Mould Temperature 40 C 25 C
(2) Setting Timing Time
Heating Time 1.2 seconds
Heating Exhaust Time 0.15 seconds
Forming Time 1.3 seconds
Forming Exhaust Time 0.20 seconds
Cutting Time 0.40 seconds
Demoulding Delay Time 0.38 seconds
Demoulding Time 0.1 seconds
Feeding Delay Time 0.25 seconds
Clamping Delay Time 0.6 seconds
(3) Setting Pressure
Clamping Pressure 0.7 MPa
Heating Pressure 0.2-0.3 MPa
Forming Pressure 0.3-0.6 MPa
Demoulding Pressure 0.2-0.5 MPa
Lifting Pressure 0.5-0.7 MPa
(4) Setting Feeding Length
Setting feeding step length and feeding speed refer to the actual operating width.
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2.Test Running
2.Test
(1) After the temperature is stable completely, before feeding the material, it should pre-adjust the
mould and heating platen so as to adjust the cutting during test running.
A.Loosen four lock nuts on the die platen a little.Adjust lifting pressure to lift up the die platen so prevent
from knocking with cutter directly when the heating platen is lifted.
B.Lift the heating platen to close the mould by manual operation.
C.Reduce the lifting pressure to 0slowly, put the mould cutter on the heating platen lightly.
D.Tighten four lock nuts on the die platen, enable the mould cutter to close to heating platen and ensure
there is no gap. If there is gap, it should lower the lock nuts (hexagon) under the die platen, and remain a
certain space.
Note: The above mentioned operation also can be done during installing the mould, then waiting for
trial-production.
(2) Cutting Adjustment
(2)Cutting
A.
A.Cut a piece of material as same size as mould, put it on the heating platen, close the safety gate,
turn the running select switch (SC1) to "semi-auto" position, press "clamping" start switch to fulfill one
circle.
B.
B.If the film havent been cut, turn four screws on the die platen to clockwise to lower the mould cutter
(lower it at most two scores once), and then retest.
C.
C.If there is only a part of film is cut, first adjust nuts on uncut surface to lower the cutter, or move nuts
on cut surface to up, that can acquire a fairly smooth cutting.
D.
D.This machine is fitted with a cutter depth adjusting tray device, which is used to adjust the depth into
film overlay during heating and forming. If the cut depth is not enough, the air will run out of the edge of
cutter, this is named as air leakage. If then depth is too deep, the film will be cut too earlier and cant
be formed to cause waste. If the leakage is happened, turn the adjusting tray to anti-clockwise until
there is no leakage, then turn it 1/4 circle. If the film is cut too earlier, turn the adjusting tray to
clockwise until the trouble is removed.
Caution: During cutting, the torque arm of mechanical construction produces a large torque, fall the
cutter height too much will damage the cutter edge. Thus, when adjusting cutting adjust with small
distance carefully to void damage to cutter. A clean and fine cutting can not be got by high pressure
and too much cutter falling. When closing mould at the first time, the closing pressure should not be
over than 0.45MPa , normally it should be kept at 0.7MPa, that will increase the operating lift of cutter
effectively.
(3).Adjustment of Performance Normally it should adjust the forming effect of product if ensure
(3).Adjustment
the film is cut normally. Change the following parameters has direct effect on the performances of product
and increasing working efficiency:
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Heating Time
ime: Adjust to a min. Value which can ensure the product quality.
Heating Exhaust Time
ime: The setting range is within 0.1-0.2 seconds according to the volume of
mould. If want to increase the transparency of product, increase time a little.
Forming Time ime: Reduce time 0.5-3 seconds as possible but dont effect product quality according
to different mould shape and sheet thickness.
Cutting Delay Time Time: Set it according to volume of different moulds. Normally set it within 0.1-0.2
seconds. Increase time for the special big mould so as to ensure the forming pressure can be
exhausted before cutting. If the set time is not enough , that will hear an air blasting sounds when
opening the mould, sometime with continuous cutting.
Cutting Time ime: Normally set it about 0.2-0.8 seconds, and increase it if the cutter is very long or
very blunt.
Demoulding Delay Time ime: Set different time according to different moulds, normally wet it within
0.15-0.4 seconds so as to ensure to eject product when opening the mould. Too high setting cant
eject the product from the mould, at that time, reduce time gradually until the product is pressed
under the action of jet pressure, the increase it a little until the indentation is cancelled.
Demoulding Time ime: Normally set it within 0.05-0.3 seconds. If the time is adjusted too high, the
products may be gathered together and returned to mould under the action of static electricity.
Feeding Delay Time ime: Adjust it properly to start pulling as soon as the product is ejected out of die
space, the win. Time is 0.05 second.
Clamping Delay Time Time: When machine running circularly, open mould and wait the second
clamping time. Setting suitable time, make machine clamping in place when pull sheet action finished,
so improve the production efficiency.
Clamping Pressure
ressure:Reduce it for first starting, and keep it at 0.7MPa for cutting and continuous
production.
Heating Pressure
ressure:Set it to the minimum 0.2MPa, increase it that has effect on transparency of
products.
Forming Pressure
ressure: Set it to the minimum 0.2MPa, increase it for special shape, but too much
pressure will break film and causes air leakage.
Demoulding Pressureressure: Set it to the minimum 0.2MPa, integrates the setting of ejecting delay
time, ensure product to be ejected out of mould.
Setting of Opening Position osition: Set it according to the shape of product, transmit the product out
of the stopping position of fallen heating platen, thus can reduce unnecessary time waste.
Adjustment of Clamping Speed peed: Increase it as possible under ensuring the vibration is not too
big.
Adjustment of Opening Speed peed: Increase it as possible during continuous production, however
too fast speed will cause big vibration.
(4)..Continuous P roduction
(4) roduction: Under the semi-automatic operation, after test running, that can
start automatic continuous production. During initial automatic production, the temperature will be
fluctuated a bit for a little transient time, use the cutter depth adjusting tray to control the change of
cutting. Whats more, it has great effect on cutting to keep the temperature of mould stable, so must
provide water coolant for ensuring stable temperature of mould.
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Points
Points for Attention for Safety
If the machine drives the crankshaft to run with high-speed compressed air,it will produce very
strong pressure,make sure not to put your hands on the heating platen or other places to avoid
damage during production.The air control valve and safety gate are not safe absolutely,so there will
occur troubles at any time and cause the heating platen closed suddenly.If there is trouble,and need to
remove it with your hands,make sure to do as follows:
1- Close the emergency stop switch,thus the heating platen will be at the lower position,then cut
offer power
2- Close and cut the air feed system
3- Exhaust all remaining air and check all the meters until they display"0"
4-Put with piece of board between the heating platen and mould( attached with the machine)
5-Make sure it is safe absolutely and then settle the abnormal and conditions
Caution: (1) Make sure not to put your hands on the heating platen,mould or other dangerous
places if there is no safety protective measures
(2)If an accident is happened,please press the emergency switch immediately that the heating
platen will be placed at the lower position at once.
(3)During normal production and commissioning,there maybe have few materials left between the
heating platen and mould,remove them by a small stick,don't by your hands directly
Care
Care and Maintenance
HFTF-2023 thermoforming machine has firm construction, it is necessary to check and clean
usually. Do as follows:
General care and maintenance:
- Main Cylinder
ylinder: For every four months, take apart three air pipe connections and fill up 40g
lubricating oil, then reconnect them, free run the machine for 10 minutes. If find the cylinder is leaked
seriously after many times running, it should change the sealing device of cylinder.
rm:: Fill with heat-resistance ball-bearing grease to lubricate every six months. The
- Torque Arm
lubricating gun has an flexible injection head with 24 filler openings in total.
- Chain: Use chain lubrication to make it smoothly.
nit::lubricate the movable parts with bearing grease every 6 months.
- Feeding Unit
Tank:: Take apart the stopper plug at the bottom of air tank periodically to drain out sediment
- Air Tank
oil water. (Note: first drain off air), remove the cylinder to repair according to the following procedures:
1. Remove the cover plates around the stand, the upper discharge plate and air pipe of heating
plate.
2. Make the machine under the mould opening state, then upper keep the connection board of
heating plate to not be fallen with two boards, adjust the clamping pressure to 0MPa
3. Remove the adjusting chain and take away it.
4. Remove all inlet pipes of cylinder.
5. Enter the position of discharge plate, loosen the connecting bolt between center ledge and
piston rod by M24 socket screw wrench and remove it .
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6. Enter the position of discharge plate, loosen the connecting bolt between center ledge and
piston rod by M24 socket screw wrench and remove it .
7. Loosen and remove four M12 bolts on the cross beam of cylinder.
8. At this time, the cylinder can be moved freely, turn it carefully and take it out of the hole of
stand. Caution: Dont damage the cylinder wall and piston rod.
9. Refer to relative provided data for repairing the cylinder (see the drawing).
10. Install the cylinder stable according to above mentioned opposite procedures.
Maintenance of Mould:
It is very important to maintain mould in order to acquire high production efficiency and high quality.
1. If dont use the mould, put it with cover.
2. Dont damage knife edge at any time.
3. Check the knife edge usually, grind it before abrasive. If use the passive knife during running,
that will cause the mould damaged.
4. Grind the cutter by emery file, keep the width of cut to approximate to 0.05mm, any knife edge
cant be damaged, at last polish the cutter lightly by No.600 abrasive paper, thus to avoid
earlier cutting due to too sharpness. Use sharp knife edge for a very thin PVC.
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Troubleshooting
HF-2023 Thermoforming machine is an equipment with excellent performances.The
machine can run smoothly without troubles if do care and maintenance as mentioned above
usually.If there is troubles,normally due to air valve and executive electric appliances.The
common trouble that is the control system of the machine has not been adjusted
well.Therefore,record and keep the correct setting adjusting data for various different materials
and different models is recommended.Refer to the following instructions for the troubles causes
and troubleshooting
1.Bad forming with big bent angle
Cause Troubleshooting
Too short heating time Increase heating time
Too low temp.Of heating platen Increase the temp.of heating platen
Too low temp.of mould Increase the temp.of mould
2.Unclear transparent products
Too high heating pressure Reduce the heating pressure
Too rough mould Polish it
Too dirt heating platen Clean the heating platen
Too high temp.of heating platen Reduce the temp.of heating platen
Dirt material Check the material
Worn and rough heating platen Blast sanding
3.Incomplete forming
Early cutting Adjust it correctly
Air leakage Reduce the height of mould
Too low temp.of heating platen Increase the temp.as possible
Too low forming pressure Increase the pressure as possible
The material is stick to the heating platen Coat with silicium
Damaged forming pressure valve Repair or replace it
Damaged pilot valve Repair or replace it
Damaged forming exhaust valve Repair or replace it
Damaged heating timer Repair or replace it
Damaged forming timer Repair or replace it
4.The product is sticked in the mould
4.The
Too long ejecting time Reduce time
Too high or too low exhaust pressure Adjust to the best working state
Too less material silicium content Add with silicium again
Too shape cutter Adjust cutting
Damaged ejecting pilot valve Replace or repair it
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5.Can't be Cut Completely The height difference between cutter and mould is not too
5.Can't
big,increase the material thickness to 1.5times
Damaged cutting valve Repair or replace it
Damaged cutting timer Repair or replace it
Worn driving cylinder Repair the cylinder
6.The material is stick to heating platen

6.The
Too high temp.of heating platen Reduce the temp.
Too small material silicium content Add with silicium
Damaged forming timer Repair or replace it
Damaged heating valve Repair or replace it
7. Clear Mirror
Too hot heating platen Reduce the temp
Too dirt heating platen Clean the heating platen
Too dirt material Check the material
Worn heating platen Blast sanding
8. For Drive System
Troubles Possible Causes Troubleshooting
Restart the machine but the Too slow closing speed Adjust the closing speed
mould can't be closed after or damaged cylinder Or repair it
machine is stopped
The running for feeding is Too low pressure of press Increase the pressure
normal,but the feeding length roll
is not enough
The feeding is running The waste block the Switch off the main power
normally,but siopped guide roller, overloader switch,restart the machine
suddenly motor in 30 second
revolution,automatic
protection
Invalid temp.controlling The thermometric
thermocouple is
damaged or the control Replace with new one
solid state relay is
broken through
The heating pipe of Replace with new heating

The main power is trip heating unit is leaked or pipe and find out causes
shorted or other part are
leaked
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Appendix A: Technical Parameters of Man-machine Interface (PWS)

Command Switch DIP SWITCHE
witchDIP SWITCHES S
SW1 SW2 Specification
ON ON PWS-31xx-TFT
OFF OFF PWS-31xx-STN/FSTN
SW3 SW4 Function
-- ON Implementation of the user application
ON OFF Implementation of production burn-in program
OFF OFF Implementation of the TOUCH correction program
SW5 Communication format
ON P.L.C Communication format according as PWS-hardware system contents working parameter setting
OFF P.L.C Communication format based on ADP3 software communications setting
SW6 Enter password or not
OFF No request enter password( man-machine working password level setting to 1)
ON Request enter password (Man-machine working password level setting to 3 not directly into connection)
SW7 Can download screen details or not directly ON-LINE connection)

OFF Directly enter ON-LINE connection,no display system contents
ON When power up. Displaying system contents
SW8 When power up,password level 1or 3( Effect on DIP SW6=OFF)
OFF When power up,no request enter password, password level setting to 3
ON When power up,no request enter password, password level setting to 3
SW9 The back of man machine COM2 specification setting
OFF COM2setting to 20mA Current Loop connection( Only apply PWS-3000)
ON COM2setting toRS232/RS422/RS485 connection
SW10 The back of man machine COM2 specification setting
OFF Only apply to MITSUBISHIA series CPU PORT=RS422+RTS control
ON Most of P.L.C.labels =RS485 or RS422+RTS not control
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Screen Download Preparatory Step
1.
1.Prepare a cable for the computer with PWS-download connection; connect the computer and
PWS-communication port.
2.
2.Allowing to download screen data when power up and adjust PWS- the behind of panel DIP-
SW7=ON.( On practical working man-machine interface with PLC directly communication after power
up;adjust the PWS-panel behind in DIP-SW = OFF)
PWS- RS232C
25-pin -----CABLE-----9-pin
RXD 3 3 SD
TXD 2 2 RD
GND 7 5 SG
RTX 4 8 CTS
CTX 5 7 RTS
6 DSR
1 CD
4 DTR
3. Man-machine interface required to stay ready to receive the download status after power up.
After the completion of the self-test after power-transmission from the system directory the top left
[Download Application] key, the PWS-stay in the DOWN-the LOAD-the MODE computer download
screen, ready to accept the implementation of the code.
Display TYPE.Color TFT Display

System RAM Size128 Kbytes
Video RAM Size..512 Kbytes
Firmware Memory Size128 Kbytes
User Memory Size640 Kbytes
Working RAM Test...Passed

Battery StatusPassed
Flash Chips U1 and U2 Checksum...Passed
Flash Chips U3 and U4 Checksum...Passed
RTC Function TestPassed
RTC Register Test.Passed
RTC Register Checksum...Passed
Communication Port 1 Test...Passed
Communication Port 2 Test...Passed
Printer Port Test.Passed
DIP Switches Setting (8..1)11011011
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Figure A-1 PWS-3200 Power On Self -t

Self-t est
-test
** PWS-series after the power started, first check the above-mentioned hardware test items
is normal: the inspection results will be displayed on the LCD screen (Figure A-1). If any one
item PWS-series not normally ,it can not run properly with the PLC on-line.
PWS-
PWS-System Contents
PWS-S
PWS-After power up, if the panel behind the command switch DIP-SW7 is in
the ON position,in self-test finished, it will display PWS-system contents as shown below:
SYSTEM MENU
Run P.L.C.
Download Application COM1/2 ADP3
Download Recipes COM1/2 ADP3
Upload Application COM1/2
Upload Recipes COM1/2
Configure PWS-
CopyApplication COM1/2 PWS
Clear Data Memory PWS- Data RAM
Copy Recipes COM1/2 PWS
Calibrate PWS-LCD //TOUCH KEY
Exit PWS-
Figure A-
A-22 PWS-3200 System Contents
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Setting
Setting of PWS-work Parameters
arameters
Users who wish to set PWS-Series system date, time and operating parameters required to boot the
system directory screen (A-2).Touch" CONFIGURE", you can get setting format of Figure (A-3) working
parameters;When the man-machine behind the DIP switch DIP-sw5 = ON,the man-machine communication
parameters are based on prevail.
Configuration Table
Date(mm-dd-yy): 01-01-96
+ -
Time(hh:mm:ss): 11:11:11
Printor: Disahlod
PLC communication: COM2
Synchronization: Disabled
Baud rate: 19200
Parity; date; Stop Bit: odd; 8 bits; 1 bits
Save & Quit
CTS handshaking: Disabled
Command delay(10ms): 010
Battery Check: Disabled
Screen Saver Time(min): 00
##P.L.C Mode Code: 00
Quit
Workstation node address:001
Download/upload/copy port: COM1
Figure A-
A-33 Working Parameters Setting Format
Configuration Table

Date (mm / dd / yy) =01/01/96
Time (hh: mm: ss) =11:11:11
Printer =disabled
P. L. C. Communications =com2 P LC; PLC=com1;

PLC=com2
Synchronization =disabled PLC disable
Baud rate =19200 192009600
Parity ; Data ; Stop Bit
=odd ;86its;1bit CTS enable; disable

handshaking =disabled
000-255; PLC
Command delay(x 10ms) =000
Battery Check =disabled enable; disable
Screen Saver Time(min) =10 01-60 00

##P. L. C. Model Code =00 SIEMENS S5-P. L. C.

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Workstation node address =001 PWS
Download/upload/copy port =com1 PWS- port
[SAVE&QUIT]
LCD Backlight Adjustment Mode:

ode
Operator can adjust the contrast of LCD(STN/FSTN LCD) or brightness(TFTLCD)at any
time,there are two methods One is button components function keys set to Contrast
Up=brightness increase Contrast Down.=brightness reduce Save Contrast.= memory
contrast brightness Second is PWS system contents press [Calibrate]key;press[LCD
Contrast]key again [UP]=brightness increase;[DOWN]=brightness reduce;after adjust press

[SAVE &QUIT]key to momery .
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TOUCH KEY Correction Adjustment Mode

Mode
Operator do not adjust TOUCH KEY correction if no necessary,only use TOUCH KEY
not correct that can be adjust;Method is PWS-system contents
press[Calibrate]key;press[Touch Panel] key again;The screen display a blank and
screen,only the upper left corner has a white spot at the white point location click,then the
lower right corner has a white spot at the white point location click,after adjust to memory.
TOUCH KEY C o r r e c t i o n A d j u s t m e n t M e t h o d
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Appendix B: Feeding Motor parameter setting table
Function selection the relevant parameters

Pn00 0FFFF 0000 - 00
0 10
Pn00 1 0FFFF 0000 - 00
1 00
Pn00 2 0FFFF 0000 - 00
2 00
Pn00 3 0FFFF 0002 - 00
3 02
Pn00 01110 0000 - 00
4 00
Pn00 - 0000 - 00
5 00
Pn10 12000 4 - 2
0 0 0
Pn10 15 2000 - 20
1 51200 00
Pn10 12000 4 - 7
2 0 0
Pn10 01000 0 - 2
3 2
Pn10 2 12000 4 - 4
4 0 0
Pn10 2 15 2000 - 20
5 51200 00
Pn10 2 12000 4 - 4
6 0 0
Pn10 0450 0 - 0
7
Pn10 0250 7 - 7
8
Pn10 0100 0 - 0
9
Pn10 06400 0 - 0
A
Pn10 02314 0000 - 00
B 00
Pn10 0800 0 - 2
C 0
Pn10 010000 0 - 0
D
Pn10 03000 0 - 0
E
Pn10 01000 0 - 0
F
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Pn110 0FFFF 0010 - 00
10
Pn111 1500 1 - 1
0 0
Pn112 - 1
0
Pn113 - 10
00
Pn114 - 2
0
Pn115 - 3
2
Pn116 - 1
6
Pn117 - 1
0
Pn118 - 1
0
Pn119 - 5
0
Pn11 - 10
A 00
Pn11 - 5
B 0
Pn11 - 7
C 0
Pn11 - 1
D 0
Pn11 - 1
E 0
Pn11F - 0
Pn12 - 0
0
Pn12 - 5
1 0
Pn12 - 0
2
Pn12 - 0
3
Pn12 010000 1 - 1
4 0 0
Pn12 0250 7 - 7
5
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Pn20 0000 - 00
0 05
Pn20 PG 16 16384 - 16384
1 16384
Pn20 165535 4 - 32768
2
Pn20 165535 1 - 5
3 0
Pn20 06400 0 - 0
4
Pn20 065535 65535 - 65535
5
Pn20 - 16584
6
Pn20 0000 0000 - 00
7 1111 00
Pn20 06400 0 - 0
8
16
Pn21 PG 2048 - 20
2 48
10737418
Pn21 199 1 - 1
7
Pn21 0000 0000 - 00
8 0001 00
Pn30 150 6 - 6
0 3000 0 0
Pn30 1 010000 0 - 1
1 0
Pn30 2 010000 2 - 2
2 0 0
Pn130 3 010000 3 - 3
3 0 0
Pn30 010000 5 - 5
4 0 0
Pn30 010000 0 - 0
5
Pn30 010000 0 - 0
6
Pn30 065535 4 - 4
7 0 0
Pn30 065535 0 - 0
8
Pn30 0500 6 - 6
9 0 0
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Pn40 10100 3 - 3
0 0 0
Pn40 065535 1 - 1
1 0 0
Pn40 0800 8 - 8
2 0 0
Pn40 0800 8 - 8
3 0 0
Pn40 0800 1 - 1
4 0 0
Pn40 0800 1 - 1
5 0 0
Pn40 0800 8 - 8
6 0 0
Pn40 010000 10000 - 10000
7
Pn40 0000 0000 - 00
8 0101 00
Pn40 1 502000 2000 - 20
9 00
Pn40 1 Q 50400 7 - 7
A 0 0
Pn40 2 502000 2000 - 20
B 00
Pn40 2 Q 50400 7 - 7
C 0 0
Pn50 0250 7 - 7
0
Pn50 010000 1 - 1
1 0 0
Pn50 010000 2 - 2
2 0 0
Pn50 0100 1 - 1
3 0 0
Pn50 NEAR 0250 7 - 7
4
Pn50 132767 1024 - 10
5 24
Pn50 - OFF 050 0 - 0
6
Pn50 010000 1 - 1
7 0 0
Pn50 OFF- 10100 5 - 5
8 0 0
Pn50 201000 2 - 2
9 0 0
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Pn50 1 2100 - 21
A 00
Pn50 2 6543 - 65
B 43
Pn50 3 8888 - 88
C 88
Pn50 4 8888 - 88
D 88
Pn50 1 3211 - 32
E 11
Pn50 2 0000 - 00
F 00
Pn51 3 0000 0000 - 00
0 0333 00
Pn511 8888 - 88
88
Pn51 0000 - 00
2 00
Pn51 5 00 0088 - 00
3 00FF 88
Pn51 032767 0 - 0
A
Pn51 132767 1 - 1
B 0 0
Pn51 010000 4 - 4
C 5 5
Pn51 0100 0 - 0
E
Pn60 0 - 0
0
Pn60 0 - 0
1
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510
480
380
240
100
()

Q235A

1 1:4
---------
01
570
540
440
340
220
100
16
457.2(18")
304.8(12")
25 4(10")
76.2(3")
510
490
76.2(3")
152. 4(6")
457. 2(18")
550
570
( )
ZL102

1 1:2

RCX5157-07-16

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0086-5777-65575608

Tel: 0086-57 Ruian HengFeng Machinery Co.,Ltd Fax:0086-5777-65575628

RUIAN HENGFENG MACHINERY CO., LTD

Machine Working Condition

Disassembly and Installation

1- Max. Forming Area 510570mm

Cooling water inlet:12mm TYPE2-Places

Don not scale drawing

1.Material Lifting Valve

12. Mould Clamping Valve (YV

Feeding Speed: Refers to the step speed of the feed material

2.2 Setting of Temperature Valve

2.3 Counting Preset and Alarm

2.3 Display Running S tate

3.2 Manual closing forbid function This two

the new PID parameters, the system will be controlled.

In the parameter recovery: to restore the "initial PID parameters.

Forbid: mould electric heating turn-off.

Open cooling water temperature:Setting mould cooling with water

6.3 Press roller control:Feeding rubber roller can

.. Adjust the production

B.Lift the heating platen to close the mould by manual operation.

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6.The material is stick to heating platen

The heating pipe of Replace with new heating

Appendix A: Technical Parameters of Man-machine Interface (PWS)

OFF OFF PWS-31xx-STN/FSTN

SW3 SW4 Function

-- ON Implementation of the user application

ON OFF Implementation of production burn-in program

OFF OFF Implementation of the TOUCH correction program

SW5 Communication format

OFF P.L.C Communication format based on ADP3 software communications setting

SW6 Enter password or not

OFF No request enter password( man-machine working password level setting to 1)

SW7 Can download screen details or not directly ON-LINE connection)

ON When power up. Displaying system contents

SW8 When power up,password level 1or 3( Effect on DIP SW6=OFF)

ON When power up,no request enter password, password level setting to 3

SW9 The back of man machine COM2 specification setting

OFF COM2setting to 20mA Current Loop connection( Only apply PWS-3000)

ON COM2setting toRS232/RS422/RS485 connection

SW10 The back of man machine COM2 specification setting

OFF Only apply to MITSUBISHIA series CPU PORT=RS422+RTS control

ON Most of P.L.C.labels =RS485 or RS422+RTS not control

Screen Download Preparatory Step

Display TYPE.Color TFT Display

Working RAM Test...Passed

Figure A-1 PWS-3200 Power On Self -t

Time (hh: mm: ss) =11:11:11

P. L. C. Communications =com2 P LC; PLC=com1;

Baud rate =19200 192009600

Parity ; Data ; Stop Bit

=odd ;86its;1bit CTS enable; disable

Screen Saver Time(min) =10 01-60 00

Workstation node address =001 PWS

Download/upload/copy port =com1 PWS- port

LCD Backlight Adjustment Mode:

Contrast]key again [UP]=brightness increase;[DOWN]=brightness reduce;after adjust press