TM3000P-3 Scan PIN Automatic Padding Three-worktray Vacuum Membrane Press / Balloon Press Machine

TM3000P-3 Automatic Padding Three-Pallet Vacuum Membrane Press / Balloon Press Machine

1. Operating Precautions

1. Before operating this machine, read the user manual carefully to understand its performance and correct operating methods.
2. Ensure a reliable grounding device is connected before connecting the machine to the power supply.
3. The machine's power cord must be connected to a power source with a protective switch. Check if the voltage and frequency of the power supply are suitable.
4. Before operating the machine, confirm the rotation direction of the vacuum pump, hydraulic pump motor, and travel motor. If not correct, adjust the power supply phase connections.
5. Before operation, check if all safety protection devices are functioning properly and if any components are loose or damaged. Adjust or replace them promptly to ensure normal function. Remember to remove any tools used for adjustment.
6. Wear tight-fitting clothing when operating the machine. Avoid loose clothing, ties, watches, bracelets, and ensure long hair is covered with a work cap.
7. Do not remove or open any safety protection devices while the machine is in operation.
8. The operator must not leave the workstation while the machine is running.
9. Do not process workpieces or accessories beyond the original design capabilities of the machine.
10. Do not operate the machine if you are in poor health or under the influence of alcohol.
11. Disconnect the main power supply before inspecting, maintaining, or cleaning the machine.
12. After completing machine operation, disconnect the main power supply and wait for the machine to stop completely before leaving.
13. To prevent accidental machine movements, never allow any part of the body to enter the pressing area of the machine when loading or unloading workpieces.
14. The machine requires a pressure of ≥0.6 MPa. It will not function properly below 0.6 MPa.
    Note: Read this manual thoroughly before operating the equipment.

2. Machine Structure and Composition

2.1 Machine Composition

• Mechanical components (main machine frame, lifting platform, material handling and flipping mechanism, worktable, etc.)
• Electrical heating and control system
• Hydraulic control system
• Vacuum piping system
• Compressed air system

2.2 Main Characteristics

• The main frame and hydraulic control principle are designed based on German European technology, ensuring compact structure, high reliability, and smooth operation.
• The machine features automatic operation for material entry and exit to improve efficiency. The balancing device is compact and operates smoothly and reliably.
• The electrical control system uses a programmable logic controller (PLC) with both manual and automatic functions. Heating time, temperature, vacuum time, and pressurizing time can be adjusted over a wide range to accommodate different material thicknesses and workpiece specifications.
• The hydraulic system is designed based on advanced foreign technology, ensuring high reliability, smooth operation, and low failure rates. The worktable lifts quickly with short pressurizing times.

3. Machine Performance and Main Parameters

3.1 Main Design Parameters

• Workpiece processing range: 1320 mm × 3000 mm (worktable inner dimensions)
• Workpiece height: 50 mm
• Machine dimensions: 18500 mm (length) × 6100 mm (width) × 27500 mm (height)
• Heating power: 18 kW (actual power consumption 12-15 kW/h)
• Total power: 90 kW (varies depending on configuration)
• Machine weight: Approximately 28 tons

3.3 Process Adjustment Parameters

• The worktable descent delay time is the time for the hydraulic station to release hydraulic pressure, typically set to 5-8 seconds (no adjustment needed).
• Depressurization time is the time for the machine to open the exhaust valve and release compressed air from the heating chamber. Adjust according to the machine's specific conditions.
• For ordinary single-color PVC and wood door PVC:
• Heating temperature: 110-150°C (maximum operating temperature 200°C)
• Heating time: 25-100 seconds
• Vacuum time: 5-15 seconds
• Positive pressure time: 20-120 seconds
• Other time settings: 0 seconds
• Work modes: Standard mode, Optimization mode, Special mode. Adjust the work mode according to the product requirements. The above times are for reference only. Please set according to the training requirements of the technicians and specific conditions.

4. Transportation, Lifting, and Installation Precautions

4.1 Transportation

• The main machine weighs approximately 20 tons with dimensions of 3700 mm (length) × 2100 mm (width) × 2700 mm (height). The main machine is packaged separately for transportation. The worktable, flipping platform, and lifting platform are disassembled and packaged separately.

4.2 Lifting

• Before on-site installation, it is recommended to use a crane with a capacity of over 30 tons for lifting. The lifting hooks should be attached to the lifting holes on the upper part of the machine. Ensure the steel wire rope is securely fastened with wire rope clips. The lifting angle of the steel wire rope must not exceed 45 degrees.

4.3 Installation

• After positioning the machine at the designated location, ensure the installation foundation is level and that sufficient space is reserved around the machine for operation and safety.

4.4 Installation and Commissioning Requirements

1. The installation ground must be solid and flat with sufficient operating space. Use a level to adjust the machine to a horizontal position.
2. The machine requires a 380V three-phase four-wire power supply. The main distribution cabinet must have a good grounding connection. Do not use water pipes or heating pipes as grounding wires.
3. Use a 25 mm² copper core cable for the power supply.
4. Turn on the main power switch and emergency stop switch. Check if the phase sequence protector indicator is correct. If the indicator flashes and then goes off, adjust the cable phase sequence.
5. Turn on the air compressor or external air source to fill the positive pressure air tank until it reaches the required working pressure. The air source must pass through a water filter to remove moisture. If installing a separate air pump, the air pump's capacity must not be less than 2 cubic meters per hour; a larger capacity is recommended.
6. After powering on the equipment, turn on the heater and set the heating temperature according to the process requirements. Check the current meter's indication after turning on the heater.
7. Turn on the air preheater and set the temperature for the air preheater.
8. Sufficient space must be reserved around the machine, and the operating area must be kept clean to prevent accidents.

1. Check if the power phase sequence is correct.
2. Ensure adequate air pressure.
3. Confirm that the worktable temperature meets the requirements.
4. Check if the hydraulic system is functioning properly.

5. Safety Operating Procedures

1. Conduct a pre-shift routine inspection before operating the machine. Only start operating after confirming there are no issues. An operator must be present to monitor the machine during operation. If any problems are detected, address them immediately.
2. Do not stack debris around the machine to ensure safe operation and facilitate evacuation in case of an emergency. All protective panels must be installed on the machine during normal use. Do not operate the machine without the protective panels.
3. When operating with a silicone rubber plate, preheat it first. Do not start the program without heating to avoid damaging the silicone rubber plate.
4. If an abnormality occurs during machine operation, immediately press the emergency stop switch to halt the work program and check for faults.
5. In case of sudden power outages or other emergencies, disconnect the power and air sources before leaving. Do not leave without addressing the issue.
6. If a fault occurs during hydraulic pressurization or air inflation, immediately cut off the power supply. Switch to manual mode, press the depressurization button, and press the worktable descent button. If the fault cannot be resolved, notify a professional maintenance person immediately.
7. Do not operate this equipment alone, especially during night shifts.
8. Operators must undergo necessary professional training and be familiar with the equipment before operating it.
9. Always exit the machine before checking the workpiece. Do not reach or extend your head into the space between the upper and lower chambers without exiting. This prevents accidental machine activation and personal injury.
10. The heating chamber operates at approximately 120°C during work. Avoid direct skin contact to prevent burns.
11. If maintenance is required during operation, especially for the balancing section, hydraulic piping, or hydraulic cylinders, ensure the worktable is raised to the top and closed. Confirm no hydraulic leakage, disconnect the power supply, have someone supervise, and place reliable support (such as wooden blocks or jacks) between the worktable pallet and hydraulic cylinder support plate before proceeding. Do not perform this task alone.
12. After the shift, clean the site, check for any issues, and disconnect the power and air sources.

6. Machine Maintenance and Care

6.1 Routine Maintenance

• Check the following items:
• Ensure the worktable moves in and out smoothly without obstruction or abnormal noise.
• Inspect the vacuum sealing strips on the worktable and lower pallet for damage and ensure no foreign objects or abnormalities on the sealing surface.
• Confirm reliable and good electrical grounding.
• Check the position of all limit switches.
• Inspect pipes for looseness and ensure all joints are well-sealed without leakage.
• Verify correct pressure gauge readings.
• Check for hydraulic oil leaks.
• Perform an empty run to ensure buttons, indicator lights, and programs function correctly. The worktable should rise smoothly, and all solenoid valves and electrical components should operate normally and sensitively.

6.2 Secondary Maintenance

• Conducted monthly by professional maintenance personnel with the operator's assistance. In addition to routine maintenance, perform the following checks and maintenance:
• Inspect the hydraulic oil tank for air bubbles, turbidity, or emulsification. Clean the oil tank and pipes and replace the hydraulic oil if necessary.
• Check the quality of the vacuum sealing strips on the worktable and lower pallet and inspect the sealing reliability. Replace the sealing strips as needed.
• Inspect all component connections for looseness.
• Check the reliability of hydraulic connections and ensure they are well-fixed.
• Ensure the balancing device's fastening screws are reliable. Clean and maintain bearings as necessary, adding grease or replacing them.
• Open the heating chamber to inspect and measure the insulation of each heating element. Check the electrical connections of the heating elements to avoid short circuits, open circuits, grounding, looseness, or damaged insulation wires. Clean the filters and mufflers. Drain and clean the air storage tank.
• After one month of use, replace the vacuum pump oil. Preheat the vacuum pump, drain the old oil, close the oil drain port, and add new vacuum pump oil through the oil filler port. Replace the vacuum pump oil every three months thereafter. If the vacuum pump oil appears white and turbid at room temperature, replace it immediately. Clean the vacuum filter monthly.

6.3 Primary Maintenance

• Conducted annually. In addition to all secondary maintenance tasks, perform the following:
• Thoroughly clean the hydraulic oil tank and pipes and replace the hydraulic oil. Repair or replace hydraulic components as necessary.
• Inspect and replace seals on hydraulic cylinders and components.
• Check and replace joint bearings and pins.
• Replace heating elements, wiring, connectors, and insulating materials.
• Clean all air and vacuum pipes, filters, and mufflers or replace them as needed. Drain and clean the air storage tank. Conduct a pressure test to ensure no significant leaks at 15 kg/cm² over 24 hours. Clean and maintain the vacuum pump. Repaint the exterior of the machine.

6.4 Machine Lubrication

7. Common Faults and Troubleshooting Methods

7.1 Electrical Control Panel Malfunction

1. Poor power contact: Check and reinforce the corresponding power cables and connectors.
2. Leakage switch activation: Identify and eliminate the fault point.

7.2 Incomplete Lamination or Adhesive Not Drying

1. Increase lamination time.
2. Insufficient vacuum pressure: Check for leaks in the vacuum pump and piping.
3. Inspect the air intake filter and clean or replace it.
4. Increase the air pressure in the working chamber.
5. Increase the positive pressure timing and adjust the negative pressure timing accordingly.

7.3 Work Chamber Air Leakage

1. Excessive air pressure in the work chamber: Adjust accordingly.
2. Foreign objects on the sealing surface: Remove the foreign objects.
3. Insufficient hydraulic station pressure: Check the hydraulic oil, pump, and oil circuit.
4. Damaged sealing rings: Replace the sealing rings.
5. Silicone rubber plate damage: Check and adjust the position or replace the plate.

7.4 Worktable Does Not Descend After Lowering, and Hydraulic Pump Continues to Run

1. Adjust or replace the lower travel switch.
2. If the worktable does not descend after the timer resets, check if the positive and negative pressure gauges on the worktable return to zero. If not, inspect the unloading valve and replace it if damaged.

8. TM3000F-P Automatic Padding Three-Pallet Laminating Machine Maintenance Manual

1. After work each day, turn off the main power switch of the equipment. Do not use the emergency stop switch as the main power switch.
2. Check the hydraulic oil quality every three months and the oil level monthly. Open the oil tank filler port to inspect the oil quality. If the hydraulic oil appears white, emulsified, or contains too many impurities, replace it immediately.
3. Check for any new oil stains from the vacuum pump or hydraulic system at the bottom of the machine each day to identify any leaks promptly. Address any issues immediately.
4. Inspect the hydraulic system pipes weekly for any issues and check if the connections are loose.
5. Check the air storage tank for water weekly. Regularly inspect the water filter cup in the positive air line for moisture or impurities and clean it promptly if any are found. If impurities or moisture accumulate frequently, check the air pump for water ingress.
6. Inspect the electrical control cabinet weekly for dust. Clean the cabinet if dust is present to prevent electrical component failures. Use a vacuum cleaner to collect the dust.
7. The electrical heating control system must be kept at a low temperature. High temperatures can severely damage components. There are no user-serviceable parts inside the heating control system, so do not open it.
   Warning: Accumulation of wood chips or dust in the control cabinet can cause a fire hazard!

9. List of Wearable Parts for TM3000F-P

1. The worktable sealing system includes silicone rubber strips with diameters of 8 mm and 10 mm. All sealing strips are made of silicone rubber.
2. Silicone rubber plates. Inspect the integrity of the silicone rubber plate immediately upon receipt. Report any issues promptly. If no problems are found, fill out the silicone rubber plate交接表交接表. Note that silicone rubber plates are not covered under warranty.
3. Hydraulic system seals, charging valve seals, and cylinder piston seals. Since all seals are made of rubber, they are not covered under warranty.
4. Vacuum pump exhaust filter elements (replace if smoke or oil is sprayed from the exhaust port). Vacuum pump oil seals are not covered under warranty. Inlet filters.
5. Vacuum pump oil should be replaced for the first time after 500 hours of operation and then every 500-2000 hours.
6. Replace hydraulic oil if it becomes deteriorated, emulsified, or contaminated.

Appendix I: List of Tools Included