Shini STM-PW Series Manual
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Shini STM-PW Series Manual

Hi-temp. water heater
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STM-PW
Series
Hi-Temp. Water Heater
Date: Dec. 2014
Version: Ver.B (English)

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  • Page 1 STM-PW Series Hi-Temp. Water Heater Date: Dec. 2014 Version: Ver.B (English)

  • Page 3: Table Of Contents

    Contents General Description .................. 7 1.1 Coding Principle ................... 8 1.2 Feature....................8 1.3 Technical Specifications..............10 1.3.1 Specification ................10 1.3.2 Pump Performance..............11 1.3.3 Reference Formula of Mould Controllers Model Selection..11 1.4 Safety Regulations ................12 1.4.1 Safety Signs and Labels ............12 1.4.2 Signs and Labels ..............
  • Page 4 2.4 Main Electrical Components Description..........35 2.4.1 Overload Relay................ 35 2.5 Operation Procedures ................ 36 2.5.1 Installation steps for options water manifold (dewaxing)..36 2.5.2 Installation steps for options water manifold (welding)..... 36 Installation and Debugging..............38 3.1 Installation Space................38 3.2 Mould and Water Coupling..............
  • Page 5 Table Index Table 1-1：Specification................... 10 Table 2-1：Parts List (STM-607-PW) ............... 20 Table 2-1：Parts List (STM-1220-PW) ............. 22 Table 2-3：Electrical Components List (STM-607-PW) (400V)......27 Table 2-5：Electrical Components List (STM-1220-PW) (400V)...... 28 Table 2-6：Electrical Components List (STM-607-PW) (230V)......33 Table 2-8：Electrical Components List (STM-1220-PW) (230V)...... 34 Picture Index Picture 1-1：Pump Performance ..............
  • Page 6 Picture 4-7: Output Setting ................47 Picture 4-8: Temperature Setting..............48 Picture 4-9: Time Setting .................. 49 Picture 4-10: Communication Setting ............... 50 Picture 4-11: Equipment Setting ............... 51 Picture 4-12: Operation Screen ................ 52 Picture 6-1：Open the Covers 1............... 57 Picture 6-2：Open the Covers 2...............

  • Page 7: General Description

    1. General Description Read this manual carefully before operation to prevent damage of the machine or personal injuries. STM- PW/HPW series high temperature water heater are used to heat up the mould and maintain temperature, although they can be used in other similar applications.

  • Page 8: Coding Principle

    1.1 Coding Principle Notes* D=Dual-heating Zones PW=Medium is Water with High Temp. HPW=Medium is Water with High Temperature and High Pressure CE=CE Conformity B=Buzzer 1.2 Feature 1) Standard configuration ● Controller adopts 3.2" LCD for easy operation. ● Equipped with the design of 7-day automatic start/stop timer. LCD screen can be converted between Chinese and English.
  • Page 9 Chapter 6, which contains service instructions intended for service engineers. Other chapters contain instructions for the daily operator. Any modifications of the machine must be approved by SHINI in order to avoid personal injury and damage to machine. We shall not be liable for any damage caused by unauthorized change of the machine.

  • Page 10: Technical Specifications

    1.3 Technical Specifications 1.3.1 Specification Table 1-1：Specification Max. pump Tank(L) Max. pump Heating Mould Inlet / Dimensions Max. Heater Pump (kw) pressure Coonling Weight flow (L/min) chamber coupling* Outlet (mm) Model temp. (kw) (50/60Hz) (bar) method (kg) Heat Cooli (50/60Hz) number (inch) (inch)

  • Page 11: Pump Performance

    1.3.2 Pump Performance Picture 1-1：Pump Performance 1.3.3 Reference Formula of Mould Controllers Model Selection Heater Power (kW) = mould weight (kg) × mould specific heat (kcal/kg ) × ℃ temperature difference between mould and environment ( ) × safety coefficient ℃...

  • Page 12: Safety Regulations

    1.4 Safety Regulations Strictly abide by the following safety regulations to prevent damage of the machine or personal injuries. 1.4.1 Safety Signs and Labels Danger! The unit is designed to endure high temp, and high pressure. For safe operation, do not remove the covers or switches. Attention! The unit should be operated by qualified personnel only.

  • Page 13: Signs And Labels

    1.4.2 Signs and Labels Regularly clean the filter screen in the copper screw to avoid blockage and as well ensure an excellent working performance. This is to indicate motor rotating direction. When phase reversal happens, the alarm sounds and indicator on control panel will indicate.

  • Page 14: Operation Regulations

    1. To maintain temperature consistency, cooling water pressure must be higher than 2 bar at all time, but should never exceed 5 bar in any case. 2. Clean Y-shape Cooling Water Strainer periodically to ensure perfect cooling capacity. Water inlet: inlet for replenishing water and cooling water.

  • Page 15: Transportation And Storage Of The Machine

    1.4.4 Transportation and Storage of the Machine Transportation 1) STM-PW series standard oil heater are packed in crates or plywood cases with wooden pallet at the bottom, suitable for quick positioning by fork lift. 2) After unpacked, castors equipped on the machine can be used for ease of movement.
  • Page 16 water to avoid potential troubles caused by the water. 4) Plastic film should be used to protect the machine from dust and rains. Working environment The machine should be operated: 1) Indoors in a dry environment with maximum temperature +45℃ and humidity not more than 80%.

  • Page 17: Exemption Clause

    Shini (including employees and agents). Shini is exempted from liability for any costs, fees, claims and losses caused by reasons below: 1. Any careless or man-made installations, operation and maintenances upon machines without referring to the Manual prior to machine using.

  • Page 18: Structure Characteristics And Working Principle

    Structure Characteristics and Working Principle 2.1 Working Principle Picture 2-1：STM-PW Working Principle The high temperature water from the mold returns to the pump inlet from the pipeline, then be pressurized by the pump and conveyed to the heater and again be heated and returns to the mold. The loop repeats. In this process, when liquid level switch detects the liquid level lowers to the set value and the machine will sound an alarm and halt.

  • Page 19: Assembly Drawing

    2.2 Assembly Drawing 2.2.1 Assembly Drawing (STM-607-PW) Remarks: Please refer to material list 2.2.2 for specific explanation of the Arabic numbers in parts drawing. Picture 2-2：Assembly Drawing (STM-607-PW) 19(65)

  • Page 20: Parts List (Stm-607-Pw)

    2.2.2 Parts List (STM-607-PW) Table 2-1：Parts List (STM-607-PW) Name Part No. Name Part No. YW64080600000 Control box Pump MP-55 Door plate EGO assembly BH90115000050 Door plate aluminum YW20660900100 Lentil-headed screw M5×10 YW62051000100 handle 6609 Base plate of control Line clamp fixing plate Thick head screw YW63062000000 Big hinge CL219-1...

  • Page 21: Assembly Drawing (Stm-1220-Pw)

    2.2.3 Assembly Drawing (STM-1220-PW) Remarks: Please refer to material list 2.2.4 for specific explanation of the Arabic numbers in parts drawing. Picture 2-3：Assembly Drawing (STM-1220-PW) 21(65)

  • Page 22: Parts List (Stm-1220-Pw)

    2.2.4 Parts List (STM-1220-PW) Table 2-2：Parts List (STM-1220-PW) Name Part No. Name Part No. Inner hexagon screw M10×25 YW61102500000 Control box Door plate Flange gasket Door plate aluminum YW20660900100 Lentil-headed screw M5×10 YW62051000100 handle 6609 Base plate of control Line clamp fixing plate Thick head screw YW63062000000 Big hinge CL219-1...

  • Page 23: Pump

    2.2.5 Pump Names of Parts: 1. Pump cover 2. Shaft sleeve 3. Inner magnetic coupler 4. Out magnetic coupler 5. Pump body 6. Paddle wheel 7. Carbonated silcon bearing 8. Ceramic stick 9. Lockup parts 10. Motor 11. Magnetic cover Picture 2-4：Pump 23(65)

  • Page 24: Electrical Diagram

    2.3 Electrical Diagram 2.3.1 Main Circuit (STM-PW)(400V) Picture 2-5：Main Circuit (STM-PW) (400V) 24(65)

  • Page 25: Control Circuit (Stm-Pw) (400V)

    2.3.2 Control Circuit (STM-PW) (400V) Picture 2-6：Control Circuit (STM-PW) (400V) 25(65)

  • Page 26: Electrical Components Layout (Stm-Pw) (400V)

    2.3.3 Electrical Components Layout (STM-PW) (400V) Picture 2-7：Thermocouple and Terminal Layout (STM-PW) (400V) 26(65)

  • Page 27: Electrical Components List (Stm-Pw) (400V)

    2.3.4 Electrical Components List (STM-PW) (400V) Table 2-3：Electrical Components List (STM-607-PW) (400V) Symbol Name Specification Part NO. Main switch YE10021160000 Circuit breakers* YE40601500000 Excitation break away YE40023560000 Contactors* 220V 50/60Hz YE00601521000 Contactors* 220V 50/60Hz YE00601800000 Timer 220V 50/60Hz YE86300600000 Overload relays* 1.8~2.5A YE01160180000 Fuse box*...
  • Page 28 Table 2-4：Electrical Components List (STM-1220-PW) (400V) Symbol Name Specification Part NO. Main switch YE10132320000 Circuit breakers* YE40603200000 Excitation break away YE40023560000 Contactors* 220V 50/60Hz YE00601521000 Contactors* 220V 50/60Hz YE00602622000 Timer 220V 50/60Hz YE86300600000 Overload relays* 4.5~6.3A YE01160450000 Fuse box* 32A 2P YE41032200000 Fuse** YE46002000100...

  • Page 29: Main Circuit (Stm-Pw)(230V)

    2.3.5 Main Circuit (STM-PW)(230V) Picture 2-8：Main Circuit (STM-PW) (230V) 29(65)

  • Page 30: Control Circuit (Stm-Pw) (230V)

    2.3.6 Control Circuit (STM-PW) (230V) Picture 2-9：Control Circuit (STM-PW) (230V) 30(65)

  • Page 31: Electrical Components Layout (Stm-Pw) (230V)

    2.3.7 Electrical Components Layout (STM-PW) (230V) Picture 2-10：Electrical Components Layout (STM-PW) (230V) 31(65)

  • Page 32: Thermocouple And Terminal Layout (Stm-Pw) (230V)

    2.3.8 Thermocouple and Terminal Layout (STM-PW) (230V) Picture 2-11：Thermocouple and Terminal Layout (STM-PW) (230V) 32(65)

  • Page 33: Electrical Components List (Stm-Pw) (230V)

    2.3.9 Electrical Components List (STM-PW) (230V) Table 2-5：Electrical Components List (STM-607-PW) (230V) Symbol Name Specification Part NO. Main switch YE10125250000 Circuit breakers* YE40602500000 Excitation break away YE40023560000 Contactors* 220V 50/60Hz YE00601521000 Contactors* 220V 50/60Hz YE00602522000 Timer 220V 50/60Hz YE86300600000 Overload relays* 2.8~4A YE01160280000 Fuse box*...
  • Page 34 Table 2-6：Electrical Components List (STM-1220-PW) (230V) Symbol Name Specification Part NO. Main switch YE10636300000 Circuit breakers* YE40606000000 Excitation break away YE40023560000 Contactors* 220V 50/60Hz YE00601621000 Contactors* 220V 50/60Hz YE00503500000 Timer 220V 50/60Hz YE86300600000 Overload relays* 7~10A YE01167100000 Fuse box* 32A 2P YE41032200000 Fuse** YE46002000100...

  • Page 35: Main Electrical Components Description

    2.4 Main Electrical Components Description 2.4.1 Overload Relay At delivery, the overload relay is set for mannual reset. (the reset button pointing to H). Manually reset the relay at the tripping of the switch. When motor overload occurs, stop the machine, then check and solve the problem. After that open the door of control box, press down the reset button of overload relay (if you can not press down the reset button, wait for one minute).

  • Page 36: Operation Procedures

    2.5 Operation Procedures 2.5.1 Installation steps for options water manifold (dewaxing) 1) Install copper joint to the level valve. 2) Install level valve with copper joint to the dewaxing water manifold. 3) Install water manifold to the machine. 4) Install Teflon to copper joint. Note! For the operating temperature not higher than 200℃, Teflon with temperature resistance 200℃...
  • Page 37 1) Install copper joint to the level valve. 2) Install level valve with copper joint to the welding water manifold. 3) Install water manifold to the machine. 4) Connect water manifold with manifold joint via screws. 5) Install Teflon to copper joint. Note! For the operating temperature not higher than 200℃, Teflon with temperature resistance 200℃...

  • Page 38: Installation And Debugging

    Installation and Debugging 3.1 Installation Space During installation of the machine, keep at least 500mm installation space around the machine as shown by the picture. Do not install the machine in a position crowded with other objects. This would cause inconvenience to operation, maintenance and repair.

  • Page 39: Power Supply

    2) Unused mould couplings can be connected with each other by a teflon pipe, as shown in. Picture 3-3：Mould and Water Couplings 2 Note! Cooling water inlet and outlet as shown by the Figure. Please do not connect reversely. Please connect the coolng water outlet with high temperature resistant pipe when temperature is above 100℃.

  • Page 40: Operation Guide

    Operation Guide Control Panel Picture 4-1：Control Panel Table 4-1：Control Panel Name Functions Remarks Display showing LCD After connect power, press “POWER ON/OFF”, initial screen is displayed and starts. ON/OFF POWER Power ON, OFF shift key Pls note that even if regulator is idle, electrci shock may happen if power is on.
  • Page 41 SUCTION is to remove medium (watre/oil) from molds. Can not start during SUCTION SUCTION switch start and stop operation or cooling. After SUCTION turns on, “SUCTION relay” and “pump inverse run relay” will turn on. Press it for 2 secs for forcedcooling, then stop heating output while output 100% cooling control.
  • Page 42 Phase error Phase disconnect or phase reverse Activated Stop Over temp. ego Contact input for ego temp. check Activated Stop Contact input for pumper overload Over pump Activated Stop check Contact input for low pressure Low press Activated Stop check Contact input for high pressure High press Activated...

  • Page 43: Menu Introduction

    Menu Introduction Pictute 4-2：Menu Outline 4.3 Machine Startup 1) Conenct pipeline from STM water in/outlet to the mold. (refer to chapter 3.2 for pipeline connection) 2) Connect chilled water port and water backup port. (refer to chapter 3.2 for pipeline connection) 43(65)

  • Page 44: Picture 4-3: Main Power Switch

    3) Open all the globa valves. 4) Switch on main power. Picture 4-3: Main Power Switch 5) Press ON/OFF POWER key to enter menu screen. Picture 4-4: Initial Menu 6) Press MENU key to enter menu selection, press ◄/► keys to select control setting, press SET key to enter setting nemu, see picture below.

  • Page 45: Picture 4-5: Control Setting

    Picture 4-5: Control Setting 7) Press MENU key to retuen to menu screen, press ◄/► key to select alarm setting then press SET to enter setting menu, see picture below. Here is parameter setting: • PHASE——used • Water out temp. deviation——0 (not opt for temp. sensor) 5 (opt for temp.

  • Page 46: Picture 4-6: Alarm Setting

    10 (opt for temp. sensor, increase it suitably if frequent alarms) • Interfere alarm——control temp.-10 • Heater alarm——depending on auctual setpoint, default setting is 0 upon delivery to make it out of service. Picture 4-6: Alarm Setting 8) Press MENU key to return to menu screen, then press ◄/► key to select output setting and press SET key to enter setting screen, see picture below.

  • Page 47: Picture 4-7: Output Setting

    • OUTPUT MODE——heating or cooling control • SUB HEATING——0 (only 1 group of heater) • 5 (two or more groups of heater) • COOLING TEMP.——35 Picture 4-7: Output Setting 9) Press MENU key to return to menu screen, then press◄/► keys to select temp.setting, press SET key to enter setting screen, see picture below.

  • Page 48: Picture 4-8: Temperature Setting

    Picture 4-8: Temperature Setting 10) Press MENU key to return to menu screen, press ◄/► key to select time setting, press SET key to enter setting screen, see picture below. Time has been set before delivery; customers can set appointment time based on actual needs.

  • Page 49: Picture 4-9: Time Setting

    Picture 4-9: Time Setting 11) Press MENU key to return to menu screen, press ◄/► key to select communication setting, press SET key to enter setting screen, see picture below. If communication function is selected as an option, customers should set communication parameters based on actual needs.

  • Page 50: Picture 4-10: Communication Setting

    Picture 4-10: Communication Setting 12) Press MENU key to return to menu screen, press ◄/► key to select device setting, press SET key to enter setting screen, see picture below. Before delivery, parameters have been set and customers can modify them based on actual needs.

  • Page 51: Picture 4-11: Equipment Setting

    Picture 4-11: Equipment Setting 13) Setting mold temperature (if temp. has been set, this step can be omitted). Press SV key and control value column would be flashing, press ◄/► key to move cursor then press ▲/▼ key to change values. Finally press SET key to confirm them.

  • Page 52: Parameter Reference Table

    control, Auto-tuning is needed if deviation of control is a little bit large. Press AT key and LED light begins flashing to enter Auto-tuning. When flashing is ended, Auto-tuning finished and parameters will auto saved. During Auto-tuning, press AT key will exit Auto-tuning process, controller will conduct temperature control based on parameters beforeAuto-tuning.

  • Page 53: Stop The Machine

    English Name Description Range Default Alarm for not reaching to the Heater alarm 0~3600s(0=off) 0=off setting temp. Heating Select between heating and Output mode Heating/cooling heating/cooling control Heating/cooling 0~550℃ Set “off temperature” in sub Sub heating 0=off heating output (0=off) Cooling temp Set compulsory cooling -50~500℃...
  • Page 54 3) Switch mian power to OFF position. Warning! When main switch is turned on, be careful of electrical shock. Note! Pump motor rotating direction should be the same as indicated. Note! In order to prolong machine lifespan, please do as above steps to turn on and off the machine.

  • Page 55: Trouble-Shooting

    Trouble-shooting Failures Possible reasons Solutions Did not connect through power Connect through power supply. LCD displays nothing supply. Replace main switch. after switch on power Main switch broken. Check electrical wires. and press ON/OFF Power supply wires problems. Fix the fuse. key.
  • Page 56 Failures Possible reasons Solutions Short circuit of main circuit. Circuit breaker tripping Transformer short circuit or Check electrical wire. off at turning on main connected with earth wire. Replace circuit breaker. switch. Problems of circuit breaker. Circuit breaker tripping Pump motor coil short circuit. Check pump motor.

  • Page 57: Maintenance And Repair

    Maintenance and Repair Pay attention to the following rules during maintenance: 1) Please reduce the temperature to room temperature (below50℃), cut off power supply and drain oil and water first while inspecting the machine; carry out operations with safety gloves on after complete confirmation of spaces for inspection and maintenance.

  • Page 58: Y Type Strainer

    2) Take down the side covers. (Refer to the pictures below) Picture 6-2：Open the Covers 2 3) Open the cover of control box. Screw off two butterfly screws to unlock the cover. (Refer to the pictures below) Picture 6-3：Open the Covers 3 6.2 Y Type Strainer 1) Clean soft water should be used as cooling water.

  • Page 59: Solenoid Valve

    6.3 Solenoid Valve Replace solenoid valve: 1) Open machine top cover. 2) Take down right side cover. 3) Unfix the solenoid valve for replacement. 4) Install the covers in a reverse order. Picture 6-5：Solenoid Valve 6.4 Pipe Heater 1) Open machine rear cover door. (Refer to pictures below) Picture 6-6：Pipe Heater 1 2) Unlock heater cap.

  • Page 60: Printed Circuit Board

    Picture 6-8：Pipe Heater 3 4) Install the pipe heater in a reverse order. Printed Circuit Board MAIN terminal board drawing (refer to next page for terminal position and number). ① SENSOR TERMINAL1 (sensor terminal) 2, 3 : control temp. sensor termnal 5, 6 : retuen water temp.
  • Page 61 9, 10 : alarm contactor output terminal 11, 12 : relay contactor output terminal 13, 14 : reserve ⑤ PHASE CHECK TERMINAL (phase detect terminal) 1 : R phase connect terminal 2 : S phase connect terminal 3 : T phase connect terminal ⑥...
  • Page 62 62(65)

  • Page 63: Displayer Terminal Connecting Diagram

    6.6 Displayer Terminal Connecting Diagram ① DI TERMINAL 1, 2: Run/stop di terminal ② COMM TERMINAL 1, 2, 3, 4: rs485 Comm terminal 5：Earth terminal ③ MAIN CN Connet to the electric cables which also connected with stm100 ④ TEST PIN Test pin No connection 63(65)

  • Page 64: Maintenance Schedule

    6.7 Maintenance Schedule 6.7.1 About the Machine Model Manufacture date Ф Voltage Frequency Power 6.7.2 Installation & Inspection Check the installation space is enough as required. Check the pipes are correctly connected. Electrical installation Voltage: Fuse melting current: 1 Phase 3 Phase Check phase sequence of power supply.

  • Page 65: Yearly Checking

    Replace the hot kerosene with a using temperature above 120~160 degree 6.7.7 Yearly Checking Replace the hot kerosene with a using temperature above 120 degree 6.7.8 3 year Checking PC board renewal. No fuse breaker renewal. Note: 1. Y-type filter has the function of filling water cooling protection effect, be sure the waterway are clear to avoid cooling failure.

This manual is also suitable for:

Stm-hpw seriesStm-607-pwStm-1220-pw

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