Shini STM-W Series Manual
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Shini STM-W Series Manual

Shini STM-W Series Manual

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STM-W
Series
Water Heater
Date: Aug. 2017
Version: Ver.E (English)

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Summary of Contents for Shini STM-W Series

  • Page 1 STM-W Series Water Heater Date: Aug. 2017 Version: Ver.E (English)

  • Page 3: Table Of Contents

    Contents General Description ..................7 1.1 Coding Principle ..................8 1.2 Feature....................8 1.3 Options....................8 1.4 Technical Specifications................ 10 1.4.1 Specification ................10 1.4.2 Pump Performance..............10 1.4.3 Reference Formula of Mould Controllers Model Selection..11 1.5 Safety Regulations ................12 1.5.1 Safety Signs and Labels .............
  • Page 4 Trouble-shooting ..................38 Maintenance and Repair ................40 6.1 Open the Covers ................... 41 6.2 Y Type Strainer ..................42 6.3 Solenoid Valve ..................42 6.4 Pipe Heater ................... 43 6.5 By-pass Globe Valve................43 6.6 Printed Circuit Board ................44 6.7 Displayer Terminal Connecting Diagram..........
  • Page 5 Picture 4-4: Initial Menu ..................27 Picture 4-5: Control Setting Screen ..............28 Picture 4-6: Alarm Setting Screen..............29 Picture 4-7: Output Setting Screen ..............30 Picture 4-8: Temperature Setting Screen ............32 Picture 6-1: Open the Covers 1 ................ 41 Picture 6-2: Open the Covers 2 ................
  • Page 6 6(48)

  • Page 7: General Description

    Read this manual carefully before operation to prevent damage of the machine or personal injuries. STM-W series water heater are used to heat up the mould and maintain temperature, although they can be used in other similar applications. High temperature water from the mould is returned to the cooling tank and cooled by either indirect cooling (For high temperature models) or direct cooling (for standard models).

  • Page 8: Coding Principle

    1.1 Coding Principle 1.2 Feature ● 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. The unit of temperature can be converted between ℉and ℃...
  • 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

    1.4 Technical Specifications 1.4.1 Specification Table 1-1: Specification Max. pump Heating Pipe Pump Max. pump Heating Mould Model Max. Cooling Dimensions Weight Pressure tank Ver. heater power (kW) flow (L/min) tank coupling* Temp. (bar) capacity method (mm) (H×W×D) (kg) STM- (kW) (50/60Hz) (50/60Hz)

  • Page 11: Reference Formula Of Mould Controllers Model Selection

    1.4.3 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 ℃ / heating duration / 860 Note: safety coefficient can select a value from 1.3 to 1.5.

  • Page 12: Safety Regulations

    1.5 Safety Regulations Strictly abide by the following safety regulations to prevent damage of the machine or personal injuries. 1.5.1 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

    1.5.2 Signs and Labels Please according to schedule to make regular maintenance. From mould: connector for circulating water/oil coming from mould. To mold: connector for circulating water/ oil to go to mould. Oil outlet valve: oil discharge outlet for renewing oil. High liquid level: the highest oil level to which machine can reach under room temperature.
  • Page 14 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. Oil inlet: oil filler for machine. Overflow Water outlet: drainage outlet.

  • Page 15: Operation Regulations

    Warning! Be careful! Be more careful when this mark appears. 1.5.3 Operation Regulations 1) Before operation, make sure that cooling water is clean soft water without pollutants. ※ Low quality water brings limescales, which may cause problems. 2) If problems of drainage or bad temperature control are noted, please clean solenoid valve and cooling water inlet and outlet.

  • Page 16: 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 17: Structure Characteristics And Working Principle

    Structure Characteristics and Working Principle 2.1 Main Functions The STM-W series of standard water heater are used to heat up the mould and maintain this temperature. Besides, they can also be used in other similar applications. High temperature water from the mould is cooled by direct cooling and then sent to the pipe heater via high-pressure pump for heating to a constant temperature.
  • Page 18 set value of high pressure switch), alarm would sounds and machine halts; when cooling water pressure fails to reach the set value, pressure switch will send a signal of water storage to launch low pressure alarm and machine halts. 18(48)

  • Page 19: 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 20: Power Supply

    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℃. Picture 3-4: Mould and Water Couplings 3 3) Connect cooling water inlet with water supply and cooling water outlet with a drainage pipe.

  • Page 21: Options Installation

    3.4 Options Installation 3.4.1 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 22: Installation Steps For Function Of Water Drainage Via. Air Blowing

    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 23: Operation Guide

    Operation Guide Control Panel Picture 4-1: Control Panel Table 4-1: Control Panel Name Functions Remarks LCD Display POWER: ON/OFF ON/OFF Button MENU Menu setting Initial password: 0000 Parameter setting Confirm paramerters Edit set value Modify process temperture ▲/▼ Edit input value ◄/►...
  • Page 24 Name Functions Remarks Press“SUCTION” button, pump reverse Control unit: Optional water runs, water drainage valve opens, machine purge via compress air. starts reverse drainage function. SUCTION (including STM-W/O) Note: in this time, press SUCTION OFF STM-W/O: Reverse drainage button, drainage valve closed, the machine function of pump.
  • Page 25 Table 4-2: Error Type Error display Cause of Error Alarm Temp. control Board error Activated Stop Calib error Activated Stop Regulator error Adc error Activated Stop Rjc error Activated Stop Eeprom error Activated Maintain its status Phase error Default phase or phase reverse Activated Stop EGO Over temp.

  • Page 26: Menu Introduction

    4.2 Menu Introduction Pictute 4-2: Menu Outline 26(48)

  • Page 27: Machine Startup

    4.3 Machine Startup 1) Conenct hose from STM water/oil in/outlet to the mold. (Refer to chapter 3.2 for hose connection) 2) Connect water to cooling/water input (Refer to chapter 3.2 for hose connection) 3) Open all the ball valves. 4) Switch on main power. Picture 4-3: Main Power Switch 5) Press ON/OFF POWER button of the controller to enter initial screen.

  • Page 28: Picture 4-5: Control Setting Screen

    1. Control Menu Picture 4-5: Control Setting Screen 2. Alarm Menu Press MENU key to return menu selection screen, press ◄/► keys to temp. setting menu, press SET key to enter setting screen, as picture. All parameters are as below: Default parameters PHASE Detection—Activate(prevent water pump reverse due to phase error) DEV1 ALARM——0 (without temp.

  • Page 29: Picture 4-6: Alarm Setting Screen

    TURB ALARM——0℃/sec. (monitor temp. variation, it alarms when control temp. drops rapidly) HEATER ALARM——activate when control temp. doesn’t rise up. If default value is 0/ sec., the function is disabled. Overheat——exceed permissible upper limit temp. n℃, machine alarms and excitation release enables power off ( n is set value, the default is 20℃). Picture 4-6: Alarm Setting Screen 29(48)

  • Page 30: Picture 4-7: Output Setting Screen

    3. Output Menu OUTPUT MODE——heating control or heating and cooling control ( Default is heating and cooling control) SUB HEATING——temp. difference of activating sub. heating ouput (SUB) function. When actual temp. is less than ( set temp. – temp. difference), main heating output and sub.
  • Page 31 4. Temperature Setting Menu Press MENU key to return menu selection screen, press ◄/► keys to temp. setting menu, press SET key to enter setting screen, as picture. All parameters are as below: UPPER LIMIT TEMP.——Software limit on maximum temperature (each model default is as below) (STM-O: 200,...

  • Page 32: Picture 4-8: Temperature Setting Screen

    Picture 4-8: Temperature Setting Screen 5. Time Setting Menu Press MENU key to return menu selection screen, press ◄/► keys to time setting menu, press SET key to enter setting screen, as picture. The time has been adjusted before delivery. All the reserve time can be set according to actual production demands.
  • Page 33 Current time——Format in YYMMDD Reserv week——Weekly auto start/stop days Reserv time——Auto start/ stop hour and minutes of the day. Format: xxHour xxMinutes Maint. time—— Machine maintenance time Work time —— Machine working hours Picture 4-9: Time Setting Screen 6. Communication Setting Menu Reserve used for RS485 communication protocol.
  • Page 34 Picture 4-10: Communication Setting Screen 7. Setting Menu Press MENU key to return menu selection screen, press ◄/► keys to machine setting menu, press SET key to enter setting screen, as picture. The parameters are set before delivery, and all the parameters can be adjusted according to actual demands.
  • Page 35 Ret/Ent Disp: Return and process water/oil temperature display. Default: Disable. W-fill tm t1: Start delay for water unit to refill water in seconds. Automatically enable after disable the breaker. Default 1 for oil unit, water unit as below table. W-fill tm t2: Interval delay for water unit to refill water in seconds. Automatically enable after disable the breaker.
  • Page 36 Picture 4-11: Machine Setting Screen 8. Input Heating Temperature 1) Set mold temperature (if temp. has been set, this step can be ignored). Press SV key and SV column will be flashing, press ◄/► key to move cursor then press ▲/▼ key to change values. Finally press SET key to confirm them. 2) After setting the SV, press RUN/RESET key to begin temperature control, 36(48)

  • Page 37: Stop The Machine

    Auto-tuning is needed if deviation of temperature is large. Press AT key and LED light begins flashing to start Auto-tuning. When flashing ends, Auto-tuning finishes and parameters will be automatically saved. During Auto-tuning, pressing AT key will exit Auto-tuning process; controller will conduct temperature control based on exisiting parameters before the Auto-tuning.

  • Page 38: Trouble-Shooting

    Trouble-shooting Failures Possible reasons Solutions Did not connect through power supply. Connect through power supply. LCD displays nothing Main switch broken. Replace main switch. after switch on power Power supply wires problems. Check electrical wires. and press ON/OFF key. Control circuit fuse melt. Fix the fuse.
  • Page 39 Failures Possible reasons Solutions Heater contactor problems. Replace the contactor. Temperature can't rise Heater problems. Replace pipe heater. Thermocouple problems. Replace thermocouple. PCB output point problems. Check and repair PCB. Short circuit of main circuit. Circuit breaker tripping Transformer short circuit or connected Check electrical wire.

  • Page 40: 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 41: Open The Covers

    6.1 Open the Covers 1) Open the top covers of the unit. (Refer to the pictures below) Picture 6-1: Open the Covers 1 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.

  • Page 42: Y Type Strainer

    6.2 Y Type Strainer 1) Clean soft water should be used as cooling water. Filter screen is used in the strainer to stop impurities and pollutants to enter into water pipe. 2) Impurities or pollutants may cause errors and bad temperature control. Clean filter screen of the strainer periodically.

  • Page 43: Pipe Heater

    6.4 Pipe Heater 1) Open machine rear cover door. (Refer to pictures below) Picture 6-6: Pipe Heater 1 2) Unlock heater cap. (Refer to pictures below) Picture 6-7: Pipe Heater 2 3) Install the pipe heater to the machine according to above opposite orders. 6.5 By-pass Globe Valve Shut off the by-pass globe vale when water pressure gauge display value is too low.

  • Page 44: Printed Circuit Board

    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. sensor terminal 8, 9 : water out temp. sensor terminal 11, 12 : 1~5V input terminal ②...
  • Page 45 ⑥ DISPLAY CN (connect terminal for dispaly) Connect stub cable with STM100. ⑦ POWER TERMINAL (power supply terminal) 1 : FG terminal 2, 3 : power supply terminal (100~240VAC) 45(48)

  • Page 46: Displayer Terminal Connecting Diagram

    6.7 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 connector 46(48)

  • Page 47: Maintenance Schedule

    6.8 Maintenance Schedule 6.8.1 About the Machine Model Manufacture date Ф Voltage Frequency Power 6.8.2 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 48: Yearly Checking

    Replace the hot kerosene with a using temperature above 120~160 degree 6.8.7 Yearly Checking Replace the hot kerosene with a using temperature above 120 degree 6.8.8 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.

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