Shini STM-PW series User manual

STM-PW Series
High Temp. WaterHeater
Date:Apr. 2013
Version: Ver.B(English)

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Contents
1. General Description..................................................................................7
1.1 CodingPrinciple...................................................................................8
1.2 Feature.................................................................................................8
1.3 TechnicalSpecifications.....................................................................10
1.3.1 Specification............................................................................10
1.3.2 PumpPerformance..................................................................11
1.3.3 ReferenceFormulaofMouldControllersModelSelection.......11
1.4 SafetyRegulations.............................................................................12
1.4.1 SafetySignsand Labels..........................................................12
1.4.2 Signsand Labels.....................................................................13
1.4.3 OperationRegulations.............................................................14
1.4.4 Transportation andStorageoftheMachine.............................15
1.5 ExemptionClause..............................................................................17
2. StructureCharacteristics and WorkingPrinciple.................................18
2.1 WorkingPrinciple...............................................................................18
2.2 AssemblyDrawing.............................................................................19
2.2.1 AssemblyDrawing(STM-940-HPW).......................................19
2.2.2 PartsList (STM-940-HPW)......................................................20
2.2.3 Pump.......................................................................................21
2.3 ElectricalDiagram..............................................................................22
2.3.1 MainCircuit (STM-940HPW230V)..........................................22
2.3.2 ControlCircuit (STM-940HPW230V)......................................23
2.3.3 Thermocoupleand TerminalLayout (STM-940HPW230V)....24
2.3.4 ElectricalComponentsLayout (STM-940HPW230V).............25
2.3.5 ElectricalComponentsList (STM-940HPW230V)...................26
2.3.6 MainCircuit (STM-940HPW400V)..........................................27
2.3.7 ControlCircuit (STM-940HPW400V)......................................28
2.3.8 Thermocoupleand TerminalLayout (STM-940HPW230V)....29
2.3.9 ElectricalComponentsLayout (STM-940HPW400V).............30
2.3.10 ElectricalComponentsList (STM-940HPW400V)...................31
2.4 MainElectricalComponentsDescription............................................32

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2.4.1 Overload Relay........................................................................32
2.5 OperationProcedures........................................................................33
2.5.1 Installation stepsforoptionswatermanifold(dewaxing)..........33
2.5.2 Installation stepsforoptionswatermanifold(welding).............33
3. Installation and Debugging.....................................................................35
3.1 Installation Space...............................................................................35
3.2 Mouldand WaterCoupling.................................................................35
3.3 PowerSupply.....................................................................................36
4. Operation Guide......................................................................................37
4.1 ControlPanel.....................................................................................37
4.2 Machine Startup.................................................................................38
4.3 Stop theMachine...............................................................................40
4.4 TemperatureController......................................................................40
4.4.1 TemperatureControllerDisplay...............................................40
4.4.2 Keyson ControlPanel.............................................................41
4.4.3 ChooseaParameter................................................................41
4.4.4 ComfirmYourSetting..............................................................42
5. Trouble-shooting.....................................................................................43
6. Maintenance and Repair.........................................................................45
6.1 OpentheCovers................................................................................45
6.2 YType Strainer..................................................................................46
6.3 SolenoidValve...................................................................................47
6.4 Pipe Heater........................................................................................47
6.5 DisplayerTerminalConnectingDiagram............................................48
6.6 MaintenanceSchedule.......................................................................49
6.6.1 About theMachine...................................................................49
6.6.2 Installation &Inspection...........................................................49
6.6.3 DailyChecking.........................................................................49
6.6.4 WeeklyChecking.....................................................................49
6.6.5 TrimonthlyChecking................................................................49
6.6.6 Half-yearlyChecking................................................................49
6.6.7 YearlyChecking.......................................................................50
6.6.8 3yearChecking.......................................................................50

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TableIndex
Table1-1 Specification...................................................................................10
Table2-4 PartsList (STM-940-HPW)............................................................20
Table2-1 ElectricalComponentsList (STM-940HPW230V).........................26
Table2-2 ElectricalComponentsList (STM-940HPW400V).........................31
PictureIndex
Picture1-1 PumpPerformance......................................................................11
Picture2-1 STM-HPWWorkingPrinciple.......................................................18
Picture2-2 AssemblyDrawing(STM-940-HPW)............................................19
Picture2-3 Pump...........................................................................................21
Picture2-4 MainCircuit (STM-940HPW230V)..............................................22
Picture2-5 ControlCircuit (STM-HPW230V)................................................23
Picture2-6 ThermocoupleandTerminalLayout (STM-HPW230V)...............24
Picture2-7 ElectricalComponentsLayout (STM-HPW230V).......................25
Picture2-8 MainCircuit (STM-940HPW400V)..............................................27
Picture2-9 ControlCircuit (STM-HPW400V)................................................28
Picture2-10 ThermocoupleandTerminalLayout (STM-HPW400V).............29
Picture2-11 ElectricalComponentsLayout (STM-HPW400V).....................30
Picture2-12 OverloadRelay..........................................................................32
Picture3-1 InstallationSpace........................................................................35
Picture3-2 MouldandWaterCouplings1......................................................35
Picture3-3 MouldandWaterCouplings2......................................................36
Picture3-4 MouldandWaterCouplings3......................................................36
Picture4-1 ControlPanel...............................................................................37
Picture4-2 MachineStartup1........................................................................39
Picture4-3 MachineStartup2........................................................................39
Picture4-4 TemperatureControllerPanel......................................................40
Picture4-5 ChooseaParameter....................................................................42
Picture6-1 Openthe Covers1.......................................................................45
Picture6-2 Openthe Covers2.......................................................................46

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Picture6-3 Openthe Covers3.......................................................................46
Picture6-4 Y Type Strainer............................................................................46
Picture6-5 SolenoidValve.............................................................................47
Picture6-6 Pipe Heater1...............................................................................47
Picture6-7 Pipe Heater2...............................................................................47
Picture6-8 Pipe Heater3...............................................................................48

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1.General Description
Read thismanualcarefullybeforeoperationtopreventdamageofthe
machine orpersonalinjuries.
STM-HPWserieswaterheaterhavebothstandardandhightemperaturemodels,
whichareusedtoheatup the mouldandmaintaintemperature, theycan be used
inothersimilarapplicationsaswell. Hightemperaturewaterfromthemouldis
returnedtothecoolingtankandcooled byeitherindirect cooling(Forhigh
temperatureand hightemperaturepluspressuremodels)ordirect cooling(For
standardmodels). It isthenpressurisedbythehigh-pressurepump,senttothe
heatingtankandfinallytothe mouldwithaconstant temperature.TheOMRON
temperaturecontrollercan ensurean accuracy of 0.5℃.
Model: STM-940HPW

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1.1CodingPrinciple
1.2Feature
1)Standardconfiguration
●P.I.D.multi-stagetemperaturecontrolsystemcan maintainanmould
temperaturewithaccuracyof 0.5 .
●Adoptshighefficiencywatercyclepump,withwhichprecisemouldsand
mouldloopwithminordiametercanachieveprecisetemperaturecontroland
highefficientheatexchange. Pumpinsideadoptsstainless steeltoavoid
explosion.
●Multiplesafetydevicesincludingpowerreversephaseprotection, pump
overload protection, overheatprotectionandlowlevelprotection thatcan
automaticallydetectabnormalperformanceand indicatethisviavisible
alarm.
●ForstandardSTM-HPW,the heatingtemperaturecanreach180℃.
●Equippedwithhighpressureprotection, safetypressurerelieving, automatic
watersupplyingand airexhausting.
●STM-HPWadoptsindirect cooling, whichmakestemperaturecontrolmore
precise.Thelowviscosityofwaterrealizesfast heat exchange.
●Adoptmagneticpumpwithnoleakage.
2)Accessoryoption
●WatermanifoldsandTeflonhoseareoptional.
●RS485 communication functionisoptional.

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All serviceworkshouldbe carried out byaperson withtechnicaltrainingor
correspondingprofessionalexperience.The manualcontainsinstructionsforboth
handlingand servicing.Chapter6, whichcontainsserviceinstructionsintendedfor
serviceengineers. Otherchapterscontaininstructionsforthedailyoperator.
Anymodificationsofthemachinemustbe approved bySHINI inordertoavoid
personalinjuryand damagetomachine.Weshall not beliableforanydamage
causedbyunauthorized changeof themachine.
Ourcompanyprovidesexcellent after-salesservice. Shouldyou haveanyproblem
duringusingthemachine,pleasecontactthecompanyorthelocalvendor.
HeadquarterandTaipeifactory
Tel:[phone]
ShiniPlastics Technologies(Dongguan), Inc
Tel:[phone]
ShiniPlastics TechnologiesIndiaPvt.Ltd.
Tel:[phone]

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1.3Technical Specifications
1.3.1Specification
Table1-1 Specification
Tank(L)
Model Max.
temp.
Heater
(kw)
Pump (kw)
(50/60Hz)
M
ax.pump
flow (L/min)
(50/60Hz)
Max.pump
pressure
(bar)
(50/60Hz)
Heating
chamber
number
Heat
ing
Cooli
ng
Coonling
method
Mould
coupling*
(inch)
Inlet /
Outlet
(inch)
Dimensions
(mm)
(H×W×D)
Weight
(kg)
STM-607-HPW 6 0.55 / 1.63 25.5 / 28 12 / 15.8 1 3.4 1 3/8 (2×2)
3/4 /
3/4
750×320×770
80
STM-913-HPW 9 1.0 / 1.2 50 / 60 12 / 15.8 1 3.4 1 3/8 (2×2)
3/4 /
3/4
750×320×770
85
STM-1213-HPW 12 1.0 / 1.2 50 / 60 12 / 15.8 1 3.4 1 1 (1×2)
3/4 /
3/4
750×320×810
95
STM-940HPW
180℃
9 2.8 150 12 1 3.4 4.6
Indirect
1 (1×2) 1/1
960×465×900
140
Note: 1)"HPW"standsforwater medium withhightemp.andhighpressure.Wereservetherighttochange
"*" standsforoptions.specificationswithoutpriornotice.
2) Toensurestablewater temperature,coolingwater pressure shouldnot
be less than2kgf/cm2,butalsonomore than5kgf/cm2.
3) Pumptestingstandard: Power of50/60Hz,purifiedwater at 20℃. (There
is 10%toleranceforeithermax.flowrateormax. pressure).
4) Power supply: 3Φ,230/400/460/575VAC, 50/60Hz.

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1.3.2PumpPerformance
Picture1-1 PumpPerformance
1.3.3ReferenceFormulaofMouldControllersModelSelection
HeaterPower(kW)=mouldweight (kg) ×mouldspecificheat (kcal/kg) ×
temperaturedifferencebetween mouldandenvironment() ×safetycoefficient
/ heatingduration / 860
Note: safetycoefficientcan selectavalue from1.3to1.5.
FlowRate(L/min)=heaterpower(kw) ×860 / [heatingmediumspecific
(kcal/kg) ×heatingmediumdensity(kg/L)×in/outlettemperaturedifference
()×time(60)]
Note:Waterspecificheat =1kcal/kg
Heatingmediumoil specificheat =0.49kcal/kg
Waterdensity=1kg/L
Heatingmediumoil density=0.842kg/L

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1.4SafetyRegulations
Strictlyabide bythe followingsafetyregulationstoprevent damageofthe
machine orpersonalinjuries.
1.4.1SafetySignsand Labels
Danger!
Theunit isdesigned toendurehightemp,andhighpressure. Forsafe
operation,do notremovethe coversorswitches.
Attention!
Theunit shouldbe operated byqualifiedpersonnelonly.
Duringoperation, avoidwearingglovesorclothesthatmaycause
danger.
Turnoff mainswitchwhen powersupplyisoff.
Stoptheunitwhentheremaybepowersupplyproblemscausedbystatic
electricity.
Put onsafetyglovesand shoesduringinstallation orrelocation.
Componentsfromourcompanycan onlybe used forreplacement.
Warning!
Donottouchthe switchwithwet object orhands.
Donotusethemachinebeforefullyawareofitsperformance.
Becarefulnot totouchorhit the switchorsensor.
Pleasekeepenoughoperationspace,andkeep awayobstacles.
Toavoidproducingstatics, cleanthefloorfromoil orwatertokeep adry
environment.
Protectthemachineagainst severevibration orcollision.
Donotremovesafetysignsormakeit dirty.
Drunken,medicine-taking, ormen withoutproperjudgement shouldnot
operatethe machine.
Warning!
Hightemperature, takecareof hands! Thislabelisattached on the
surfaceofheatingparts.

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1.4.2Signsand Labels
Regularlyclean the filterscreen in
the copperscrewtoavoidblockage
and aswell ensurean excellent
workingperformance.
Thisistoindicatemotorrotating
direction.Whenphasereversal
happens,thealarmsoundsand
indicatoron controlpanelwill
indicate.
Pleaseexchangethe placeof twoof
the electricalwirestosolvethis
problem.
Highvoltage! Electricalshock may
happen.Carefulness isrequired from
the operator.
Attentions!
Thisisgeneralwarningswhich
operatorsshouldpayattention to.
Frommould: connectorfor
circulatingwater/oil comingfrom
mould.
Pumppressuremeter:indicating
actualpressureofsystem.
Tomold: connectorforcirculating
water/ oil togotomould.

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1.Tomaintaintemperature
consistency, coolingwater
pressuremustbehigherthan2
baratall time,but shouldnever
exceed 5barinanycase.
2. CleanY-shape CoolingWater
Strainerperiodicallytoensure
perfect coolingcapacity.
Waterinlet: inletforreplenishing
waterand coolingwater.
Wateroutlet: drainageoutlet.
Pleaseabide bythe safetyguide when you operatethemachinesoastoprevent
damageof themachineandpersonalinjuries.
All electricalcomponentsshouldbe installedbyqualified electricians. Turn
offmainswitchand controlswitchduringrepair and maintenance.
Warning! Highvoltage!
Thismarkisattachedonthecoverofthe controlbox.
Warning! Becareful!
Be morecarefulwhen thismarkappears.
1.4.3OperationRegulations
1)Beforeoperation,makesurethat coolingwateriscleansoft waterwithout
pollutants.
※Lowqualitywaterbringslimescales,whichmaycauseproblems.
2)Ifproblemsof drainageorbadtemperaturecontrolarenoted,pleaseclean
solenoidvalveand coolingwaterinlet and outlet.
3)Donotmovetheunit when it isinoperation.
4)Wheninneed ofrepairing, wait until oil temperaturefallsbelow30 .
5)Motoroverload maybe causedbyphaseshortage,pipe obstruction,broken

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bearing, etc. Motoroverload relaywilltripofftostopthemachine when this
happens.Fixingthe problems, pressRESETon overloadrelaytoclearthe
alarm.
6)Beforeturnoff thepump, wait until oil temperaturefallsblow50 .Orthelife
oftheunit wouldbeaffected.
7)Ifthe settingtemperatureisbelow100℃, then thepressureswitchsetting
value shouldbe1.5-2bar;Ifthesettingtemperaturesetsbetween100℃and
200℃,then the recommendablepressureswitchsettingvalue shouldbe2.8
bar. If thecoolingwaterpressureistoo low, then thepressureswitchsetting
value can beadjusted properlytoensurenormalrunning. However,it may
affectthelimitation ofsettingtemperatureorcauseunstabletemperature
control.
8)Pleaseconnectthecoolngwateroutlet withhightemperatureresistantpipe
when temperatureisabove100℃.
1.4.4Transportation andStorageoftheMachine
Transportation
1)STM-PWseriesstandardoil heaterarepacked incratesorplywood cases
withwooden palletat the bottom,suitableforquick positioningbyforklift.
2)Afterunpacked, castorsequipped on the machinecan be usedforeaseof
movement.
3)Donot rotatethemachineandavoidcollision withotherobjectsduring
transportationtoprevent improperfunctioning.
4)The structureofthe machine iswell-balanced,althoughit shouldalsobe
handled withcarewhenliftingthemachineforfearoffallingdown.
5)The machine anditsattachedpartscanbekeptat atemperaturefrom-25℃
to+55 forlongdistancetransportationandforashort distance, itcan be
transported withtemperatureunder+70 .
Storage
1)STM-PWseriesstandardoil heatershouldbe stored indoorswith
temperaturekeptfrom5 to40 andhumiditybelow80%.
2)Disconnect all powersupplyand turnoffmainswitchand controlswitch.
3)Keepthe wholemachine,especiallythe electricalcomponentsawayfrom

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watertoavoidpotentialtroublescaused bythe water.
4)Plasticfilm shouldbeusedtoprotect the machinefromdust and rains.
Workingenvironment
Themachineshouldbeoperated:
1)Indoorsinadryenvironment withmaximumtemperature+45 and humidity
notmorethan 80%.
Donotusethemachine:
1)Ifit iswithadamaged cord.
2)Onawet floororwhen it isexposed toraintoavoidelectricalshock.
3)Ifithasbeendropped ordamaged until it ischeckedorfixed byaqualified
serviceman.
4)Thisequipmentworks normallyintheenvironmentwithaltitudewithin3000m.
5)At least aclearanceof1msurroundingthe equipment isrequired during
operation.Keepthisequipment awayfromflammablesourcesat least two
meters.
6)Avoidvibration, magneticdisturbanceat theoperationarea.
Rejectedpartsdisposal
When the equipmenthasrun out itslifetimeand can notbe usedanymore,
unplugthepowersupplyand disposeof it properlyaccordingtolocalcode.
FireHazard
Incaseoffire, Co2drypowderfireextinguishershouldbe applied.
Pleaseabidebythesafetyguide when you operatethemachinesoasto
prevent damageofthemachine andpersonalinjuries.
All electricalcomponentsshouldbe installedbyqualified electricians.
Turnoff mainswitchand controlswitchduring repair and maintenance.
Warning! Highvoltage!

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Thismarkisattachedon the coverof thecontrolbox.
Warning! Becareful!
Be morecarefulwhen thismarkappears.
Warning!
Hightemperature, takecareof hands! Thislabelisattached on the
surfaceofheatingparts.
1.5 Exemption Clause
Thefollowingstatementsclarifytheresponsibilitiesandregulationsbornbyany
buyeroruserwho purchasesproductsandaccessoriesfromShini(including
employeesandagents).
Shiniisexempted fromliabilityforanycosts,fees,claimsandlossescausedby
reasonsbelow:
1. Anycarelessorman-madeinstallations,operation andmaintenancesupon
machineswithoutreferringtothe Manualpriortomachineusing.
2. Anyincidentsbeyondhumanreasonablecontrols, whichincludeman-made
viciousordeliberatedamagesorabnormalpower,and machine faultscaused
byirresistiblenaturaldisastersincludingfire,flood,stormand earthquake.
3. Anyoperationalactionsthatarenotauthorized byShiniuponmachine,
includingaddingorreplacingaccessories, dismantling,deliveringorrepairing.
4. Employingconsumablesoroil mediathatarenotappointed byShini.

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2. Structure Characteristics andWorkingPrinciple
2.1WorkingPrinciple
Picture2-1 STM-HPWWorkingPrinciple
Thehightemperaturewaterfromthemouldreturnstopumpand then flowsto
heaterafterbeingpressurized. Then itwill be heated andflowtothemould
again.Theprocesscirculateslikethis.Inthisprocess,machinewill stop and
givean alarmwhen liquidlevelswitchdetectsthattheliquidlevelhasdropped
downtothe set point. However, ifthe temperatureofthat wateristoohigh, the
systemwill activatethe solenoidvalveforcoolingtolet coolingwatercomeinto
the systemandcoolsdownthe water, thusconstant temperaturecanbe
maintained. Systemwillactivateitsovertemperaturealarmandstop working
when thatwatertemperatureisstill higherthanEGOsetpoint. Safetyvalvewill
be openedforpressurereleasewhen systempressurehasreachedsetpoint of
pressureswitch.Ifthe systempressurekeepsbeyond thesetpointofthe safety
valve, machine will soundsalarmand halts.

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2.2AssemblyDrawing
2.2.1AssemblyDrawing(STM-940-HPW)
Remarks:Please refertomateriallist2.2.2forspecificexplanation oftheArabicnumbers
inpartsdrawing.
Picture2-2 AssemblyDrawing (STM-940-HPW)

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2.2.2PartsList (STM-940-HPW)
Table2-4 PartsList (STM-940-HPW)
No. Name Part No. No. Name Part No.
1 Door plate - 26
Copper Teflonpipe male
elbow3/8PT×3/8HL BH12030800610
2 Main power switch* YE10200300000 27 Solemoid valve*3/8”YE32331000000
3 Fixed plateof cable
clamp - 28
Copper pipecoupler
3/8PT×3/8PT BH12030800110
4 ScrewM6 YW62061000000
29
Copper Teflonpipe
contactor3/8PT×3/8HL YW04030800300
5 Side plate - 30 StainlesssteelT-joint3/8”YW52030800000
6 Control cabinet base
plate- 31
Y –type filter1/2PT YW57010200000
7 Rockerswitch YE10210400000 32 Copper inserted core BH12131200010
8 Temperaturecontroller YE85005000000 33
Copper Teflonpipe
contactor1/4PT×3/8H BH12010400510
9 Control panel - 34 Coppercontactor unit 8 BH12060704810
10 Electric cabinet - 35
General coppercontactor for
unit fron 1to4. -
11
Rear plateof electric
cabinet - 36
Pipe shield BL80091000120
12 Rack- 37
Copper pipecoupler
1/4PT×3/8PT BH12010400310
13
Pressureguage
0~15kG YW85015000000
38 Thermocouple BE90342500050
14
High pressureswitch
controllerYE90002000000
39 Heater 9kW BH70091000150
15
Lowpressureswitch
controller YE90000800000
40
Copper Teflonpipe
contactor1/4PT×1/4HL YW04010400400
16 Cover plate - 41
Copper Teflonpipe
contactor1/4PT×1/4HBH12010400410
17
Cover plateand
supportingplateof rear
plate
- 42 Pumpinlet -
18 Coolingtankcover - 43 Heatingtank -
19
M10×25 sockethaed
cap screw YW61102500000
44
Copper pipecoupler
1/4PT×1/4PT BH12010400110
20 Flat washer10×25 YW66102500000 45 Bufferflydamper 1/4”YW50220000000
21 Spring washer 10 YW65010000000 46 Magnetic pumpMP-280 BM20283300050
22 Coolingpipe - 47 Coppercontactor unit 7 BH12091000010
23 Electricalfloating ball YE13001500000 48
Copper Teflonpipe
contactor1/2PT×3/8HL YW04010200200
24
Copper Teflonpipe
contactor1/2PT×3/8HL
YW04010200200 49 Non-returnvalve1/2”YW59010200100
25 Safetyvalve14kgopen - 50 Coolingtank-