Shini STM-W Technical manual

Water Heaters
STM-W
Operation Instruction
Model: STM-910W

Contents
1. General Description
---------------------------------------------------------------
--------------------
--------------------------------------------
--------------------------------------------------
------------------------------------------------------
-------------------------------------------------
Contents
6. Maintenance and Repair
5. Trouble-shooting
4. Application and Operation
3. Installation and Debugging
2. Structure Characteristics and Working Principle

1. General Description
Please read through this operation manual before using and
installation to avoid damage of the machine and personal injuries.
STM - W series water heaters 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). It is then pressurised by the high - pressure pump, sent to
the heating tank and finally to the mould with a constant temperature. The
o
OMRON temperature controller can maintain an accuracy of 1 C.
General Description
1.1 Main Features:
1) P.I.D. multi - stage temperature control system can maintain a mould
temperature with accuracy of
2) Adopt high efficiency high temperature pump with great pressure and stable
performance.
3) Multiple safety devices can automatically detect abnormal performance and
indicate this via visible alarm.
4) Compact design, easy to operate and maintain.
5) Inner parts made from stainless steel to ensure corrosion - free operation.
6) With stable performance and accuracy within , for standard STM - W,
the heating temperature can reach 120 .
7) STM - W adopts direct cooling method for better cooling effect and
automatic water refilling to quickly reduce water temperature to the set - point.
8) Pump reverse running for water drainage is an optional function for STM - W.
9) Upon request, it can be built to comply with worldwide electrical safety
standards ( For example : CE, UL, CSA, JIS etc. ).
o
1C.
o
1C
o
C

1. General Description
All service work should be carried out by a person with technical training or
corresponding professional experience. The manual contains instructions for
both handling and servicing. Chapter 7, 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.
Our company provides excellent after-sales service. Should you have any
problem during using the machine, please contact the company or the local
vendor.
Headquarter and Taipei factory
Tel: [phone]
Shini USA Service Information
Tel: [phone]

Pipe heater: 3 kW
Pump power: 0.25 kW
Max. pump flow: 12 L/min
Max. pump pressure: 4.0 Bar
Cooling method: direct
Mould coupling : 3/8 (Optional) "(1 1)
Max. temperature: 120
1.2.1 STM-304W
Specifications
Outer dimensions
Pum performance curvep
Pressure (Bar)
5
4
3
2
1
00 5 10 15 20 25 30 35
Flow rate (L/min)
1.2 Technical Specifications
350
General Description
1.2.2 STM-607W / 607WR
35
Pipe heater: 6 kW
Pump power: 0.55 kW
Max. pump flow: 27 L/min
Max. pump pressure: 3.8 Bar
Cooling method: direct
Mould coupling : 3/8 (Optional) "(2 2)
Max. temperature: 120
Specifications
Pum performance curvep
Pressure (Bar)
5
4
3
2
1
00 5 10 15 20 25 30
Flow rate (L/min)

Outer dimensions
635
General Description
1.2.3 STM-607W-D
Specifications
Outer dimensions
Pum performance curvep
Pipe heater: 6 kW 2
Pump power: 0.55 kW 2
Max. pump flow: 27L/min 2
Max. pump pressure: 3.8 Bar
Cooling method: direct
Mould coupling : 3/8
(Optional) "(4 2)
Max. temperature: 120
655
Pressure (Bar)
5
4
3
2
1
00 5 10 15 20 25 30 35
Flow rate (L/min)

Specifications
Outer dimensions
Pum performance curvep
Pipe heater: 9 kW
Pump power: 0.75kW
Max. pump flow: 42 L/min
Max. pump pressure: 5.0 Bar
Cooling method: direct
Mould coupling : 3/8 (Optional) "(2 2)
Max. temperature: 120
655
1.2.4 STM-910W / 910WR
Pressure (Bar)
5
4
3
2
1
00 10 20 30 40 50 60 70
Flow rate (L/min)
General Description
1.2.5 STM-910W-D
Specifications
Pum performance curvep
Pipe heater: 9 kW 2
Pump power: 0.75 kW 2
Max. pump flow: 42 L/min 2
Max. pump pressure: 5.0 Bar
Cooling method: direct
Mould coupling : 3/8
(Optional) "(4 2)
Max. temperature: 120
Pressure (Bar)
5
4
3
2
1
00 10 20 30 40 50 60 70
Flow rate (L/min)

Outer dimensions
655
General Description
1.2.6 STM-1220W / 1220WR
Specifications
Outer dimensions
Pum performance curvep
Pipe heater: 12 kW
Pump power: 1.5 kW
Max. pump flow: 74 L/min
Max. pump pressure: 6.2 Bar
Cooling method: direct
Mould coupling : 3/8 (Optional) "(4 2)
Max. temperature: 120
740
Pressure (Bar)
10
8
6
4
2
00 20 40 60 80 100 120 140
Flow rate (L/min)

Pipe heater: 24kW
Pump power: 2.8kW
Max. pump flow: 130L/min
Max. pump pressure: 8.0Bar
Cooling method: direct
Mould coupling : (Optional) 1" (1 2)
Max. temperature: 120
Pum performance curvep
Specificatios
Outer dimensions
790
930 360
80
Pressure (Bar)
10
8
6
4
2
00 25 50 75 100 125 150 175
Flow rate (L/min)
1.2.7 STM-2440W / 2440WR
General Description
Pipe heater: 36 kW
Pump power: 4.0 kW
Max. pump flow: 200 L/min
Max. pump pressure: 8.0 Bar
Cooling method: direct
Mould coupling (Optional): 1
" (1 2)
Max. temperature: 120
1.2.8 STM-3650W / 3650WR
Specificatios
Pum performance curvep
Flow rate (L/min)
Pressure (Bar)

Outer dimensions
General Description
1.2.9 Specification List
STM-607W
STM-910W
STM-1220W
Model Max.
Temp.
120
STM-2440W
Direct
STM-607W-D
Dimensions
(H )xWxD
STM-910W-D
Mould
coupling*
Pipe
heater
Pump
power
Max. pump
flow
Max. pump
pressure
Heating tank
number
Heating tank
capacity Cooling
method
Weight
(Kg)
STM-3650W
3
6
62
0.25 / 0.25
0.55 / 0.63
0.55 2
/ 0.63 2
12 / 12
27 / 30
27 2
/ 30 2
4.0 / 4.9
3.8 / 5
1
1
2
1.0
3.0
3.0 2
12 1.5 / 1.9 74 / 84 6.2 / 7.2 26.0
9 0.75
/ 0.92 42 / 50 5.0 / 6.4 13.0
920.75 2
/ 0.92 2 42 2
/ 50 2 5.0 / 6.4 23.0 2
24
36
2.8 / 3.4
4.0
130 / 132
170 / 170
8.0 / 10.2
8.0 / 8.0
2
4
7.4
17.7
3.8 / 5
STM-304W
3/8" (1 1)
3/8" (2 2)
3/8" (4 2)
350x320x680
635x280x740
655x510x740
1
(1 2)
870x360x930
980x415x930
40
55
95
695x340x815 120
655x510x740 105
655x280x740 60
3/8" (2 2)
3/8" (4 2)
3/8''(4 2)
140
150
Note: 1) "D" stands for double stage, "*" stands for options.
2) Automatic drain facility can be added for all models as optional feature. ( Model denotes "R" )
3) In order to maintain stable temp. of heat transfer media, cooling water pressure should be no less
22
than 2 kg / cm , but also no more than 5 kg / cm .
4) Pump testing standard Power of 50 / 60Hz purified water at 20 . ( There is 10% tolerance
for either max. flowrate or max.pressure ).
5) Power supply: 3 , 230/400/460/575V, 50/60Hz.
(kW)
(50/60Hz) (L/min)
(50/60Hz) (Bar) (50/60Hz) (L) (Inch) (mm)

1.3 Safety Regulations
1.3.1 Safety Signsand Labels
General Description
Danger!
The unit is designed 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.
During operation, avoid wearing gloves or clothes that may cause
danger.
Turn off main switch when power supply is off.
Stop the unit when there may be power supply problems caused by
static electricity.
Put on safety gloves and shoes during installation or relocation.
Components from our company can only be used for replacement.
Warning!
Do not touch the switch with wet objects or hands.
Do not use the machine before fully aware of its performance.
Be careful, not to touch or hit the switch or sensor.
Please keep enough operation space, and keep away obstacles.
To avoid producing statics, clean the floor from oil or water to keep
a dry environment.
Protect the machine against severe vibration or collision.
Do not remove safety signs or make it dirty.
Drunken, medicine-taking, or men without proper judgement should
not operate the machine.
Attention
No need for regular inspection because all the electrical parts in the
control unit are fixed tightly

1.3.2 Signs and Labels
(Attached to pump cover)
This is to indicate motor rotating direction.
When phase reversal happens, the alarm
sounds and indicator on control panel will
indicate. Please exchange the place of two
of the electrical wires to solve this problem.
Attentions!
This is general warnings which operators
should pay attention to.
High voltage! Electrical shock may happen.
Carefulness is required from the operator.
N6148015
In order to keep a stable temperature,
cooling water pressure should not be less
than 2bar, but also no more than 5bar.
Clean the Y type strainer to ensure cooling
capacity of the machine.
1) Before operation, make sure that cooling water is clean soft water without
pollutants.
Low quality water brings limescales, which may cause problems.
Low quality water may be the reasons for heater wire break, worn pump
leaf, less flow rate, that eventually affect temperature rising.
2) If problems of drainage or bad temperature control are noted, please clean
solenoid valve and cooling water inlet and outlet.
3) Do not move the unit when it is in operation.
4) When in need of repairing, wait until oil temperature falls below 30 .
5) Motor overload may be caused by phase shortage, pipe obstruction, broken
bearing, etc. Motor overload relay will trip off to stop the machine when this
happens. Fixing the problems, press RESET on overload relay to clear the
alarm.
6) Before turn off the pump, wait until oil temperature falls blow 50 . Or the
life of the unit would be affected.
1.3.3 Operation Regulations
General Description

7) In order to keep stable water temperature, cooling water pressure should
be 2~5bar.
8) If the setting temperature is below 100 , then the pressure switch setting
value should be 1.5-2 bar; if the setting temperature sets between 100
and 200 , then the recommendable pressure switch setting value should
be 2.8 bar If the cooling water pressure is too low, then the pressure switch
setting value can be adjusted properly to ensure normal running. However,
it may affect the limitation of setting temperature or cause unstable
temperature control.
9) Please connect the coolng water outlet with high temperature resistant pipe
when temperature is above 100 .
1.3.4 Transportation and Storage of The Machine
Transportation
1) STM-W series standard water heaters 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.
3) Do not rotate the machine and avoid collision with other objects during
transportation to prevent improper functioning.
4) The structure of the machine is well-balanced, although it should also be
handled with care when lifting the machine for fear of falling down.
5) The machine and its attached parts can be kept at a temperature from -25
to +55 for long distance transportation and for a short distance, it can be
transported with temperature under +70 .
General Description
1) STM-W series standard water heaters should be stored indoors with
OO
temperature kept from 5 C to 40 C and humidity below 80%.
2) Disconnect all power supply and turn off main switch and control switch.
3) Keep the whole machine, especially the electrical components away from
water to avoid potential troubles caused by the water.
4) Plastic film should be used to protect the machine from dust and rains.
Storage

Working environment
The machine should be operated:
1) Indoors in a dry environment with max. temperature +45 and humidity no
more than 80%.
Do not use the machine:
1) If it is with a damaged cord.
2) On a wet floor or when it is exposed to rain to avoid electrical shock.
3) If it has been dropped or damaged until it is checked or fixed by a qualified
serviceman.
4) This equipment works normally in the environment with altitude within 3000m.
5) At least a clearance of 1m surrounding the equipment is required during
operation. Keep this equipment away from flammable sources at least two
meters.
6) Avoid vibration, magnetic disturbance at the operation area.
Rejected parts disposal
When the equipment has run out its life time and can not be used any more,
unplug the power supply and dispose of it properly according to local code.
In case of fire, Co dry powder fire extinguisher should be applied.
2
Please abide by the safety guide when you operate the machine so as
to prevent damage of the machine and personal injuries.
Fire hazard
General Description
All electrical components should be installed by qualified electricians.
Turn off main switch and control switch during repair and
maintenance.
Warning High voltage
This mark is attached on the cover of the control box.
Warning Be careful
Be more careful when this mark appears.
Warning
High temperature, take care of hands! This label is attached on the
surface of heating parts.

2.2.1 STM-W (single heating tank) Working Principle
High temperature water returns to the machine and then be pressured by
pump to the heaters. After being heated, water will be forced to mould and
continue the circle. In the process, if the temperature is too high, the system
will activate the solenoid valve to let cooling water cool down the temp. directly
until the water is down to the system requirement. If the temp. keep increasing
and reach to the set point of EGO, system will alarm and stop operation. The
system will have low pressure alarm and stop working if cooling water pressure
doesn reach set point.
The STM-W series of standard water heaters 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 heaters via high-pressure pump
for heating to a constant temperature. With our optimised design, water can
o
reach a maximum of 120 C and the OMRON temperature controller can
o
maintain an accuracy of 1 C.
EGO
Cooling water outlet
Tomould
Pressure meter
From mould
Cooling water inlet
Pressure switch
Pump
Filter
Thermal sensor
Solenoid valve
Heater
Mould
Ball valve
Ball valve
Ball valve
2.1 Main Functions
Structure characteristics and working principle
2. Structure Characteristics and Working Principle
2.2 Working Principle

P
System flow for vacuum drainage function
T
EGO
Nonretrun valve Manual release valve
High temperature water returns to mould temperature controller through
piping, which is conveyed to the heaters after being pressured by pump.
After being heated, water will be forced to mould and the circle continues in
this way. In the process, if the temperature is too high, the system will
activate the solenoid valve 2 to let cooling water cool down the temp directly,
by which it will realize the purpose of keeping constant temp. If the temp of
high temperature water keeps increasing and reaches to the set point value
of EGO, system will activate high temperature alarm and stop operation; if
the pressure of cooling water cannot reach to the set requirements, pressure
switch will send signal of water deficiency and system will activate low
pressure alarm and stop operation. When system needs vacuum drainage,
it will shut off the solenoid valve 1 and the solenoid valve 2, turn on solenoid
valve 3 and start reverse pumping, which will make water in the system
drainaged through solenoid valve 3 by pumping.
2.2.2 STM-WR Working Principle
Cooling water outlet
To mould
Pressure meter
From mould
Cooling water inlet
Pressure switch
Pump
Filter 1
Thermal sensor
Solenoid valve 2
Heater
Mould
Ball valve
Ball valve
Filter 1
Solenoid valve 3
Structure characteristics and working principle

2.3 STM-304W Series Assembly Drawing
Structure characteristics and working principle

2.4 STM-304W Parts List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
NameNo. Part No. NameNo. Part No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
* means possible broken parts. ** means easy broken part. and spare backup is suggested.
F1301000
L2201000
-
E4128000
F1907004
F1330000
-
F1222000
D2210001
T3110011
T2107001
-
F1708000
F1804000
F1908000
A2200902
F1215001
-
-
T3235000
M3X5 thick-headed screw
Pressure gauge
Front panel
Operation panel
M5 Nut
M6X 15 lentil-headed screw
Electric-controlled ground plate
M8X20 Inner hexagon screw
Knob
Pressure gauge*
1 / 2 Teflon pipe connection
1 / 2 Teflon pipe connection
(Equipped with 1 4PT tooth
in the middle)
6 Flap gasket
6 Elastic washer
M6 Nut
Shock absorber
M6 Inner hexagon screw
Heating bucket mounting plate
Heating bucket
3/8'' Teflon pipe connection
Copper connection1
Electric heating pipe
shield
Mini cover board of
backboard planker
Backboard
Mini cover board of
backboard
D3403601
F1321000
-
-
T1214000
M3303010
-
T2211000
T3102001
T1260701
-
-
T2115003
-
Door holder
M6 10 Thick-headed
screw
Cover plate
Water pump (SPECK)*
M6 20 Inner hexagon
screw
Heating pipe ( )2'', 3kW *
Connection 1
3 / 8'' Electromagnetic
valve*
Copper connection 2
Clapboard
Beam
1 / 2 Teflon pipe connection
Ground plate
1 / 4'' Filtering valve*
T1260700
T3206000
-
-
-
Structure characteristics and working principle

2.5 STM-607W / 607WR / 607W-DAssembly Drawing
Structure characteristics and working principle