Shini STM-PW series User Manual Download

Page: 1 / 69

Date : June. 2009

Version : V2.3 (English)

STM-PW

series

Hi-Temp. Water Heaters

Summary of Contents for STM-PW series

Page 1: ...Date June 2009 Version V2 3 English STM PW series Hi Temp Water Heaters ...

Page 2: ......

Page 3: ...Signs and Labels Operation Regulations Installation Installation Space Mould and Water Couplings Power Supply Operation Guide Check Before Starting Start the Machine Stop the Machine Temperature Controller Service Maintenance Open the Covers Y Type Strainer Solenoid Contents Contents ...

Page 4: ...Contents 7 5 The Useful Life of The Key Parts of The Product ...

Page 5: ...aintain 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 OMRON temperature c...

Page 6: ...ng water flow 8 Upon request it can be built to comply with worldwide electrical safety standards For example CE UL CSA JIS etc o 1 C 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 ch...

Page 7: ...cifications 2 1 1 Specifications Pum Performance curve p Pipe heater 6 kW Pump power 0 55 0 63 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 160 Flow rate L min 2 1 2 Outer dimensions pressure Bar ...

Page 8: ...2 2 Optional STM 910 PW Outer demensions 765 2 Technical Specifications Pum Performance curve p 10 30 40 50 60 70 Flow rate L min pressure Bar ...

Page 9: ...2 3 Optional STM 1220 PW Specifications Outer demensions 2 Technical Specifications Pum Performance curve p 8 6 4 2 20 60 80 100 120 140 Flow rate L min pressure Bar 10 ...

Page 10: ... tolerance for either max flowrate or max pressure 4 Power supply 3 230 400 460 575V 50 60Hz model Max temp STM 607 PW STM 910 PW STM 1220 PW 160 Heater kw 6 9 Pump kw 50 60Hz 0 55 0 63 0 75 0 92 Max pump flow L min 50 60Hz 27 30 42 50 Max pump pressure bar 50 60Hz 3 8 5 0 5 0 6 4 6 2 7 2 Heating chamber number 1 1 1 Heating cooling tank L 3 4 2 0 Cooling method Indirect Mould coupling inch 3 8 2 ...

Page 11: ...stant temp of process water Owning to aximum 160 by a high pressure ptimizing design m 1 o of process water could be supplied OMRON temperature controller is installed to ensure water temp within the accuracy of Uni directional cut off valve Pressure switch 1 Filter Cooled water inlet Cooling electromagnetic valve Ball valve Liquid level switch Cooler Safety valve Water replenishing electromagneti...

Page 12: ...ooled water will enter the system to cool water at high temperature indirectly and reduce its temperature by which the purpose of maintaining constant temperature is achieved If water is still at high temperature and maintains at the level of the set EGO temperature system will start up high temperature alarm and stops working When system pressure arrives at set value of safety valve safety valve ...

Page 13: ...elocation Components from our company can only be used for replacement Warning Do not touch the switch with wet object 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 m...

Page 14: ...ng capacity of the machine 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 High voltage Electrical shock may happen Carefulness is required from the operator Attentions This is general warnings which operators s...

Page 15: ...ing 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...

Page 16: ...ation and for a short distance it can be transported with temperature under 70 Storage 1 STM PW series standard oil heaters should be stored indoors with O O 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...

Page 17: ...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 Fire hazard 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 oper...

Page 18: ...ep 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 Do not sit on the machine Keep away flammable and explosive goods ...

Page 19: ...Figure 5 2 2 2 3 Figure 5 2 1 Figure 5 2 2 Figure 5 2 3 1 It is necessary while connecting from the access to mould to use two spanners to fix the switching connection and ball valve before screw tightly the horn nut of the connection pipe otherwise water might leaks from the machine Figure 5 2 1 Note Cooling water inlet and outlet as shown by the Figure 5 2 3 Please do not connect reversely Pleas...

Page 20: ...on 5 3 Power Supply Make sure that power supply is the same as required before installation Mould heaters are generally set to be used with 3 400V power supply or other specifications according to customers requirement ...

Page 21: ...t the machine with power supply and turn on main switch This indicator turns green When phase reversal or phase shortage occurs it becomes red The buzzer sounds and system stop working Note Do not remove any electrical parts or terminals after the power is on Turn off the machine Exchange the place of two of the electrical wires of main power supply ...

Page 22: ... higher than EGO temperature sensor setting value this indicator becomes red The buzzer sounds and system stops working EGO setting value should be higher than temperature settings of temperature controller Check if there are problems of temperature detecting probe 5 Low level alarm When there is circulating water shortage the alarm light will become red The buzzer sounds and system stops working ...

Page 23: ...5 2 for details 3 Turn all the ball valves on 4 Turn on the main power switch 5 Turn on the pump switch to start the pump 6 Turn on the heater switch 7 Set mould temperature if it is already set neglect this step Press to set the temperature For STM PW series maximum temperature setting value is 160 8 Overtemperature setup for system cooling set as 1 before delivery which means that whenever actua...

Page 24: ...be careful of electrical shock Note Pump motor rotating direction should be the same as indicated Note In order to prolong machine life please do as above steps to turn on and off the machine 6 3 Stop the Machine 1 Switch off heater power 2 Wait until oil temperature falls below 50 turn off pump switch 3 Turn off main switch ...

Page 25: ...s not used on this unit ALM3 alarm 3 Alarm 3 function is not used on this unit HB heater break When heater break is detected this indicator will become bright OUT1 output control 1 OUT1 is used for heating control When it is bright it means that pipe heater is working OUT2 output control 2 OUT2 is used for cooling control When it is bright cooling water valve is open and cooling function is in pro...

Page 26: ...ent screen shows the last parameter 2 Press and to adjust the value of parameters Keep the parameter unchanged for at least 2 seconds or press to confirm your setting Menu press this key to show the items you want to reset mode press this key to choose a parameter increase value press this key to increase setting value decrease value press this key to decrease setting value 6 Operation Guide ...

Page 27: ... Before delivery the parameters of temp controller are set already Do not reset the parameters unless it is necessary 3 4 Before power supply is cut off press to confirm your setting Confirm your setting when changing to another menu ...

Page 28: ...ote that it is dangerous to check or tear down the machine during operation 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 2 It is necessary to carry out periodic inspections in order to prolong ...

Page 29: ...nt 4 Install the covers in a reverse order 7 2 Solenoid valve 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 3 Cleaning steps turn off power and cooling water sup...

Page 30: ...ar cover door Refer to pictures below 2 Unlock heater cap Refer to pictures below 3 Unlock the screws of pipe heater to take it out Refer to the pictures below 4 Install the pipe heater in a reverse order 7 3 7 Service and Maintenance ...

Page 31: ...7 4 7 Service and Maintenance 7 5 The Useful Life of The Key Parts of The Product ...

Page 32: ...ower supply low voltage Phase shortage Phase reversal Check power supply Check power supply Exchange two of the wires of power supply Abnormal fluctuations of power supply Pump blocked Pump motor problems Overload relay F1 setting value error Check power supply Check the pump Check pump motor Set the setting current of overload relay to equal to 1 1 times of motor rated current Please refer to pag...

Page 33: ...incorrect parameters with reference to chapter 6 5 Replace solenoid valve 9 Temperature can t rise up Heater contactor problems Heater problems Thermocouple problems Temperature controller operation mode set to STOP Temperature output problems Replace the contactor Replace pipe heater Replace thermocouple Set temperature controller to working mode Replace or repair temperature parameters 10 Circui...

Page 34: ...9 1 9 Assembly Drawing and Parts List 9 Assembly Drawing and Parts List ...

Page 35: ...9 2 607 P 9 Assembly Drawing and Parts List ...

Page 36: ...peration panel Alternation switch Circuit board buzzer Side plate Back plate of electric control box M8X20 Inner hexagon screw Beam Clapboard Inlet pressure switch Covering plate Back plate Pressure gauge splint Pressure gauge Cooling pipe Mini cover board of backboard planker Mini cover board of backboard PT 1 4 PT Ltype Teflon pipe connection Safety valve connection ...

Page 37: ...ering valve Core Electric heat tube unit M10x25 Inner hexagon screw Electric heat tube shield Release electromagnetic valve Thermocouple 4 4 PT H Teflon pipe connection Stainless steel elbow Pumping Stainless steel ball valve 1 2 PT H Teflon pipe connection Release valve switch 3 4 3 4 PT H Teflon pipe connection L type 1 2 Cut off valve 1 2 PT H Teflon pipe connection L type Connection Electronic...

Page 38: ...Ground plate EGO EGO mounting panel Rib reinforcement Plastic core rubber tires Fan 1 4 8 PT 3 H copper connection with external teeth at the two ends L type Indicates latent wearing parts Indicates latent wearing parts and it s suggested to back them up ...

Page 39: ... 910 P 9 6 9 Assembly Drawing and Parts List ...

Page 40: ...peration panel Alternation switch Circuit board buzzer Side plate Back plate of electric control box M8X20 Inner hexagon screw Beam Clapboard Inlet pressure switch Covering plate Back plate Pressure gauge splint Pressure gauge Cooling pipe Mini cover board of backboard planker Mini cover board of backboard PT 1 4 PT Ltype Teflon pipe connection Safety valve connection ...

Page 41: ...ring valve Core Electric heat tube unit M10x25 Inner hexagon screw Electric heat tube shield Release electromagnetic valve Thermocouple 4 4 PT H Teflon pipe connection 4 Stainless steel elbow Pumping Stainless steel ball valve 1 2 PT H Teflon pipe connection Release valve switch 3 4 3 4 PT H Teflon pipe connection L type 1 2 Cut off valve 1 2 PT H Teflon pipe connection L type Connection Electroni...

Page 42: ...Ground plate EGO EGO mounting panel Rib reinforcement Plastic core rubber tires Fan 1 4 8 PT 3 H copper connection with external teeth at the two ends L type Indicates latent wearing parts Indicates latent wearing parts and it s suggested to back them up ...

Page 43: ... 1220 P 9 10 9 Assembly Drawing and Parts List ...

Page 44: ...peration panel Alternation switch Circuit board buzzer Side plate Back plate of electric control box M8X20 Inner hexagon screw Beam Clapboard Inlet pressure switch Covering plate Back plate Pressure gauge splint Pressure gauge Cooling pipe Mini cover board of backboard planker Mini cover board of backboard PT 1 4 PT Ltype Teflon pipe connection Safety valve connection ...

Page 45: ...tering valve Core Electric heat tube unit M10x25 Inner hexagon screw Electric heat tube shield Release electromagnetic valve Thermocouple 1 PT 1 H Teflon pipe connection 1 Stainless steel elbow Pumping Stainless steel ball valve 1 2 PT H Teflon pipe connection Release valve switch 1 PT 1 H Teflon pipe connection L type 1 2 Cut off valve 1 2 PT H Teflon pipe connection L type Connection Electronic ...

Page 46: ... Ground plate EGO EGO mounting panel Rib reinforcement Plastic core rubber tires Fan 1 4 8 PT 3 H copper connection with external teeth at the two ends L type Indicates latent wearing parts Indicates latent wearing parts and it s suggested to back them up ...

Page 47: ...1 2 3 4 5 6 7 8 9 10 9 14 9 Assembly Drawing and Parts List 1 Pump body 2 Sleeve 3 O shape ring 4 Key 5 Pump cover 6 Socket cap screw 7 Neck ring 8 Mechanical seal 9 Rotary ring 10 Motor ...

Page 48: ...20PW 1 5 1 5 1 5 0 5 0 75 1 5 6 0 9 0 12 0 1 8 2 3 4 7 9 1 13 5 2 5 2 5 18 4 0 10 9 15 8 22 7 2 5 4 0 6 0 16 25 32 16 25 32 2 0 2 5 5 1 1 3 5 2 4 6 SYMBOL MODE 2 2 C1 3 2 A1 0 75mm 2 T 400V 230V F11 1 2 1 2 1 PE L1 L2 L3 3 PE W1 U1 V1 F1 6 5 4 3 2 1 M1 Q1 A SET A L11 L12 L13 IN A kW PUMP MOTOR 6 5 4 3 2 1 PE IN A kW EH1 HEATER U2 V2 W2 K1 K2 b c e f g h i j k mm 2 mm 2 mm 2 1 3 5 2 4 6 1 3 5 2 4 6...

Page 49: ... 1 3 K3 9 5 9 Y2 2 3 Fan S1 2 1 4 5 S2 2 1 5 4 FM 4 3 S3 X X 2 P C1 C2 Q2 25 1 5 X X 0 75mm 2 21 22 COM 1 2 3 4 L3 L2 L1 G OUT AC1 AC0 CN4 CN1 CN2 CN3 Excitation Break Away 1 B4 1 B3 K8 A2 A1 Middle Relay 5 9 K8 7 8 K7 43 8 X 1 L23 L22 L21 P 5 X S4 23 44 6 K1 97 98 F1 K3 K3 K5 K5 12 13 14 20 24 2 1 AC110 240V CONTACTOR HEATER 6 5 OUT1 4 3 OUT2 19 20 13 14 X X A1 A2 K1 A2 A1 96 95 F1 K1 Y1 Main mot...

Page 50: ... directly 1 2 3 7 PE 8 9 PE 10 11 12 PE 4 5 6 PE 2 1 4 3 L1 L2 L3 PE PE 15 16 17 P 2 1 5 PE P S3 S4 1 5 Overheat Protector Hydraulic Switch 1 2 PE Y1 1 2 PE Y2 Valve Solenoid Cool Valve 1 2 3 4 Switch Float 4 12 8 10 17 2 PE 11 2 PE 4 25 4 11 13 14 PE PE 1 5 PE P S5 1 5 Hydraulic Switch 22 24 Outside Inside Exhaust Solenoid X PE PE PE PE S7 Thermocouple Connect with control board ground wire Conne...

Page 51: ...10 4 10 Electrical Circuit 10 1 4 Electrical components layout up on K1 A2 A1 K2 up on K5 K3 K4 A2 F1 Q2 T K6 O I O I S1 S2 PC OFF K7 Q1A2 A1 X K8 F11 ...

Page 52: ...Float Switch Circuit Board Solenoid Valve Terminal Board Terminal Board Motor Heater Fan 16A 16A 230V 50 60Hz 230V 50 60Hz 1 6 2 5A IN 400V OUT 230V 500mA 32A 2P 2A 4P WH 230VAC 50 60Hz 230VAC 50 60Hz 230VAC 50 60Hz 250V 5 4 A AC 230V 12A 230VAC 50 60Hz 230VAC 50 60Hz 400V 50Hz 0 5kW 400V 50Hz 230V 50 60Hz E1416000 E3121030 E3121010 E1130100 E1140102 E1140012 E1131000 E1216250 E3305000 E3232002 E3...

Page 53: ...1130100 E1140102 E1140012 E1131000 E1202320 E3305000 E3232002 E3205002 E1304000 E2105000 E2208004 E5202000 E5204000 T3110010 T3110009 E2304002 E5104001 E5104004 E5125001 E5125002 Symbol Name Specifications Part No NO Main switch Circuit_breakers Excitation Break Away Contactors Auxiliary contact terminal Auxiliary contact terminal Contactors Overload Relays Transformer Fuse box Fuse Control Switch...

Page 54: ...7 26 27 EH1 FM Heater Fan 400V 50Hz 230V 50 60Hz Symbol Name Specifications Part No NO Indicates latent wearing parts Indicates latent wearing parts and it s suggested to back them up 10 Electrical Circuit ...

Page 55: ...140012 E1131000 E1204631 E3305000 E3232002 E3205002 E1304000 E2105000 E2208004 E5202000 E5204000 T3110010 T3110009 E2304002 E5106002 E5106004 E5104004 E5125001 E5125002 Symbol Name Specifications Part No NO Main switch Circuit_breakers Excitation Break Away Contactors Auxiliary contact terminal Auxiliary contact terminal Contactors Overload Relays Transformer Fuse box Fuse Control Switch Temperatu...

Page 56: ...Eh1 FM Heater Fan Motor 400V 50Hz 1 5kW 400V 50Hz 230V 50 60Hz Symbol Name Specifications Part No NO Indicates latent wearing parts Indicates latent wearing parts and it s suggested to back them up 10 Electrical Circuit ...

Page 57: ...cts are shown in position 95 96 and 97 98 repectively 7 Main circuit connection No must be correspond with terminal Number of contactor 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...

Page 58: ... Installation Check the installation space is enough as required Check the pipes are correctly connected Electrical installation Voltage V Hz Fuse melting current 1 Phase A 3 Phase A Check phase sequence of power supply 11 Maintenance Schedule Total power Frequency 11 Maintenance Schedule ...

Page 59: ...s Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup func...

Page 60: ...heck all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wire...

Page 61: ...chine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check all the electrical wires Check machine startup function Check...

Page 62: ...rical connections Check and clean Y type strainer Check solenoid valve Check motor overload and phase reversal alarm function Check machine startup function Check all the electrical wires Check loose electrical connections Check and clean Y type strainer Check solenoid valve Check motor overload and phase reversal alarm function Check machine startup function Check all the electrical wires Check l...

Page 63: ...ections Check and clean Y type strainer Check solenoid valve Check motor overload and phase reversal alarm function Check machine startup function Check all the electrical wires Check loose electrical connections Check and clean Y type strainer Check solenoid valve Check motor overload and phase reversal alarm function Check machine startup function Check all the electrical wires Check loose elect...

Page 64: ...ections Check and clean Y type strainer Check solenoid valve Check motor overload and phase reversal alarm function Check machine startup function Check all the electrical wires Check loose electrical connections Check and clean Y type strainer Check solenoid valve Check motor overload and phase reversal alarm function Check machine startup function Check all the electrical wires Check loose elect...

Page 65: ... loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y ...

Page 66: ...ectrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type strainer Clean solenoid valve Check loose electrical connections Check and clean Y type stra...

Page 67: ...k damaged pipes Check and clean Y type strainer Clean solenoid valve Check damaged pipes Check and clean Y type strainer Clean solenoid valve Check damaged pipes Check and clean Y type strainer Clean solenoid valve Check damaged pipes Check and clean Y type strainer Clean solenoid valve Check damaged pipes Check and clean Y type strainer Clean solenoid valve Check damaged pipes Check and clean Y t...

Page 68: ...nctions or damages resulting from not complying with the recommended manner as outlined in our operation manual in relation with the application installation operation and maintenance b Defects from using wrong electrical supply misuse or damage by negligence and abuse c Malfunctions or damages resulting from natural disaster fire civil unrest and or accidents d Wear parts and accessories 7 If you...

Page 69: ...1 Shini Road Dalang Dongguan Guangdong China Tel 0769 8331 3588 Fax 0769 8331 3589 Corporate e mail shini shini com Corporate internet www shini com 10 The warranty is deemed valid only if the followings are completely filled in Purchaser s name and address Your supplier s name and address Date of purchase Serial number 11 12 Local Warranty Statement ...

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