Shini STM-1220-PW, Manual

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

Page 2: ......

Page 3: ...nd Working Principle 18 2 1 Working Principle 18 2 2 Assembly Drawing 19 2 2 1 Assembly Drawing STM 607 PW 19 2 2 2 Parts List STM 607 PW 20 2 2 3 Assembly Drawing STM 1220 PW 21 2 2 4 Parts List STM 1220 PW 22 2 2 5 Pump 23 2 3 Electrical Diagram 24 2 3 1 Main Circuit STM PW 400V 24 2 3 2 Control Circuit STM PW 400V 25 2 3 3 Electrical Components Layout STM PW 400V 26 2 3 4 Electrical Components ...

Page 4: ...l Panel 40 4 2 Menu Introduction 43 4 3 Machine Startup 43 4 4 Parameter Reference Table 52 4 5 Stop the Machine 53 5 Trouble shooting 55 6 Maintenance and Repair 57 6 1 Open the Covers 57 6 2 Y Type Strainer 58 6 3 Solenoid Valve 59 6 4 Pipe Heater 59 6 5 Printed Circuit Board 60 6 6 Displayer Terminal Connecting Diagram 63 6 7 Maintenance Schedule 64 6 7 1 About the Machine 64 6 7 2 Installation...

Page 5: ... 3 Pump 23 Picture 2 4 Main Circuit STM PW 400V 24 Picture 2 5 Control Circuit STM PW 400V 25 Picture 2 6 Thermocouple and Terminal Layout STM PW 400V 26 Picture 2 7 Main Circuit STM PW 230V 29 Picture 2 8 Control Circuit STM PW 230V 30 Picture 2 9 Electrical Components Layout STM PW 230V 31 Picture 2 10 Thermocouple and Terminal Layout STM PW 230V 32 Picture 2 11 Overload Relay 35 Picture 3 1 Ins...

Page 6: ... 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 58 Picture 6 3 Open the Covers 3 58 Picture 6 4 Y Type Strainer 58 Picture 6 5 Solenoid Valve 59 Picture 6 6 Pipe Heater 1 59 Picture 6 7 Pipe Heater 2 59 Picture 6 8 Pipe Heater 3 60 ...

Page 7: ...ugh 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 HANYOUNG temperature controller can maintain...

Page 8: ...ntain a mould temperature with accuracy of 0 5 Adopts high efficiency water cycle pump which can meet the demands of temperature control for precise moulds and mould loop with minor diameter to achieve precise temperature control and high efficient heat exchange Pump inside adopts stainless steel to avoid explosion Multiple safety devices including power reverse phase protection pump overload prot...

Page 9: ...esponding professional experience The manual contains instructions for both handling and servicing 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 un...

Page 10: ...1220PW 160 12 1 0 1 0 50 50 8 5 8 7 77 1 3 2 0 8 Indirect 3 8 2 2 3 4 3 4 670 320 900 80 Note 1 PW stands for high temp water heater HPW stand for water We reserve the right to change heater with high temperature and high pressure stands for specifications without prior notice options 2 To ensure stable water temperature cooling water pressure should not be less than 2kgf cm2 but also no more than...

Page 11: ... between mould and environment safety coefficient heating duration 860 Note safety coefficient can select a value from 1 3 to 1 5 Flow Rate L min heater power kw 860 heating medium specific kcal kg heating medium density kg L in outlet temperature di fference time 60 Note Water specific heat 1kcal kg Heating medium oil specific heat 0 49kcal kg Water density 1kg L Heating medium oil density 0 842k...

Page 12: ...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 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 ...

Page 13: ...ator 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 should pay attention to From mould connector for circulating water oil coming from mould Pump pressure meter indicating actual pressure of system To m...

Page 14: ...lectricians 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 1 4 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 prob...

Page 15: ...ve 100 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 3 Do not rotate the machine and avoid collision with other objects during transportation to preve...

Page 16: ...hin 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 Fire...

Page 17: ...ility 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 2 Any incidents beyond human reasonable controls which include man made vicious or deliberate damages or abnormal power and machine faults caused by irresistible natural disasters including fire f...

Page 18: ...he machine will sound an alarm and halt If the temperature of the water exceeds the set value the system will automatically start the solenoid valve to let the cooling water come into the double pipes structure of the heating tank and cool down the water then a constant temperature can be maintained If the temperature still maintains high to the EGO set value the system will sound an alarm and hal...

Page 19: ...65 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 ...

Page 20: ...ssure on off controller 0 0 8MPa YE90000800000 12 Low pressure pipe 35 Hot water by pass pipe 13 Heating tank parts 36 Filling pipe connector parts 14 Cooling water inlet pipe 37 Cooling water by pass pipe 15 Water drainage pipe 38 Water drainage pipe parts 16 Y type filtering water valve 1 2 YW57010200000 39 Side plate 17 Copper core M13 1 2PT BH12131200010 40 Inner hexagon screw M10 30 YW6110300...

Page 21: ...21 65 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 ...

Page 22: ...arts 38 High pressure pipe 14 Cooling water inlet pipe 39 Low pressure on off controller 0 0 8MPa YE90000800000 15 Water drainage connector parts 40 Hot water by pass pipe 16 Filling pipe connector parts 41 Cooling water by pass pipe 17 Copper core M13 1 2PT BH12131200010 42 Water drainage pipe 18 Y type filtering water valve 1 2 YW57010200000 43 Side plate 19 Lentil headed screw M6 10 YW620610000...

Page 23: ...ames 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 ...

Page 24: ...24 65 2 3 Electrical Diagram 2 3 1 Main Circuit STM PW 400V Picture 2 5 Main Circuit STM PW 400V ...

Page 25: ...25 65 2 3 2 Control Circuit STM PW 400V Picture 2 6 Control Circuit STM PW 400V ...

Page 26: ...26 65 2 3 3 Electrical Components Layout STM PW 400V Picture 2 7 Thermocouple and Terminal Layout STM PW 400V ...

Page 27: ...A YE41001000000 11 T Transformer IN 400V OUT 230V 500mA YE70402300800 12 S1 Thermocouple 13 S2 S3 Thermocouple 14 S4 Overheat protector 15 S5 S7 Pressure switch 0 8bar YE90000800000 16 S6 Float switch YE59100000000 17 PC1 A Circuit board 100 240VAC 50 60Hz YE81100010000 18 Y1 Y2 Solenoid valve 230VAC 50 60Hz 19 X1 Terminal board YE61250040000 20 Terminal board YE61253500000 21 M1 Motor 400V 50Hz 0...

Page 28: ...2 S1 Thermocouple 13 S2 S3 Thermocouple 14 S4 Overheat protector 15 S5 S7 Pressure switch 0 8bar YE90000800000 16 S6 Float switch 17 PC1 A Circuit board 100 240VAC 50 60Hz YE59100000000 YE81100010000 18 Y1 Y2 Solenoid valve 230VAC 50 60Hz 19 X1 Terminal board YE61250040000 20 Terminal board YE61253500000 21 Terminal board YE61043500000 22 Terminal board YE61040000000 23 Terminal board YE6104350000...

Page 29: ...29 65 2 3 5 Main Circuit STM PW 230V Picture 2 8 Main Circuit STM PW 230V ...

Page 30: ...30 65 2 3 6 Control Circuit STM PW 230V Picture 2 9 Control Circuit STM PW 230V ...

Page 31: ...31 65 2 3 7 Electrical Components Layout STM PW 230V Picture 2 10 Electrical Components Layout STM PW 230V ...

Page 32: ...32 65 2 3 8 Thermocouple and Terminal Layout STM PW 230V Picture 2 11 Thermocouple and Terminal Layout STM PW 230V ...

Page 33: ... Thermocouple 11 S2 S3 Thermocouple 12 S4 Overheat protector 13 S5 S7 Pressure switch 0 8bar YE90000800000 14 S6 Float switch YE59100000000 15 PC1 A Circuit board 100 240VAC 50 60Hz YE81100010000 16 Y1 Y2 Solenoid valve 230VAC 50 60Hz 17 X1 Terminal board YE61250040000 18 Terminal board YE61253500000 19 Terminal board YE61040000000 20 Terminal board YE61043500000 21 M1 Motor 230V 50Hz 0 5kW 22 EH1...

Page 34: ...Thermocouple 12 S4 Overheat protector 13 S5 S7 Pressure switch 0 8bar YE90000800000 14 S6 Float switch YE59100000000 15 PC1 A Circuit board 100 240VAC 50 60Hz YE81100010000 16 Y1 Y2 Solenoid valve 230VAC 50 60Hz 17 X1 Terminal board YE61250040000 18 Terminal board YE61253500000 19 Terminal board YE61060000000 20 Terminal board YE61063500000 21 M1 Motor 230V 50Hz 1 5kW 22 EH1 Heater 230V 50Hz 12kW ...

Page 35: ...of overload relay if you can not press down the reset button wait for one minute Picture 2 12 Overload Relay 1 Terminal for contact coil A2 2 Setting current adjusting scale 3 Reset blue H manual reset A automatic reset 4 Switch position indication green Tripping of a manual resetting is indicated by a pin projecting from the front plate 5 Test button red 6 Auxiliary contact terminals shown in 95 ...

Page 36: ... 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 is usable for the operating temperature from 200 to 300 must use Teflon with temperature resistance 300 2 5 2 Installation steps for options water manifold welding ...

Page 37: ...nstall 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 is usable for the operating temperature from 200 to 300 must use Teflon with temperature resistance 300 ...

Page 38: ...ld cause inconvenience to operation maintenance and repair Do not sit on the machine Keep away flammable and explosive goods Picture 3 1 Installation Space 3 2 Mould and Water Coupling 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 fro...

Page 39: ...r 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 After that turn on water supply 3 3 Power Supply Make sure that power supply is the same as required before installation Mould heater are generally set to be used with 3Ф400V power supply or...

Page 40: ...starts Pls note that even if regulator is idle electrci shock may happen if power is on 3 MENU LCD menu shift key Initial password 3588 4 SET Parameters setting Confirm paramerters 5 SV Change set value Modify setting temp 6 Change parameters 7 Cursor movement 8 RUN RESET Control start and stop 9 AT AUTO TUNING switch start and stop Auto tuning can run during operation Auto tuning cannot work unde...

Page 41: ...d alarm relay are idle even error occurs 13 AUTO START Start and stop key 14 SUCTION OFF SUCTION relay switch start and stop Under SUCTION is on this key is to turn on or off SUCTION relay 15 F Not used for extension 16 HEAT Heating output MAIN display LED 17 SUB Heating output SUB display LED 18 COOL Cooling output display LED 19 PUMP_D Display pump running LED 20 PUMP_R Display pump inverse runn...

Page 42: ... water level check Activated Stop Appear on temperature display Sensor abnormality Activated Stop Dve1 alarm Deviation between control temp and entered temp Activated Maintain its status Dev2 alarm Deviation between control temp and retrieved temp Activated Maintain its status Turb Alarm Control temp is suddenly dropped Activated Maintain its status Heater alarm Control temp does not rise Activate...

Page 43: ...e 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 ...

Page 44: ... 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 Parameter setting is based on AT auto tuning Never change it privately ...

Page 45: ... 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 sensor increase it suitably if frequent alarms Return water deviation 0 ont opt for temp sensor ...

Page 46: ...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 Here is parameter setting ...

Page 47: ...key to return to menu screen then press keys to select temp setting press SET key to enter setting screen see picture below H LIMIT TEMP based on actual operation L LIMIT TEMP based on actual operation TEMP UNIT C elsius and Fahrenheit TEMP DEGREE 0 1 CTR TEMP BIAS based on actual operation RET TEMP BIAS based on actual operation ENT TEMP BIAS based on actual operation ...

Page 48: ... 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: ... 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: ...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: ...his 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 Maximum setting temperature of STM is 160 14 After setting desired value press RUN RESET key to begin temperature ...

Page 52: ...emp 50 500 Ret pv Retrieved water temp 50 500 Ent pv Entered water temp 50 500 Sv Control taget temp 50 500 50 Hout Amount of heating output 0 100 0 Cout Amount of cooling output 0 100 0 Pb Heating proportional band 0 550 20 Ti Integral time 1 3600s 240s Td Derivative time 1 3600s 60s Pbc Derivative time 0 550 20 Ct Time for heating output 1 100s 15s Ctc Time for cooling output 1 100s 15s Phase al...

Page 53: ...ensation 550 550 0 0 Current time Year month date day hour minute 99 12 31 mo su 24 59 Auto st week Mon tue wed thur fri sat sun Mo Su Auto st time Hour minute 24 59 0 Protocol Proto col Modbus rtu Modbus rtu Address Communication address 0 99 1 Bps Communication speed 4800 9600 19200 9600 Data length Data length 7 8 8 Stop bit Stop bit 1 2 1 Parity bit Parity bit None even odd None Language Selsc...

Page 54: ...tion 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: ... one minute then press the blue button to reset EGO overheat EGO temperature setting mistakes EGO poor temperature detecting Heater contactor K1 and K2 problems Correctly set EGO temperature EGO temperature setting value temperature setting value 10 Replace EGO Replace the contactor Low liquid level Oil shortage 0 Fill high temp oil Temp window displays Abnormal sensor Check and repair sensor Once...

Page 56: ...ms of circuit breaker Check electrical wire Replace circuit breaker Circuit breaker tripping off at turning on pump switch Pump motor coil short circuit Problems of circuit breaker Check pump motor Replace circuit breaker Circuit breaker trippingoff after short heater output Heater tube short circuit or shell contact Problems of circuit breaker Replace heater tube Replace circuit breaker ...

Page 57: ...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 service life of the system and prevent from safety accidents Please note that it is dangerous to check or tear down the machine during operation 6 1 Open the Covers 1 Open the top covers of the unit Refer to the pictures b...

Page 58: ... 3 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 3 Cleaning steps turn off power and cooling water supply Open the top cover of filter screen to clean the fi...

Page 59: ...e 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 Refer to pictures below Picture 6 7 Pipe Heater 2 3 Unlock the screws of pipe heater to take it out Refer to the pictures below ...

Page 60: ...al 15 16 EGO overheat contactor input terminal 17 18 underpressure contactor input terminal 19 20 overpressure contactor input terminal 21 22 lower water limit contactor input terminal 23 24 upper water limit contactor input terminal OUTPUT TERMINAL output terminal for controlling 1 2 heating control output MAIN RELAY output 3 4 heating control output SUB RELAY output 5 6 coling control output REL...

Page 61: ...eserve PHASE CHECK TERMINAL phase detect terminal 1 R phase connect terminal 2 S phase connect terminal 3 T phase connect terminal DISPLAY CN connect terminal for dispaly Connect stub cable with STM100 POWER TERMINAL power supply terminal 1 FG terminal 2 3 power supply terminal 100 240VAC ...

Page 62: ...62 65 ...

Page 63: ...rminal Connecting Diagram DI TERMINAL 1 2 Run stop di terminal COMM TERMINAL 1 2 3 4 rs485 Comm terminal 5 Earth terminal MAIN CN Connet to the electric cables which also connected with stm100 TEST PIN Test pin No connection ...

Page 64: ... Daily Checking Check machine startup function Check all the electrical wires 6 7 4 Weekly Checking Check loose eletrical connections Check and clean Y type filter 1 Check solenoid valve Check motor overload and phase reversal alarm function Check whether pipeline joints are under looseness Check the sensitivity of EGO 6 7 5 Trimonthly Checking Check level switch Check the contactor 2 Replace the ...

Page 65: ...lion four hundred thousand times if work eight hours per day recommended replacing frequency is 1 5 years if work day and night replacement is suggested to be done every six months 3 Hot kerosene coke will influence the detection accuracy of internal temperature probe and the efficiency of heat elements three months replacing frequency is suggested 4 Hot kerosene coke will influence the detection ...