STM-E ''Standard'' Heater

STM-E ''Standard'' Heater Date: Apr. 2013 Version: Ver.B (English)

Contents 1. General Description... 7 1.1 Coding Principle... 8 1.2 Feature... 8 1.3 Technical Specifications... 10 1.3.1 Specification... 10 1.3.2 Pump Performance... 11 1.3.3 Reference Formula of Mould Controllers Model Selection... 11 1.4 Safety Regulations... 12 1.4.1 Safety Signs and Labels... 12 1.4.2 Signs and Labels... 13 1.4.3 Operation Regulations... 14 1.5 Exemption Clause... 14 2. Structure Characteristics and Working Principle... 16 2.1 Working Principle... 16 2.2 Assembly Drawing... 18 2.2.1 System Structure Drawing (STM-405E)... 18 2.2.2 Parts List (STM-405E)... 19 2.2.3 Heating Tank Assembly (STM-405E)... 20 2.2.4 Parts List (STM-405E)... 21 2.2.5 Cooling Water Inlet Connecting Assembly (STM-405E)... 22 2.2.6 Parts List (STM-405E)... 22 2.2.7 Cooing Water Outlet Connecting Assembly (STM-405E)... 23 2.2.8 Parts List (STM-405E)... 23 2.2.9 System Structure (STM-405N-WE)... 24 2.2.10 Parts List (STM-405N-WE)... 25 2.2.11 Pump... 26 2.3 Electrical Diagram... 27 2.3.1 Main Circuit (STM-405E)... 27 2.3.2 Control Circuit (STM-405E)... 28 2.3.3 Ternimal Connection (STM-405E)... 29 2.3.4 Electrical Components Layout (STM-405E)... 30 3(57)

2.3.5 Electrical Components List (STM-405E)... 31 2.3.6 Main Circuit (STM-405N-WE)... 32 2.3.7 Control Circuit (STM-405N-WE)... 33 2.3.8 Ternimal Connection (STM-405N-WE)... 34 2.3.9 Electrical Components Layout (STM-405N-WE)... 35 2.3.10 Electrical Components List (STM-405N-WE)... 36 2.4 Main Electrical Components Description... 37 2.4.1 Thermal Overload Relay... 37 2.5 Operation Procedures... 38 2.5.1 Installation steps for options water manifold (dewaxing)... 38 2.5.2 Installation steps for options water manifold (welding)... 38 3. Installation and Debugging... 40 3.1 Installation Space... 40 3.2 Mould and Water Coupling... 41 3.3 Power Supply... 42 4. Operation Guide... 43 4.1 Control Panel... 43 4.2 Machine Startup... 44 4.3 Machine Shutdown... 45 4.4 Temperature Controller... 46 4.4.1 Temperature Controller Display... 46 4.4.2 Keys on Control Panel... 47 4.4.3 Choose a Parameter... 48 4.4.4 Confirm the Setting... 48 5. Trouble-shooting... 49 6. Maintenance and Repair... 51 6.1 Open the Covers... 51 6.2 Y Type Strainer... 52 6.3 Solenoid Valve... 53 6.4 Pipe Heater... 53 6.5 Cooling Pipe... 54 6.6 Maintenance Schedule... 56 6.6.1 About the Machine... 56 4(57)

6.6.2 Installation & Inspection... 56 6.6.3 Daily Checking... 56 6.6.4 Weekly Checking... 56 6.6.5 Trimonthly Checking... 56 6.6.6 Half-yearly Checking... 56 6.6.7 Yearly Checking... 57 6.6.8 3 year Checking... 57 Table Index Table 1-1:Specification...10 Table 2-1: Parts List (STM-405E)...19 Table 2-2: Parts List (STM-405E)...21 Table 2-3: Parts List (STM-405E)...22 Table 2-4: Parts List (STM-405E)...23 Table 2-5: Parts List (STM-405N-WE)...25 Table 2-6: Electrical Components List (STM-405E)...31 Table 2-7: Electrical Components List (STM-405N-WE)...36 Picture Index Picture 1-1:Pump Performance...11 Picture 2-1:Working Principle...16 Picture 2-2:Working Principle...17 Picture 2-3:System Structure Drawing (STM-405E)...18 Picture 2-4:Heating Tank Assembly (STM-405E)...20 Picture 2-5:Cooling Water Inlet Connecting Assembly (STM-405E)...22 Picture 2-6:Cooling Water Outlet Connecting Assembly (STM-405E)...23 Picture 2-7: System Structure (STM-405N-WE)...24 Picture 2-8: Pump...26 Picture 2-9: Main Circuit (STM-405E)...27 Picture 2-10: Control Circuit (STM-405E)...28 Picture 2-11: Ternimal Connection (STM-405E)...29 Picture 2-12: Electrical Components Layout (STM-405E)...30 5(57)

Picture 2-13: Main Circuit (STM-405N-WE)...32 Picture 2-14: Control Ciruit (STM-405N-WE)...33 Picture 2-15: Ternimal Conection (STM-405N-WE)...34 Picture 2-16: Electrical Components Layout (STM-405N-WE)...35 Picture 2-17: Thermal Overload Relay...37 Picture 3-1: Installation Space...40 Picture 3-2: Mould and Water Coupling 1...41 Picture 3-3: Mould and Water Coupling 2...41 Picture 3-4: Mould and Water Coupling 3...42 Picture 4-1: Control Panel...43 Pictuer 4-2: Machine Startup...45 Picture 4-3: Control Panel...46 Picture 4-4: Choose a Parameter...48 Picture 6-1: Open Cover 1...52 Picture 6-2: Open Cover 2...52 Picture 6-3: Open Cover 3...52 Picture 6-4: Y Type Strainer...53 Picture 6-5: Solenoid Valve...53 Picture 6-6: Pipe Heater 1...53 Picture 6-7: Pipe Heater 2...54 Picture 6-8: Pipe Heater 3...54 Picture 6-9: Cooling Pipe 1...54 Picture 6-10: Cooling Pipe 2...55 6(57)

1. General Description Read this manual carefully before operation to prevent damage of the machine or personal injuries. STM-E (WE) series are applicable for heating up the moulds and maintaining temperature, and they also can be used in other similar applications. Firstly, these series adopt different cooling methods to cool down mediums, then mediums are conveyed to the moulds after pressurized by pump and heated up by electrical heated tube. The optimal design renders water be heated up to 120 and oil up to 150. Model: STM-405WE 7(57)

1.1 Coding Principle 1.2 Feature 1) Standard configuration P.I.D. multi-stage temperature control system can maintain a mould temperature with accuracy of ±1. Adopts high efficiency high temperature pump to achieve high efficient heat exchange. Multiple safety devices including power reverse phase protection, pump overload protection, overheat protection and low level protection that can automatically detect abnormal performance and indicate this via visible alarm. STM-E is equipped with low level protection. STM-WE is equipped with water inlet low pressure protection, system high pressure protection, automatic air exhaust and water supplying. 2) Accessory option Water manifolds, Teflon hose and Transfer oil are optional. 8(57)

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 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. 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: (886) 2 2680 9119 Shini Plastics Technologies (Dongguan), Inc: Tel: (86) 769 8111 6600 Shini Plastics Technologies India Pvt.Ltd.: Tel: (91) 250 3021 166 9(57)

1.3 Technical Specifications 1.3.1 Specification Table 1-1:Specification Model Max. Temp. Pipe Heate r (kw) Pump Power (kw) Max. pump Flow (L / min) Max. pump Pressure (bar) Heating Tank Number Main / Sub. Oil Tank (L) Water Heating Tank Capacit y (L) Coolin g Metho d Mould Coupling* STM-405E 150 4 0.37 23.5 3 1 4.6 / 3.3 - Indirect 3/8" (2 2) STM-405N- WE (inch) 120 4 0.37 23.5 3 1-2.3 Direct 3/8" (2 2) Note: 1) Pump testing standard: Power of 50/60Hz, purified water at 20. (There is ±10% tolerance for either max. flow rate or max. pressure). 2) "*" stands for options. 3) Power supply: 3Φ, 230 / 400 / 460 / 575VAC, 50 / 60Hz. Dimensions Inlet/Outlet Weight (mm) (inch) (kg) (H W D) 3 / 4 / 3 / 4 575x325x530 44 3 / 4 / 3 / 4 575x285x505 33 10(57)

1.3.2 Pump Performance Picture 1-1:Pump Performance 1.3.3 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. Flow Rate (L/min) = heater power (kw) 860 / [heating medium specific (kcal/kg ) heating medium density (kg/l) in/outlet temperature difference ( ) time (60)] Note: Water specific heat =1kcal/kg Heating medium oil specific heat =0.49kcal/kg Water density =1kg/L Heating medium oil density =0.842kg/L 11(57)

1.4 Safety Regulations Strictly abide by the following safety regulations to prevent damage of the machine or personal injuries. 1.4.1 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. 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 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 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. 12(57)

Warning! High temperature, take care of hands! This label is attached on the surface of heating parts. 1.4.2 Signs and Labels Clean the filter screen of Y type strainer timely to avoid obstruction which may affect machine performance. It is used for oil heater. Max. temperature setting of this unit is 200. 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 should pay attention to. From mould: connector for circulating water/oil coming from mould. 13(57)

To mold: connector for circulating water/ oil to go to mould. 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. Water inlet: inlet for replenishing water and cooling water. Water outlet: drainage outlet. 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 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. 1.5 Exemption Clause 14(57)

The following statements clarify the responsibilities and regulations born by any buyer or user who purchases products and accessories from 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. 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, flood, storm and earthquake. 3. Any operational actions that are not authorized by Shini upon machine, including adding or replacing accessories, dismantling, delivering or repairing. 4. Employing consumables or oil media that are not appointed by Shini. 15(57)

2. Structure Characteristics and Working Principle 2.1 Working Principle 2.1.1.1 System flow for STM-405E (Indirect Cooling) Picture 2-1:Working Principle The high temperature oil returns to the machine and then be pressured by pump to the heater. After being heated, oil will be forced to the mould and continue the circle. In the process, if the temp. is too high, the system will activate the solenoid valve to let cooling water lower the temperature indirectly until the it reaches the system requirement. If the temperature keeps increasing and reaches the set point of EGO, the system will alarm and stop operation. The system will sound low level alarm and stop working if oil level falls down below the set point. 16(57)

2.1.1.2 System flow for STM-405N-WE (Direct Cooling) Picture 2-2:Working Principle The high temperature water returns from the mould to the temperature controller machine is pressurized by pump and conveyed to the heater. After being heated, it will be again flow to the mould to maintain the temperature, and this circle repeats. In the process, if water temperature is too high, system will activate the solenoid valve to let cooling water directly cool down the high temperature water to maintain constant temperature. If the temperature keeps increasing and reaches to the set point of EGO, machine starts high temperature alarm and halts; if system pressure is too high and reaches the set value of high pressure switch, system will launch high pressure alarm and 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. 17(57)

2.2 Assembly Drawing 2.2.1 System Structure Drawing (STM-405E) Remarks: Please refer to material list 2.2.2 for specific explanation of the Arabic numbers in parts drawing. Picture 2-3:System Structure Drawing (STM-405E) 18(57)

2.2.2 Parts List (STM-405E) Table 2-1: Parts List (STM-405E) No. Name Parts No. No. Name Parts No. 1 Black rubber caster 2 YE03000200000 19 2 Thick head screw M4 6 YW63040600000 20 Aluminum oil pipe cap EGO (with no plastic box) BH12030403040 BH90115000150 3 Flat head screw M6 15 YW63061700000 21 Breaker platen - 4 Electrical supporting plate - 22 Hexagon screw M5 YW64000600000 5 Cover plate - 23 Operation panel - 6 Plastic operation panel YR40009500000 24 Rack - 7 Flat head screw M6 10 YW62061000000 25 8 Oil exhast coupling - 26 Copper flared joint 3/4 H 1/2 PT 55 Outer hexagobalbolt M8 25 BH12030401010 YW60082500300 9 Copper male connector - 27 Hexagon nut M8 YW64080600000 10 11 12 Cooling water inlet coupling Cooling water outlet copling Thermocouple oil type (short) - 28-29 13 Oil outlet - 31 14 Liquid level indicator base Flat washer 8 16 1.5 Spring washer 8mm YW66081600000 YW65008000100 BE90100000150 30 Pump TP-37 BM20023450050 Hexagon socket head cap screw M10 25 YW61102500000 BW20000001010 32 Flat washer 10 YW66102500000 15 Glass tube YW70961400000 33 Spring washer 10 YW65010000000 16 17 Liauid level indicator male connector Liquid level indicator screw BH12010406210 34 Hexagon nut M10 YW64001000300 BH12060700110 35 Copper flared joint 3/4 H 1/2 PT 75 BH12030401110 18 Heating tank assembly - * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. 19(57)

2.2.3 Heating Tank Assembly (STM-405E) Remarks: Please refer to material list 2.2.4 for specific explanation of the Arabic numbers in parts drawing. Picture 2-4:Heating Tank Assembly (STM-405E) 20(57)

2.2.4 Parts List (STM-405E) Table 2-2: Parts List (STM-405E) No. Name Parts No. No. Name Parts No. 1 Cover plate of change-over switch 2 Microswitch YE14152400000 14 3 Screw M5 YW64000600000 15-13 Heating tank - Stainless steel pipe bundle 4.5 Flat heat screw M6 10 YW02004500000 YW62061000000 4 Flat head screw M5 30 YW60530000000 16 Screw 1/2PT BH12010200510 5 6 Heat insulation gasket of liquid level indicator Copper Teflon pipe coupling 1/4H 1/4PT YR10109000000 17 Heater set - BH12010400410 18 Cooling pipe set - 7 Nut M6 YW64000600300 19 Floating ball - 8 Heater cover BL80091000120 20 9 Socket head cap screw M10 25 YW61102500000 21 10 Flat washer 10 25 YW66102500000 22 11 Spring washer 10 YW65010000000 23 Heating tank wrapper sheet 1 Heating tank wrapper sheet 2 Cooling tank wrapper sheet 1 Cooling tank wrapper sheet 2 Flexible graphite washer 12 YR20121200000 120 120 2.0mm * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. - - - - 21(57)

2.2.5 Cooling Water Inlet Connecting Assembly (STM-405E) Remarks: Please refer to material list 2.2.6 for specific explanation of the Arabic numbers in parts drawing. Picture 2-5:Cooling Water Inlet Connecting Assembly (STM-405E) 2.2.6 Parts List (STM-405E) Table 2-3: Parts List (STM-405E) No. Name Parts No. No. Name Parts No. 1 Cooling water inlet/outlet connector - 3 2 Copper nipple 3/8" BH12030800110 4 Solenoid valve 3/8" Copper Teflon pipe coupling 3/8H 3/8PT YE32213100000 BH12030800610 * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. 22(57)

2.2.7 Cooing Water Outlet Connecting Assembly (STM-405E) Remarks: Please refer to material list 2.2.8 for specific explanation of the Arabic numbers in parts drawing. Picture 2-6:Cooling Water Outlet Connecting Assembly (STM-405E) 2.2.8 Parts List (STM-405E) Table 2-4: Parts List (STM-405E) No. Name Parts No. No. Name Parts No. Copper Teflon Cooling water 1-2 pipe coupling BH12030800610 inlet/outlet connector 3/8H 3/8PT * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. 23(57)

2.2.9 System Structure (STM-405N-WE) Remarks: Please refer to material list 2.2.10 for specific explanation of the Arabic numbers in parts drawing. Picture 2-7: System Structure (STM-405N-WE) 24(57)

2.2.10 Parts List (STM-405N-WE) Table 2-5: Parts List (STM-405N-WE) No. Name Parts No. No. Name Parts No. 1 Thick head screw M4 6 YW63040600000 21 2 Flat washer 6 YW66061600000 22 3 Flat head screw M6 10 4 Front plate - 24 5 Platen - 25 Copper Teflon pipe coupler 1/4 1/4PT(L) Water flow regulator connector YW04010400400 YW62061000000 23 Cover plate - Alumimum square handle 120L(M6) Stainless steel T-joint - BW20012000040 YW52010400000 6 Operation panel YR40009500000 26 Pipe couple 1/4 BH12010400110 7 8 9 10 11 Temperature controller V200 Electrical mounting plate EGO assembly (without plastic box) High and low pressure switch HLP830HMW Copper Teflon pipe coupler 3/4 1/2 PT YE81020024000 27-28 BH90115000150 29 Copper connector for water refilling Copper Teflon pipe connector 1/4H 1/4PT Copper connector unit 3 - BH12010400410 YE90832500000 30 Solenoid valve YE32331000000 BH12030401010 31 Rack - 12 Heating tank - 32 Hexnut M10 YW64001000300 13 Heater - 33 Copper Teflon pipe coupler 3/4 H PT 1/4 - BH12030401010 14 Heater guard BL80091000120 34 Pump TP-37 BM20023450050 15 Hexnut M6 YW64000600300 35 16 Hexagon socket head cap screw M10 25 Black rubber castor 2 YW03000200000 YW61102500000 36 Hexnut M8 YW61000800200 17 Spring washer 10 YW65010000000 37 Spring washer 8 YW65008000200 18 Flat washer 10 YW66102500000 38 Falt washer 8 YW66082200100 19 Copper Teflon pipe coupler 3/8H 3/8PT(L) YW04030800300 39 Hexbolt M8 25 YW60082500300 20 Thermocouple (short) BE90100000150 * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. 25(57)

2.2.11 Pump Parst Name: 1. Pump body 2. O-shape ring 3. Inpeller 4. Key 5. Pump lid 6. Hexagonal head screw 7. Snap ring 8. Mechnical shaft seal 9. Rotary ring 10. Motor Picture 2-8: Pump 26(57)

2.3 Electrical Diagram 2.3.1 Main Circuit (STM-405E) Picture 2-9: Main Circuit (STM-405E) 27(57)

2.3.2 Control Circuit (STM-405E) Picture 2-10: Control Circuit (STM-405E) 28(57)

2.3.3 Ternimal Connection (STM-405E) Picture 2-11: Ternimal Connection (STM-405E) 29(57)

2.3.4 Electrical Components Layout (STM-405E) Picture 2-12: Electrical Components Layout (STM-405E) 30(57)

2.3.5 Electrical Components List (STM-405E) Table 2-6: Electrical Components List (STM-405E) No. Symbol Name Specification Parts No. 1 Q1 Breaker* 20A YE40602000000 2 K1 Contactor* 220V 50/60Hz YE00301000000 3 K2 Contactor** 220V 50/60Hz YE00320000000 4 F1 Thermal overload relay 2~3.2A YE01123200000 5 F11 Fuse** 2A YE41001000000 6 S1 S2 Alternative switch 4P (WH) YE10210400000 7 K3 Temp. controller* 220VAC 50/60Hz YE85020000000 8 S3 Overheat protector* 250V 5(4)A YE21503000000 9 S4 Limit switch* 250V 5(4) YE14511200000 10 PC Circuit board** 220VAC 50/60Hz YE80000100000 11 FM Fan* 230V 50/60Hz YM60922500100 12 X1 Terminal - YE61250040000 13 - Earthing terminal - YE61253500000 14 - Terminal - YE61040000000 15 - Erathing terminal - YE61043500000 16 M1 Motor** 400V 50/60Hz BM20005500250 17 EH1 Heater** 400V 50/60Hz BH70040500050 * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. 31(57)

2.3.6 Main Circuit (STM-405N-WE) Picture 2-13: Main Circuit (STM-405N-WE) 32(57)

2.3.7 Control Circuit (STM-405N-WE) Picture 2-14: Control Ciruit (STM-405N-WE) 33(57)

2.3.8 Ternimal Connection (STM-405N-WE) Picture 2-15: Ternimal Conection (STM-405N-WE) 34(57)

2.3.9 Electrical Components Layout (STM-405N-WE) Picture 2-16: Electrical Components Layout (STM-405N-WE) 35(57)

2.3.10 Electrical Components List (STM-405N-WE) Table 2-7: Electrical Components List (STM-405N-WE) No. Symbol Name Specification Parts No. 1 Q1 Breaker* 20A YE40602000000 2 K1 Contactor* 220V 50/60Hz YE00301000000 3 K2 Contactor** 220V 50/60Hz YE00320000000 4 F1 Thermal overload relay 2~3.2A YE01123200000 5 F11 Fuse** 2A YE41001000000 6 S1 S2 Alternative switch 4P (WH) YE10210400000 7 K3 Temp. controller* 220VAC 50/60Hz YE85020000000 8 S3 Overheat protector* 250V 5(4)A YE21503000000 9 S4 Limit switch* 250V 5(4) YE14511200000 10 PC Circuit board** 220VAC 50/60Hz YE80000100000 11 FM Fan* 230V 50/60Hz YM60922500100 12 X1 Terminal - YE61250040000 13 - Earthing terminal - YE61253500000 14 - Terminal - YE61040000000 15 - Earthing terminal - YE61043500000 16 M1 Motor** 400V 50/60Hz BM20005500250 17 EH1 Motor** 400V 50/60Hz BH70040500050 * means possible broken parts. ** means easy broken part. and spare backup is suggested. Please confirm the version of manual before placing the purchase order to guarantee that the item number of the spare part is in accordance with the real object. 36(57)

2.4 Main Electrical Components Description 2.4.1 Thermal Overload Relay Upon delivery, the overload relay is set for mannual reset. When motor overload occurs, stop the machine, then check and solve the problem. After that open the door of control box, press down the reset button of overload relay (if you can not press down the reset button, wait for one minute). 1 2 7 6 5 3 4 6 Picture 2-17: Thermal Overload Relay About the 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 95.96.97.98. NC and NO contacts are shown in position 95.96. and 97.98. repectively. 7) Main circuit connection No. must be corresponded with terminal Number of contactor. 37(57)

2.5 Operation Procedures 2.5.1 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 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) 38(57)

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 is usable; for the operating temperature from 200 to 300, must use Teflon with temperature resistance 300. 39(57)

3. 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. Do not sit on the machine or place stuff on that. Keep away flammable and explosive goods. Picture 3-1: Installation Space 40(57)

3.2 Mould and Water Coupling 1) When connect mould coupling with pipes from the mould. Use a spanner to secure one end of the coupling, insert mould connecting pipe and fasten it by another spanner. Picture 3-2: Mould and Water Coupling 1 2) Unused mould couplings can be connected with each other by a teflon pipe, as shown in picture. Picture 3-3: Mould and Water Coupling 2 Attention! Cooling water inlet and outlet as shown in picture. No reversal! 41(57)

Picture 3-4: Mould and Water Coupling 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 3Ф 400V power supply or other specifications according to customers' requirement. 42(57)

4. Operation Guide 4.1 Control Panel Picture 4-1: Control Panel Table 4-1: Control Panel No. Name Functions Remarks 1 Power indicator 2 Phase reversal alarm Connect the machine with power supply and turn on main switch. This indicator will become green. When phase reversal or phase shortage occurs, it becomes red. The buzzer sounds, and system stop working. Warning! Do not remove any electrical parts or touch any terminals after the power is on. Turn off the machine. Exchange the place of two of the electrical wires of main power supply. Indicator and buzzer would not reset until touble-shooting is settled. 43(57)

No. Name Functions Remarks 3 Motor overload alarm When motor current exceeds the limits, the buzzer sounds. Motor overload alarm is red and system stops working. Check that if motor shaft is blocked or the bearing is broken or setting current of overload relay is too low. After the problems solved, wait for one minute and then press the blue RESET button to reset the overload relay and clear the alarm. 4 Overheat alarm 5 Low level alarm 6 High pressure alarm light When oil temperature is higher than EGO (temperature sensor) setting value, this indicator becomes red. The buzzer sounds and system stops working. When oil in auxiliary tank is in shortage, the alarm light will become red. The buzzer sounds and system stops working. When system pressure is too high and reach the limited set value, the light will be on and system will stop and sound an alarm. 7 Temp. controller Temperature setting and control. - 8 Pump switch Turn on and off the pump. 9 Heater switch Turn on and off the heater. 4.2 Machine Startup 1) Switch On the circuit breaker. 2) Switch On the pump. 3) Swicth On the heate. EGO setting value should be higher than temperature setting value of temperature controller. Check if there are problems of pipe heater contactor. Ensure oil supply from the auxiliary tank. Check whether the mould circulating water valve is blocked and check the pressure switch. Note: motor rotating direction should be correct. Heater switch is applicable only after pump is turned on. 44(57)

Pictuer 4-2: Machine Startup 4) Set the temperature. 4.3 Machine Shutdown 1) Swicth Off heater. 2) Wait until oil temperature falls below 50, turn off pump switch. 3) Turn off main switch. 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. 45(57)

4.4 Temperature Controller Temperature controller control panel: Picture 4-3: Control Panel 4.4.1 Temperature Controller Display Practical value: Display practical temperaure value or parameter code of temperature controller. Setting value: Display set temperature value or parameter value, or display input value when you set parameters. Operation indicator 1. ALM1 (alarm point output) This indicator becomes bright to indicate that alarm point is on and display AL1. Function of the alarm point is to control pipe heater 2. When deviation of actual temperature between setting value is more than 5, heater 2 will be cut off and AL1 light is on. (Only for machine with dual-heating zone) 2. OP1 (control output 1) Indicator turns bright when control output 1 is On. OP1 is to control heating and indicator s on means heating is on running. 46(57)

3. OP2 (control output 2) Indicator turns bright when control output 2 is On. OP2 is to control cooling and indicator s on means cooling valve turns on and cooling is on running. 4.4.2 Keys on Control Panel Selection key of paremeters :1. Press this key under normal state to enter selection mode of parameters, and press this key to select parameter layers. For entering parameters mode just press. 2. Press this key under parameter mode and parameter mode will pop out to enter selection mode. 3. Press this key under setting mode and parameters will be saved and setting mode pops out to enter parameter mode. 4. Under all modes, press for tow secs. To return the normal state. Setting key Up key : 1. Press this key in normal mode and you can set values directly. 2. Press this key in parameter selection mode to return previous parameter layer. 3. Press this key in parameter selection mode to enter setting mode andset values. 4. Press this key in setting mode and you can select setting digits or saving values and return parameter mode. : 1. Press this key in parameter selection mode to eneter parameter mode. 2. Press this key in parameter mode to select parameters in current layer. Down key 3. Press this key in setting mode to increase values till upper limits. : 1. Press this key in parameter selection mode to enter parameter mode. 2. Press this key in parameter mode to select paramerters in current layer. 3. Press this key in setting mode to increase values till lower limits. 47(57)

4.4.3 Choose a Parameter Press to choose a parameter or switch to next parameter. 4.4.4 Confirm the Setting Picture 4-4: Choose a Parameter 1) Press to come back to the first parameter if current 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. 3) Confirm your setting when changing to another menu. 4) Before power supply is cut off, press to confirm your setting. Sometimes setting and parameters can not be modified by solely pressing and. Attention! Upon delivery, the parameters of temperature controller have been set already. Do not reset the parameters unless it is necessary. 48(57)

5. Trouble-shooting Faults Resons Solutions Main power indicator does not become bright after circuit breaker switch is turned on. Both power and phase reverse indicator are bright after breaker switch is turned on. The buzzer sounds to raise alarm. Pump overload relaly is bright. The buzzer sounds and system stops working. Overheat indicator is bright. The buzzer sounds and system stops working. Low level indicator is bright. The buzzer sounds and system stops working. Main switch indicator won't become bright after turning on main switch. Pump can not start when turning on pump switch. No display of temperature controller after turning on pump and heater switch. Too big deviation between setting temperature and actual temperature. Did not connect through power supply. Main switch broken. Power supply wires problems. Control circuit fuse melt. Transformer broken. Power supply low voltage. Phase shortage. Phase reversal. PCB problems. Abnormal fluctuations of power supply. Pump blocked. Pump motor problems. Thermalrelay setting current value error. EGO temperature setting mistakes. EGO poor temperature detecting. Heater main contactor are sticky. Low pressure of of water supply. Pressure switch problems. PCB output relay problems. Pump switch problems. Time relay (K5) problems. Electrical circuit problems. Heater switch problems. Temperature controller problems. Electrical circuit problems. Too short time after machine startup. Temperature parameter setting error. Cooling water valve problems. Connect through power supply. Replace main switch. Check electrical wires. Fix the fuse. Replace the transformer. Check power supply. Check power supply. Exchange two of the wires of power supply. Replace the PCB. Check power supply. Check the pump. Set the setting current of thermal relay to equal to 1.1 times of pump current. Please refer to Main components for details of thermalrelaly. Reset relay: Wait for one minute, then press the blue button to reset. Correctly set EGO temperature. (EGO temperature setting value= temperature setting value+10 ) Replace EGO. Replace the contactor. Increase the pressure of water supply. Replace pressure switch. Check or replace the PCB. Replace the switch. Replace time relay. (K5) Check electrical circuit. Replace the switch. Replace temperature controller. Check electrical circuit. Wait for a while. Check temperature parameters. Please refer to the standard manual of setting parameters. Replace solenoid valve. 49(57)

Temperature can't rise up. Circuit breaker tripping off at turning on main switch. Circuit breaker tripping off at turning on pump switch. Circuit breaker tripping off at turning on controller OUT1 output. Heater contactor problems. Heater problems. Thermocouple problems. Temperature controller operation mode set to STOP. Temperature output problems. Short circuit of main circuit. Transformer short circuit or connected with earth wire. Problems of circuit breaker. Pump motor coil short circuit. Problems of circuit breaker. Pipe heater short circuit or contact with heating tank. Problems of circuit breaker. Replace the contactor. Replace pipe heater. Replace thermocouple. Set temperature controller to working mode. Replace or repair temperature parameters. Check electrical wire. Replace circuit breaker. Repalce transformer Check pump motor. Replace circuit breaker. Replace pipe heater. Replace circuit breaker. 50(57)

6. Maintenance and Repair Pay attention to the following rules during maintenance: 1) Need at least two persons present when checking the machine. Let the machine cool down, turn off power supply, drain out the oil and water. Make sure enough place before checking and maintenance. 2) The machine works in high temperature. Stop the machine, wait it to cool down. Put on protective gloves before servicing or maintenance. 3) In order to prolong the life of the machine and to prevent accidents, check the machine at a fixed frequency. 4) During operation, the oil is heated up to a high temperature, wait it to fall below 50 to perform repairing or maintenance. (Please note that it is dangerous to check or tear down the machine during operation.) 6.1 Open the Covers 1) Lift the top cover gently to open it. (Refer to the pictures below) 51(57)

Picture 6-1: Open Cover 1 2) Pull the bottom of side cover outward, and lift it to open. (Refer to the pictures below) Picture 6-2: Open Cover 2 3) Open the cover of control box. Screw off two butterfly screws to unlock the cover. (Refer to the pictures below) 6.2 Y Type Strainer Picture 6-3: Open Cover 3 1) Clean soft water should be used as cooling water. Filter screen is used in the strainer to stop impurities and pollutants entering 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 52(57)

of filter screen to clean the filter. 6.3 Solenoid Valve Picture 6-4: Y Type Strainer Replace solenoid valve: 1) Open machine top cover. 2) Take down right side cover. 3) Unfix the solenoid valve for replacement. 4) Install the covers in a reverse order. 6.4 Pipe Heater Picture 6-5: Solenoid Valve 1) Pull the black door locker downward, then draw it outward to open machine rear cover. (Refer to pictures below) Picture 6-6: Pipe Heater 1 53(57)

2) Unscrew the screws of heater cap and take it down. (Refer to pictures below) Picture 6-7: Pipe Heater 2 3) Unscrew the screws of pipe heater to take it out. (Refer to pictures below) Picture 6-8: Pipe Heater 3 4) Re-fix the pipe heater in a reverse order. 6.5 Cooling Pipe 1) Pull the black door locker downward, then draw it outward to open machine rear cover. (Refer to pictures below) Picture 6-9: Cooling Pipe 1 2) Screw off the screws of cooling pipe to take it out. (Refer to pictures below) 54(57)

Picture 6-10: Cooling Pipe 2 3) Re-fix the cooling pipe in a reverse order. Because the heat transfer oil may become carbonized agglutination after a long time heating, which will shorten the lifespan of the pump, so it is suggested to replace every three monthes. Oil used parameters recommended: Use kerosene up to 200 degrees model: Model: Nanhai MCH32. For using other brands, fire point should be higher than 240 degrees. Use kerosene up to 300 degrees model: Model: Goddess HT-3 heat trsnfer oil. For useing other brands, fire point should be higher than 340 degrees. 55(57)

6.6 Maintenance Schedule 6.6.1 About the Machine Model SN Manufacture date Voltage Ф V Frequency Hz Power kw 6.6.2 Installation & Inspection 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. 6.6.3 Daily Checking Check machine startup function. Check all the electrical wires. 6.6.4 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. 6.6.5 Trimonthly Checking Check level switch. Check the contactor 2. Replace the hot kerosene with a using temperature above 160 degree 3. 6.6.6 Half-yearly Checking Check damaged pipes. Clean process heater/cooler. Check indicator and buzzer. 56(57)

Replace the hot kerosene with a using temperature above 120~160 degree 4. 6.6.7 Yearly Checking Replace the hot kerosene with a using temperature above 120 degree 5. 6.6.8 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. 2. Manufacturer laboratory data for AC contactor is two million times in life. we suggest service life for one million 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 accuracy of internal temperature probe and the efficiency of heat elements, six months replacing frequency is suggested. 5. Hot kerosene coke will influence the detection accuracy of internal temperature probe and the efficiency of heat elements, suggested replacing frequency is one year. 57(57)