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Preface

Thank you for choosing the CHV110 series of injection molding machine energy savers

developed by Shenzhen INVT Electric Co., Ltd..

This operating instruction manual must be made available for actual operators of the

equipment.

To guarantee the safety of users and to achieve the optimal energy saving effect while

satisfying technological requirements of energy savers, please read this operating

instruction manual carefully before use.

CHV110 series energy savers are applicable to various injection molding machines with

constant delivery pumps under hydraulic transmission control. According to different

pressures and rates of flow required for different operational stages of injection molding

machines, the user can adjust the output power of the oil pump accordingly to save

energy by 25% to 50%. They feature high energy conservation ratio, high reliability, motor

soft start, and easy operation.

If you have any problems during use, please contact our technical department.

Please keep this operating instruction manual properly as a reference in future

maintenance, repair, and use in a different operating condition.

The company reserves the right to constantly improve its products. Any technical

improvement, if without impact on the use of the equipment, shall be made without notice.

Содержание CHV110 Series

Страница 1: ...ery pumps under hydraulic transmission control According to different pressures and rates of flow required for different operational stages of injection molding machines the user can adjust the output power of the oil pump accordingly to save energy by 25 to 50 They feature high energy conservation ratio high reliability motor soft start and easy operation If you have any problems during use pleas...

Страница 2: ...of Operation Panel 13 4 7 Operation Procedures 15 4 8 Installation and Debugging Procedures 21 5 Operating Guide 26 5 1 Switchover between Mains Supply Mode and Energy Saving Mode 26 5 2 Test Stage 26 5 3 Normal Operation Stage of Energy Saver 27 6 Fault Diagnosis 28 6 1 Fault Diagnosis and Corrective Action 28 6 2 Handling of Common Faults 32 6 3 Adjustment of Common Product Defects 33 7 Repair a...

Страница 3: ...mping injection melting mold opening and ejector pin and according to the set pressure and speed requirements so that the actual oil supply quantity of the oil pump can be consistent with the actual load flow rate of the injection molding machine at any stage As a result it minimizes the energy consumption when the motor operates in its load range eliminates overflow phenomenon and ensures stable ...

Страница 4: ... heavy load as injection and no influence upon the production efficiency ensuring product quality Automatic reset and power failure reset function ensuring production continuity and efficiency CHV110 series feature integrated structure and dual power supply switching and control system With a protection grade of IP54 full closed design perfect dust proof gas proof and corrosive proof performance a...

Страница 5: ...e delivery pumps 2 Injection molding technology The energy saving ratio will not reach the lowest rate if the molding period is too short less than 10 seconds or most technological parameters of the equipment are close to or up to the full load 3 Equipment condition For the old model of injection molding machines or those with circuit defects such problems as large noise and motor overheat may occ...

Страница 6: ... hazards that if not avoided could result in minor or medium injury or damage to the equipment It can be used to warn unsafe operations It can be used to warn unsafe operations CAUTION In some cases even contents described in CAUTION may result in major accidents Therefore follow these important safety instructions in any cases Therefore follow these important safety instructions in any cases Note...

Страница 7: ...e cabinet Do not hold the panel to move the inverter Otherwise the main unit may fall off and may result in personal injury Install the inverter on fire retardant materials such as metal otherwise it may result in fire To install two or more inverters in a cabinet it is necessary to install a cooling fan to keep the air temperature below 45ºC overheat may result in file or damage to the equipment ...

Страница 8: ... source Flammables thinners and solvents shall be kept far away from the equipment The equipment shall be prevented from dust oily dust floating fiber and metallic particles The equipment shall be installed on a solid base without vibration It shall be securely fixed if it is mounted on the wall 4 2 Outside Dimensions of Energy Saver 6 ...

Страница 9: ...age Therefore after the power switch is turned off wait at least 5 minutes before performing any operation to make sure the inverter is completely discharged The grounding terminal of the inverter must be securely grounded Grounding resistance for 200V grade shall be 100Ω or lower Grounding resistance for 400V grade shall be 10Ω or lower Grounding resistance for 660V grade shall be 5Ω or lower Non...

Страница 10: ... molding machine with energy saver 3 Phase power supply Injection molding machine energy saver Main circuit of energy saver Main oil pump motor of injection molding machine Mains supply indicator Energy saving indicator Fault indicator Control loop of energy saver PC synchronization signal P5 03 1 FWD P5 03 2 REV P5 04 16 multi step speed 1 Common terminal Signal processor Figure 4 3 1 Schematic D...

Страница 11: ...10Ω or lower Grounding resistance for 660V grade shall be 5Ω or lower Nonobservance of this WARNING may result in electric shock or fire Make sure the input terminals R S T and output terminals U V W of the inverter are correctly connected any wrong connection may cause damage to the inverter Never connect the wires or operate the inverter with wet hand otherwise it may result in an electric shock...

Страница 12: ...Ω AI2 Analog input voltage 0 10V current 0 20 mA optional through J18 Input impedance 10 KΩ voltage input 250Ω current input 10V 10V power supply provided for the inverter GND Reference zero potential for 10V Note GND is isolated from COM Y1 Y2 Open collector output terminal with the corresponding common terminal as CME External voltage range 0 24V Output current range 0 50 mA CME Common terminal ...

Страница 13: ...IA 1IB 2 Current signal channel 2 2IA 2IB 1IA 1IB 2IA 2IB Figure 4 3 4 Pressure and flow current signal input terminals 4 4 Operating Instructions for Current Signal Acquisition Card 4 4 1 The appearance of the current signal acquisition card is shown in Figure 4 4 1 1 11 1IA 1IB 2IA 2IB Figure 4 4 4 1 Appearance of Current Signal Acquisition Card The card has four wiring terminals as shown in Fig...

Страница 14: ...he on board LED will indicate whether the wiring is correct For the current signal card if the current signal is greater than 0 6A the LED will light up and its brightness will increase with the input signal 4 4 2 Special Functions Functional code P4 12 If it is set to 0 it indicates the terminal control command is invalid upon power up if it is set to 1 it indicates that the terminal control comm...

Страница 15: ... and proportional flow signal amplifier board On the signal amplifier board the user can find power amplification transistors for pressure and flow signals In other words the circuit board that has two power transistors is the proportional pressure and proportional flow signal board Moreover the first letters of pressure and flow are marked on the wiring terminals of the circuit pressure P P and f...

Страница 16: ...ignal 4 6 Description of Operation Panel 4 6 1 Schematic diagram of operation panel Digital display Programming exit key Shortcut key RUN key Number modification keys Function indicator Unit indicator Data confirmation key SHIFT key STOP RESET key Figure 4 6 1 Schematic Diagram of the Operation Panel 4 6 2 Functions of keys Key Symbol Name Function Description PRG ESC Programming key Enters or exi...

Страница 17: ...same time the inverter free stops 4 6 3 Description of Indicators 1 Description of functional indicators Indicator Indication RUN TUNE If the indicator is off it indicates the inverter stops if the indicator flickers it indicates the inverter is in the parameter self learning state if the indicator is on it indicates the inverter is in the operation state FWD REV Forward Reverse rotation indicator...

Страница 18: ...ode ID level 2 menu 3 Functional code set value level 3 menu Note In level 3 menu operation press PRG ESC or DATA ENT to return to the level 2 menu The difference between two keys is if you press DATA ENT the system saves set parameters in the control board returns to the level 2 menu and automatically shifts to the next functional code if you press PRG ESC the system directly returns to the level...

Страница 19: ...e equipment before modifying the functional code 4 7 2 Shortcut menu Shortcut menu provides a quicker and more convenient means for viewing and modifying functional parameters The user can add frequently used functional parameters to the shortcut menu Parameter in the shortcut menu is displayed in the format of hp0 11 indicating that it is the functional parameter P0 11 Modifying a parameter in th...

Страница 20: ...e functional parameters to or from the shortcut menu when the functional code F7 03 is set to 0 4 7 2 1 Adding shortcut parameter To set the functional code P0 00 as a shortcut parameter for example operate as follows ...

Страница 21: ...isplayed content stops flickering and the operation is completed To cancel the setting press PRG ESC The displayed content stops flickering and the operation is cancelled If the system has already stored 16 parameters it will give a prompt of FULLP if the user tries to store another parameter 4 7 2 2 Operation of shortcut parameters The shortcut menu contains only two levels corresponding to the l...

Страница 22: ... the and keys to select different shortcut parameters and then press DATA ENT to enter the level 2 shortcut menu Modification method of level 2 shortcut menu is the same as that for level 3 menu common parameters To return to the previous menu press QUICK JOG If the NULLP appears when the user enters the level 1 shortcut menu it indicates the shortcut menu is null 4 7 2 3 Deleting shortcut paramet...

Страница 23: ...ed To cancel the deletion press QUICK JOG The display stops flickering and the deletion operation is cancelled If the shortcut parameter to be deleted is the last one the NULLP appears after the deletion indicating there are no shortcut parameters 4 7 3 Fault reset If a fault occurs with the inverter the inverter will give a prompt on fault information The user can perform fault reset operation th...

Страница 24: ... parameter self learning are as follows Firstly select the operation command channel selection P0 01 as the keypad command channel Then enter the following parameters according to the name plate of the motor P2 01 Rated frequency of the motor P2 02 Rated rotation speed of the motor P2 03 Rated voltage of the motor P2 04 Rated current of the motor P2 05 Rated power of the motor Set P0 17 to 1 For d...

Страница 25: ...s for current signal channel 1 and the corresponding internal channel is AI3 The functional code is P0 03 2 and the corresponding parameters are set to P5 25 P5 29 Where the 1IA is the positive input terminal of differential current and the 1IB is the negative input terminal of differential current 2IA and 2IB are input terminals for current signal channel 2 and the corresponding internal channel ...

Страница 26: ... the name plate of the motor P2 03 Rated voltage of the motor On the name plate of the motor P2 04 Rated current of the motor On the name plate of the motor 4 8 2 2 Change the following parameters P0 01 Keypad control 0 P0 11 Acceleration time 20 P0 12 Deceleration time 20 4 8 2 3 Turn the energy saver to the energy saving state and start the motor of the injection molding machine ensure the conne...

Страница 27: ...oning with the keypad to observe whether the system runs normally and whether motor parameters are correct 4 8 3 1 Set P0 00 0 Open loop vector control P0 11 0 1s acceleration time P0 10 50 00 Hz Conduct acceleration and deceleration for several times If no OC fault occurs the system is normal 4 8 3 2 When the motor reaches its rated frequency P2 01 view the output voltage with the SHIFT key on th...

Страница 28: ...nal Code Function Description Functional Code Function Description P5 25 Lower limit of channel 1 P5 30 Lower limit of channel 2 P5 26 Setting corresponding to the lower limit of channel 1 P5 31 Setting corresponding to the lower limit of channel 2 P5 27 Upper limit of channel 1 P5 32 Upper limit of channel 2 P5 28 Setting corresponding to the upper limit of channel 1 P5 33 Setting corresponding t...

Страница 29: ...ed is required for the commissioning of some injection molding machines try the following methods 4 8 5 1 Set the following parameters through the JOG terminal S2 Functional Code Function Description P5 03 S2 terminal function selection 4 FWD JOG 5 REV JOG P8 06 JOG run frequency Set according to actual situations less than the maximum frequency P8 07 JOG acceleration time 0 7 P8 08 JOG decelerati...

Страница 30: ...ion indicator is on Shut down the main oil pump motor and make sure the motor stops Turn the changeover switch and the energy saving operation indicator becomes on The energy saver operates in the energy saving state Turn on the main motor of the injection molding machine and perform normal operations Key Point Make sure to shut down the motor of the injection molding machine before carrying out t...

Страница 31: ...lways turn it to the energy saving operation mode unless it is required to have a test It is not necessary for a user to adjust the parameters of the energy saver when a different type of mold is used No matter what kind of product is produced it is only required to set the flow speed and pressure parameters of the injection molding machine at different stages such as mold clamping injection melti...

Страница 32: ...e is strong interference source among peripherals 4 Check the grounding method and state of the grounding cable OC1 Acceleration operation over current 1 Acceleration is too quick 2 Power grid voltage is too low 3 The power of the inverter is too low 1 Increase acceleration time 2 Check power supply 3 Select an inverter with a larger scale of power OC2 Deceleration operation over current 1 Deceler...

Страница 33: ...k power supply of the power grid OL1 Motor overload 1 Power grid voltage is too low 2 Rated current of the motor is incorrectly set 3 Rotation of motor blocked or excessive sudden change 4 Close loop vector control code wheel in reverse direction long term low speed operation 5 The load is too light 1 Check the voltage of the power grid 2 Set rated current of the motor again 3 Check the load and a...

Страница 34: ...s damaged 4 Ambient temperature is too high 5 Wires or connectors of the control board become loose 6 Auxiliary power supply is damaged under voltage with drive voltage 7 Straight through of power module bridge leg 8 Control board fails 1 Refer to solution to over current 2 Redistribute cables 3 Clean air duct or replace the fan 4 Decrease ambient temperature 5 Check and connect again 6 Seek for s...

Страница 35: ...s and parameter settings PCE Coder wire broken fault 1 With PG vector control coder signal line broken 2 Coder damage 1 Check coder wires and reconnect the line 2 Check whether the coder has output PCDE Coder reverse fault 1 With PG vector control coder signal line is reversely connected 1 Check coder wires and adjust the connection OPSE System fault 1 Severe interference prevents main control boa...

Страница 36: ... the oil pump motor 6 2 2 No display when energy saver powered on Check whether the power supply of the energy saver is consistent with the rated voltage If there is a fault with the power supply check and remove the fault Check whether the 3 phase rectifier bridge is in good condition If it is broken seek for external service Check whether the CHARGE indicator is on If it is off the fault usually...

Страница 37: ...ccurs occasionally and the distance between the motor and the energy saver is far an output AC reactor may be added Note In general it is unnecessary for the user to adjust parameters of the energy saver If it is required so please make adjustment under the direction of our technicians Improper adjustment may result in injection molding machine fault or product defect 6 3 Adjustment of Common Prod...

Страница 38: ...al temperature or mold Adjust parameters of the injection molding machine Wires and ripple on the product surface Injection pressure is too low Increase the value of injection pressure parameters Mold or mold temperature Improve mold and adjust parameters of the injection molding machine Warpage Cooling time is not long enough Increase the value of corresponding time parameters Defect with materia...

Страница 39: ...rameters Injection pressure is too high Decrease the value of injection pressure parameters Injection time is too shot Increase the value of corresponding time parameters Color fading Injection pressure holding time is too long Decrease the value of corresponding time parameters Defect with material temperature or mold Adjust parameters of the injection molding machine Product strength deteriorati...

Страница 40: ...e energy saver Daily maintenance covers Check Item Content Temperature humidity Make sure the ambient temperature is about 0 C to 50 C and the related humidity is about 20 to 90 Oil mist and dust Make sure there are no oil mist dust or condensed water Inverter Check whether the inverter has abnormal overheat or vibration Fan Make sure the fan works normally and is not blocked Power supply Make sur...

Страница 41: ...tion time exceeding 20 000 hours 1 Clean irrelevant objects 2 Replace the fan Electrolytic capacitor Whether the color changes or with foreign smell Replace the electrolytic capacitor Heat sink Dust and dirt Clean dirt or dust with dry compressed air Power components Dust and dirt Clean dirt or dust with dry compressed air ...

Страница 42: ...ranty does not apply to but paid maintenance service is available for Fault or damage caused by inappropriate operation or unauthorized repair or modification Fault or damage caused by use against the requirements specified in standards and specifications Component aging or fault caused by the use in an environment incompliant with the environment requirements provided in this manual Damage arisin...

Страница 43: ...41 ...

Страница 44: ...s running at different speeds Higher Temperature about 5 C The energy saver is driven by multiple pulses Therefore the temperature of the motor operating in the energy saving mode is slightly higher than that of the motor operating in the mains supply mode At the low speed operation stage the temperature may increase by 5 to 8 C Since the oil pump motor of an injection molding machine usually runs...

Страница 45: ...ist are described as follows Functional Code in the first column number of the functional parameter group and parameter Name in the second column complete name of the functional parameter Detailed Parameter Description in the third column detailed description of the functional parameter Setting Range in the fourth column valid setting range of the functional parameter Default Value in the fifth ro...

Страница 46: ... 5 To protect parameters more efficiently the energy saver provides password protection for the functional codes After a user password that is the parameter if user password P7 00 is not zero is set when the user press PRG ESC to enter functional code edit status the system will first enter user password verification state displaying The operator has to enter the correct user password otherwise th...

Страница 47: ...ng 7 Remote communication setting 0 7 0 Frequency A command selection 3 P0 04 Frequency B command selection 0 Analog AI2 setting 1 Analog AI4 setting 2 High speed pulse setting HDI2 0 2 0 Frequency B command selection 4 P0 05 Frequency B command reference object selection 0 Maximum output frequency 1 Frequency A command 0 1 0 O Reference job 5 P0 06 Setting source combination mode 0 A 1 B 2 A B 3 ...

Страница 48: ...e lower frequency limit the lower frequency limit is valid if it is greater than zero 0 Run at lower frequency limit 1 Stop 2 Dormant and standby 0 2 0 Action at lower frequency limit 17 P2 01 Rated frequency of motor 0 01Hz P0 07 maximum frequency 0 01 P0 07 50 00 Hz Rated frequency of motor 18 P2 02 Rated rotation speed of motor 0 36000 rpm 0 36000 1460 rpm Rated rotation speed of motor 19 P2 03...

Страница 49: ...1 P5 04 S3 terminal function selection 0 47 7 S3 function selection 32 P5 05 S4 terminal function selection 0 47 0 S4 function selection 33 P5 06 S5 terminal function selection 0 47 0 S5 function selection 34 P5 07 HDI 1 terminal digital input function selection 0 47 0 HDI1 function selection 35 P5 08 HDI 2 terminal digital input function selection 0 47 0 HDI2 function selection 36 P5 09 S6 termin...

Страница 50: ... integrated enable and direction 1 Two wire control with separated enable and direction 2 Three wire control 1 3 Three wire control 2 0 3 0 Terminal run mode 41 P5 14 Terminal UP DOWN Frequency increment change rate 0 01 50 00 Hz s 0 01 50 00 0 50 Hz s O Frequency increment change rate 42 P5 15 Lower AI1 limit 0 00 V 10 00 V 0 00 10 00 0 00 V O Lower AI1 limit 43 P5 1 6 Corresponding setting of lo...

Страница 51: ...filter time 57 P5 30 Lower AI4 limit 0 00 V 10 00V 0 00 10 00 0 00 V O Lower AI4 limit 58 P5 31 Corresponding setting of lower AI4 limit 100 0 100 0 100 0 100 0 0 0 O Lower AI4 limit setting 59 P5 32 Upper AI4 limit 0 00 V 10 00V 0 00 10 00 10 00 V O Upper AI4 limit 60 P5 33 Corresponding setting of upper AI4 limit 100 0 100 0 100 0 100 0 100 0 O Upper AI4 limit setting 61 P5 34 AI4 input filter t...

Страница 52: ...00 0 100 0 O Upper HDI2 limit setting 73 P5 46 HD2 frequency input filter time 0 00 s 10 00s 0 00 10 00 0 10 s O HDI2 filter time 74 P7 00 User password 0 65535 0 65535 0 O User password 75 P7 01 LCD display language selection 0 Chinese 1 English 0 1 0 O Language 76 P7 04 STOP RST stop function selection 0 Valid only for panel control 1 Valid for panel and terminal control 2 Valid for panel and co...

Страница 53: ...eat fault of inverter module OH2 17 External fault EF 18 Communication fault CE 19 Current detection fault ITE 20 Motor self learning fault TE 21 Coder disconnection fault PCE 22 Coder reverse direction fault PCE 23 System fault OPSE 24 FEPROM operation fault EEP 25 PID feedback disconnection fault PIDE 26 Brake unit fault BCE 27 reserved Fault type 3 83 P7 16 Current fault run frequency Frequency...

Страница 54: ...eed compensation 2 Variable frequency motor without low speed compensation 0 2 2 Motor overload selection 95 Pb 03 Motor overload protection current 20 5 120 0 rated current of the motor 20 0 120 0 100 0 O Overload protection current 96 Pb 04 Overload alarm point 20 0 150 0 20 0 150 0 130 0 O Overload alarm point 97 Pb 05 Overload alarm selection 0 corresponding to the rated current of the motor t...

Страница 55: ...disabled 1 protection enabled 0 1 0 O Overvoltage stall speed protection 102 Pb 10 Overvoltage stall speed protection voltage 120 150 120 150 130 O Overvoltage stall speed voltage 103 Pb 11 Overcurrent stall speed protection 0 protection disabled 1 protection enabled 0 1 0 O Overcurrent stall speed protection 104 Pb 12 Overcurrent stall speed protection current 100 200 100 200 150 O Overcurrent st...

Страница 56: ...Attachment 2 Standard Wiring Diagram 54 ...

Страница 57: ...ielded cable A 脉冲 Pulse A B 脉冲 Pulse B 脉冲监视输出最大 30ma Pulse monitoring output max 30mA 频率设定 PID 给定 Frequency setting by PID 0 10V 输入 0 10V input 0 4 20mA 输入 0 4 20mA input 10V 频率设定用电源 10V frequency setting power AI1 多功能模拟量输入 AI1 multifunction analog input 电压电流输入转换跳线 Voltage current input switching jumper 多功能扩展用接口 Multifunction extension interface 模拟输出 Analog output MA 电流信号 MA current signal 继电器 1 ...

Страница 58: ...ons delivered with the device and the product is allowed to leave factory Qualification certificate Note 1 Warranty contents A warranty of repair replacement or return in one month from the date of shipment Repair or replacement in three months from the date of shipment and Repair in 18 months from the date of shipment 2 For overseas use excluding domestic use the warranty covers repair in the pla...

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