英威腾英文说明书

PrefaceThank 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.42Table of Contents1. Energy Saving Principle.12. Product Features.23. Application Environment.34. Installation and Configuration.44.1 Environmental Requirements.54.2 Outside Dimensions of Energy Saver64.3 Connection of Injection Molding Machine with Energy Saver74.4 Operation Instructions for Current Signal Acquisition Card.104.5 Signal Acquisition Method of Injection Molding Machine.114.6 Description of Operation Panel.134.7 Operation Procedures154.8 Installation and Debugging Procedures.215. Operating Guide265.1 Switchover between Mains Supply Mode and Energy Saving Mode.265.2 Test Stage265.3 Normal Operation Stage of Energy Saver.276. Fault Diagnosis.286.1 Fault Diagnosis and Corrective Action.286.2 Handling of Common Faults.326.3 Adjustment of Common Product Defects.337. Repair and Maintenance.367.1 Daily Check.367.2 Periodic Check.368. Warranty.389. Additional Information.39Attachment 1: List of Functional Parameters40Attachment 2: Standard Wiring Diagram.50Attachment 3: Warranty Card.52Energy Saving PrincipleFor traditional injection molding machines with constant delivery pumps, valve adjustment is required to change load flow rate and pressure. In this case, input power changes slightly, and a large proportion of energy is consumed by the valve in the form of pressure difference, causing overflow. CHV110 energy saver can automatically adjust the rotation speed and oil supply quantity of the oil pump based on the current working state of an injection molding machine, like mold clamping, 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 and precise operation of the motor. Application of CHV110 energy saver makes soft start possible for the motor of injection molding machines, improves the power factor COS of the motor, and dynamically adjusts the output power of the motor of injection molding machines. In this way, the energy is saved. Product FeaturesCHV110 series of products are the latest products launched by Shenzhen INVT Electric Co.,Ltd. based on its years of experience in research, development, production, and on-site rebuilding of energy savers for injection molding machines. The products represent the leading level in the same industry. Compared with existing product, CHV110 series have the following features: Fast current limiting function, with an instantaneous impulse current as high as 250% and an overload capability up to 180%/30 seconds; ensuring normal operation under such 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 and strong environment adaptability, prolonging the service life of the equipment; Independent air duct design, providing better heat dissipation effect, preventing electrostatic dusts from causing damage to electronic components; Small size, easy to install, user-friendly structure design; compact structure, supporting cabinet installation and wall mounting; Application EnvironmentTo achieve better energy saving effect, the following aspects must be taken into account before carrying out the energy saving rebuilding for injection molding machines:1) Type of injection molding machine: The energy saver is applicable to injection molding machines with hydraulic constant delivery pumps only, and it is not applicable to other types of injection molding machines (such as those with electric or variable 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 occur when the energy saver is installed.4) Installation environment: It is recommended not to install any other high-precision analog test meters on the same circuit of the energy saver because they may be interfered by the higher-order harmonic.Installation and Configuration Safety InstructionsPlease read this operating instruction manual careful before installing, operating, maintaining or checking the equipment.Safety information in this manual is divided into “WARNING” and “CAUTION”.WARNINGIndicates potential hazards that, if not avoided, could result in loss of life or serious injury.CAUTIONIndicates potential 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.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 Procedure taken to ensure correct operation.Warning signs are marked on the front cover of the inverter.Follow these instructions when using the inverter.Warning MarkWARNING Operation on the component/system of the inverter by untrained personnel or nonobservance of requirements stipulated in the warning may result in severe personal injury or property loss. Only qualified personnel who have received training in equipment design, installation, debugging and operation can work on the component/system of the equipment. Power feeding line can only be permanently connected and the equipment must be securely grounded. Even when the inverter is disabled, the following terminals may have dangerous voltage: - Power terminals R, S, T- Terminals to be connected to the motor: U, V, W After the power switch is turned off, wait at least 5 minutes before installation so that the inverter is completely discharged. The minimum sectional area of the grounding conductor must be equal to or greater than that of the power supply cable.Caution Hold the base to lift the 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 45C; overheat may result in file or damage to the equipment.4.1 Environmental RequirementsEnergy savers have good heat dissipation performance. To ensure high performance and long service life of energy savers, follow the suggestions below when selecting an installation site. Keep a clearance between the energy saver and adjacent articles. The energy saver shall be prevented from rain and direct sunshine when it is located close to a window; otherwise, it may result in equipment damage. The equipment shall be protected from mechanical impact or vibration; It is recommended to operate the equipment in the temperature range -10C to 40C. Excessively high or extremely low temperature may lead to equipment fault. The surrounding shall be free of electromagnetic interference and the equipment shall be kept at a distance away from any interference 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 SaverModel and Power RangeA (mm)B(mm)C(mm)Outside DimensionsCHV110-(07R5-015)T3300685250CHV110-(018-030)T3350846270CHV110-(037-055)T3390935285CHV110-075T3 431985360Warning To ensure safe operation of the inverter, only qualified and service-trained electrician can work on the equipment. It is strictly forbidden to test the insulation of the cables connected to the inverter with high-voltage insulation testing equipment. Even when the inverter is disabled, other power feeding lines, DC loop terminals and motor terminals may have dangerous voltage. 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 100 or lower;Grounding resistance for 400V grade shall be 10 or lower;Grounding resistance for 660V grade shall be 5 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.CAUTION Confirm that the rated voltage of the inverter is consistent with the AC power voltage. Power cables and motor cables must be connected securely and permanently.4.3 Connection of Injection Molding Machine with Energy Saver4.3.1 Schematic diagram of connection of injection molding machine with energy saverFigure 4.3.1 Schematic Diagram of Connection of Injection Molding Machine to Energy SaverWARNING To ensure safe operation of the inverter, only qualified and service-trained electrician can work on the equipment. It is strictly forbidden to test the insulation of the cables connected to the inverter with high-voltage insulation testing equipment. Even when the inverter is disabled, other power feeding lines, DC loop terminals and motor terminals may have dangerous voltage. 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 100 or lower;Grounding resistance for 400V grade shall be 10 or lower;Grounding resistance for 660V grade shall be 5 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.CAUTION Confirm that the rated voltage of the inverter is consistent with the AC power voltage. Power cables and motor cables must be connected securely and permanently.4.3.2 Main loop terminals consist of:1) Three-phase AC power input terminals: R, S, T2) Ground wiring terminal:3) Motor wiring terminals: U, V, WDistribution of main loop terminals is shown in Figure 4.3.2 Figure 4.3.2 Main Loop Terminal Block of the Energy Saver for Injection Molding Machine 4.3.3 Terminals of control loop:Figure 4.3.3 Wiring Terminals of Control LoopTerminal NamePurpose and DescriptionS1S5Digital input terminals, forming optical coupling isolation input with PW and COM; Input voltage range: 930VInput impedance: 3.3 KWHDI1 (HDI2)High-speed pulse or digital input, forming optical coupling isolation input with PW and COM;Range of pulse input frequency: 0-50 KHzInput voltage range: 930VInput impedance: 1.1 KWPWExternal power supply; the user can directly connect it (with COM) or use the +24V power supplied by the equipment. When the inverter is delivered out of the factory, +24V and PW are short-circuited by default. If you use the external power supply, disconnect the +24V power supply.+24V+24V power supply provided for the inverter;Maximum output current: 150 mACOMCommon terminal for +24V or external power supplyAI1 (AI3, AI4)Analog input, voltage range: 0V10VInput impedance: 10 kWAI2Analog input: voltage (010V)/current (020 mA), optional through J18;Input impedance: 10 K (voltage input)/250 (current input)+10V+10V power supply provided for the inverter;GNDReference zero potential for +10V (Note: GND is isolated from COM)Y1 (Y2)Open collector output terminal, with the corresponding common terminal as CMEExternal voltage range: 024VOutput current range: 050 mACMECommon terminal for open collector outputHDOHigh-speed pulse output terminal, with the corresponding common terminal as COM;Output frequency range: 050 KHzAO1 (AO2)Analog output terminal: optional voltage or current output through jumper J19;Output range: voltage (010V)/current (020 mA)PEGrounding terminalRO1A, RO1B, RO1CRO1 relay output, RO1A common terminal, RO1B normally close, RO1C normally openContact capacity: AC 250V/3A, DC 30V/1ARO2A, RO2B, RO2CRO2 relay output, RO2A common terminal, RO2B normally close, RO2C normally openContact capacity: AC 250V/3A, DC 30V/1ARO3A, RO3B, RO3CRO3 relay output, RO3A common terminal, RO3B normally close, RO3C normally openContact capacity: AC 250V/3A, DC 30V/1A4.3.4 Composition of pressure and flow signal input terminalsThe composition of pressure and flow signal input terminals of the energy saver for injection molding machine is shown in Figure 4.3.41) Current signal channel 1, 1IA, 1IB2) Current signal channel 2, 2IA, 2IB1IA 1IB 2IA 2IBFigure 4.3.4 Pressure and flow (current signal) input terminals4.4 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. 1IA 1IB 2IA 2IB Figure 4.4.4-1 Appearance of Current Signal Acquisition CardThe card has four wiring terminals, as shown in Figure 4.4.4-2. 1IA 1IB 2IA 2IBFigure 4.4.4-2 Wiring TerminalsWhere, 1IA and 1IB are input terminals of the current signal channel, and the corresponding internal channel is AI3. Its functional code is P0.03=2, and the corresponding parameters are set to P5.25-P5.29. 1IA is the positive input of the differential current, and 1IB is the negative input of the differential current. 2IA and 2IB are input terminals of current signal channel 2, and the corresponding internal channel is AI4. Its functional code is P0.04=1, and the corresponding parameters are set to P5.30-P5.34. 2IA is the positive input of the differential current, and 2IB is the negative input of the differential current. In addition, the combination mode of the two signal channels is set by parameter P0.05. Upon wiring, pay attention to the flow direction of the current over the signal line; otherwise, the inverter cannot operate normally. If any signal is input, the 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 FunctionsFunctional 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 command is valid upon power-up.4.4.3 Precautions on Wiring The signal line of the injection molding machine card should be separated from the power line. Parallel wiring is forbidden. To prevent injection molding machine signals from interference, please select a shielded cable as the signal line of the injection molding machine card. The shielding layer of the shielded signal line cable of the injection molding machine card should be grounded (such as terminal PE of the inverter), and furthermore, only one end is grounded, to prevent signal interference.4.5 Signal Acquisition Method of Injection Molding Machine To install an energy saver correctly for an injection molding machine, it is necessary to precisely identify the proportional flow and proportional pressure signals, which serve as input signals for the energy saver. There are three methods as follows:Method 1: Collecting signals from proportional flow and proportional pressure ammeters. Most injection molding machines have these two ammeters. They are usually installed on the panel of or in the distribution box of an injection molding machine. The range of an ammeter is usually 0-1A. To distinguish a proportional flow ammeter from a proportional pressure ammeter, set an action parameter of the injection molding machine to 0 (for flow) or 50 (for pressure) and then perform the action. The ammeter whose pointer moves is the proportional pressure ammeter. The proportional flow ammeter is alike. Proportional Flow Ammeter Proportional Pressure AmmeterMethod 2: Collecting signals from proportional pressure 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 flow (F+, F-). The user can