Delta HES Series User manual

+6(
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Preface
Thank you for choosing the Hybrid Energy System (HES) designed exclusively for the Delta Injection
Machine, which consists of Hybrid Servo Controller (VFD-VJ) series and servo oil pump.
These production instructions provide the users with complete information regarding the installation,
parameter configuration, anomaly diagnosis, troubleshooting, and routine maintenance of the Hybrid
Servo Driver. To ensure correct installation and operation of the hybrid servo driver, please read the
instructions carefully before installing the machine. In addition, please store the enclosed CD-ROM
properly and pass down to the machine users.
The Hybrid servo driver is a delicate power electronics product. For the safety of the operators and the
security of the machine, please only allow professional electrical engineers to conduct installation, tests,
and adjust machine parameters. Please carefully read the contents of the instructions that are marked
with "Danger" and "caution". Please contact your local Delta agents for any questions and our
professional team will be happy to assist you.
PLEASE READ PRIOR TO INSTALLATION FOR SAFETY.
DANGER
;Make sure to turn off the power before starting wiring.
;Once the AC power is turned off, when the POWER indicator of the Hybrid Servo
Controller is still on, it means there is still high voltage inside the Hybrid Servo
Controller, which is very dangerous and do not touch the internal circuits and
components. To conduct the maintenance safely, please make sure the voltage
between ＋1 and －is lower than 25Vdc using the handheld multimeter before
starting the operation.
;The internal circuit board of Hybrid Servo Controller houses CMOS IC, which is
vulnerable to electrostatics. Please do not touch the circuit board by and without
any anti-electrostatics measures.
;Never modify the components or wiring inside the Hybrid Servo Controller.
;The E terminal of Hybrid Servo Controller must be grounded correctly. The 230V
series uses the third type of ground scheme while the 460V series uses special
ground.
;This series of products cannot be operated in environments that endanger human
safety.
;Please keep children or strangers from approaching Hybrid Servo Controller.
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;Never connect AC power to the output terminals U/T1, V/T2, and W/T3 of Hybrid
Servo Controller.
;Please do not conduct stress test on the internal components of Hybrid Servo
Controller, for the semiconductor devices therein may be damaged by high-voltage
breakdown.
;Even when the servo oil pump is off, the main loop terminal of Hybrid Servo
Controller can still be loaded with high voltage that can be seriously dangerous.
;Only qualified professional electrical engineers can conduct tasks of installation,
wiring, and maintenance of Hybrid Servo Controller。
;When Hybrid Servo Controller uses external terminals as its run command sources,
the servo oil pump may start running immediately after the power is connected,
which may be dangerous with any personnel present.
;Please choose a safe area to install Hybrid Energy System, where there is no high
temperature, direct sunlight, moisture, and water dripping and splash.
;Please follow the instructions when installing Hybrid Energy System. Any
unapproved operation environment may lead to fire, gas explosion, and
electroshock.
;When the wiring between the hybrid controller and the hybrid servo motor is too
long, it may compromise the interlayer insulation of the motor. Please install a
reactor between them (please refer to Appendix A) to avoid burning of the hybrid
servo motor from damaged insulation.
;The voltage rating of the power supply of Hybrid Servo Controller 230 series cannot
be higher than 240V (no higher than 480V for 460 series) and the associated
current cannot exceed 5000A RMS ( no higher than 10000A RMS for models with
40HP (30kW))
NOTE
To provide detailed product descriptions, the illustrations are made with the exterior cover or safety shield removed. When
the product is running, please make sure the exterior cover is secured and the wiring is correct to ensure safety by following
the instructions of the manual.
The figures in the manual are made for illustration purposes and will be slightly different from the actual products. However,
the discrepancy will not affect the interests of clients.
Since our products are being constantly improved, for information about any changes in specifications, please contact our
local agents or visit ( http://www.delta.com.tw/industrialautomation/ ) to download the most recent versions.
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Table of Contents
Chapter 1 Use and Installation
1-1 Exterior of Product................................................................................................................1-2
1-2 Specifications........................................................................................................................1-3
1-3 Introduction of Hybrid Energy System...................................................................................1-5
1-4 Installation ............................................................................................................................1-6
1-5 Dimensions...........................................................................................................................1-9
Chapter 2 Wiring
2-1 Wiring...................................................................................................................................2-2
2-2 Wiring of Servo oil Pump ......................................................................................................2-4
2-3 Descriptions of Main Loop Terminals ....................................................................................2-5
2-4 Descriptions of Control Loop Terminals.................................................................................2-8
Chapter 3 Simple Flows of Panel and Machine Adjustment
3-1 Simple Description of Panel..................................................................................................3-2
3-2 Flowchart of System Configuration .......................................................................................3-4
3-3 Steps of System Configuration Flow ..................................................................................... 3-5
Chapter 4 Parameter Functions
4-1 Parameter Function List........................................................................................................4-2
4-2 Parameter Functions Explained..........................................................................................4-10
Chapter 5 Methods of Anomaly Diagnosis
5-1 System Troubleshooting .......................................................................................................5-2
5-2 Signal Display of Hybrid Servo Controller............................................................................. 5-2
5-3 Steps of Troubleshooting for Hybrid Servo Controller............................................................5-7
5-3-1 Over Current (oc)........................................................................................................5-7
5-3-2 Ground Fault (GFF)....................................................................................................5-7
5-3-3 Over Voltage (ov)........................................................................................................5-8
5-3-4 Low Voltage (Lv).........................................................................................................5-8
5-3-5 Overheat (oH1)...........................................................................................................5-9
5-3-6 Overload (oL)..............................................................................................................5-9
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5-3-7 Phase Loss (PHL).....................................................................................................5-10
5-3-8 Resolutions for Electromagnetic Noise and Induction Noise......................................5-11
5-3-9 Environment and Facilities for Installation.................................................................5-12
Chapter 6 Maintenance
Regular Maintenance..................................................................................................................6-2
Appendix A. Instructions of Product Packaging
A-1 Descriptions of Product Packaging.......................................................................................A-2
A-2 Detailed List of Product Packaging.......................................................................................A-3
Appendix B Optional Accessories
B-1 Non-fuse Circuit Breaker.......................................................................................................B-2
B-2 Reactor.................................................................................................................................B-3
B-3 Digital Keypad KPV-CE01.....................................................................................................B-8
B-4 Communication Card..........................................................................................................B-12
B-5 EMI Filter............................................................................................................................B-13
B-6 Brake Unit………………………………………………………………………………………..…B-15
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Chapter 1 Use and Installation|HES Series
1-1
Chapter 1 Use and Installation
1-1 Exterior of Product
1-2 Product Specifications
1-3 Introduction of Hybrid Energy System
1-4 Product Installation
1-5 Product Dimensions
Upon receipt of the product, the clients are advised to keep the product in its original packaging box. If
the machine won't be used temporarily, for future maintenance safety and compliance with the
manufacturer's warranty policy, please pat attention to the following for product storage:
;Store in a clean and dry location free from direct sunlight or corrosive fumes.
;Store within an ambient temperature range of -20°C to +60°C.
;Store within a relative humidity range of 0% to 90% and non-condensing
environment.
;Avoid storing the product in environments with caustic gases and liquids.
;Avoid placing the product directly on the ground. The product should be placed on
suitable benches and desiccators should be placed in the packaging bags in harsh
storage environments.
;Avoid installing the product in places with direct sunlight or vibrations.
;Even if the humidity is within the required value, condensation and freezing can still
happen when there is drastic change of temperature. Avoid storing products in such
environment.
;If the product has been taken out of the packaging box and in use for over three
months, the temperature of the storage environment must be below 30°C. This
considers the fact when the electrolytic capacitor is stored with no current conduction
and the environment temperature is too high, its properties may deteriorate. Please
do not store the product in the situation of no current conduction for more than one
year.
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Chapter 1 Use and Installation|HES Series
1-2
1-1 Exterior of Product
All Hybrid Energy System has passed strict quality control before being shipped outfrom the factory,
with enforced packaging that sustains impacts. Upon opening the packaging of the Hybrid Energy
System, the customers are recommended to conduct the examination by the following steps:
;Check if there is any damage to Hybrid Energy System during shipping.
;Upon opening the box, check if the model number of Hybrid Energy System matches that
listed on the external box.
For any mismatch of the listed data with your order or any other issues with the product, please
contact your local agent or retailer.
Model Explanation
HES 100 G 43 A
Version
Input Voltage 23: 230V 3-PHASE
43:460V 3-PHASE
Flow Rate
HybridEnergySystem
063: 63L/min
080: 80L/min
100: 100L/min
125: 125L/min
Pressure G: 140bar
H:180bar
Z: 180bar
160 160L min
200 200L min
250 250L min
: /
: /
: /
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Chapter 1 Use and Installation|HES Series
1-3
1-2 Specifications
230V Series Specifications HES____23A
Model Number 063H 080G 080H 100G 100H 100Z 125G 125H 160G
Oil Pump Capacity cc/rev 25 32 40 50 64
Flow Rate L/min 63 80 100 125 160
Maximum Flow Rate* L/min 75 96 120 150 192
Linear % Below 1% F.S.
Flow Rate
Specifications
Magnetic Hysteresis % Below 1% F.S.
Maximum Pressure Mpa 18 14 18 14 18 18 14 18 14
Minimum Pressure Mpa 0.1
Linear % Below 1% F.S.
Pressure
Specifications
Magnetic Hysteresis % Below 1% F.S.
Power kW 11 15
Insulation Grade Grade A (UL)
Cooling Method Forced Air Cooling
Environment Temperature 0 ~ 40 °C
Environment Humidity 20 ~ 90 RH (No condensation)
Servo Oil
Pump
Specifications
Weight kg 82 83 95 108 110
VFD-___VL23A-J 110 150 185 220 300
Maximum Output Voltage (V) 3-Phase Proportional to Input Voltage (200~240V, 50/60Hz)
Rated Output Capacity kVA 19 25 29 34 46
Weight kg 10 13 13 13 36
Brake Unit Built-in Plugged-in
Speed Inspector Resolver (Revolving Transformer)
Pressure Command Input 0~10V Support three-point calibration
Flow Rate Command Input 0~10V Support three-point calibration
Multi-functional Input Terminal 5ch DC24V 8mA
Multi-functional Output Terminal 2 ch DC24V 50mA, 1 ch Relay output
Analog Output Voltage 1 ch dc 0~10V
Cooling Method Forced Air Cooling
Environment Temperature -10 ~ 45 °C
Environment Humidity Below 90 RH (No condensation)
Servo
Controller
Specifications
Protection Functions Over current, over voltage, low voltage,, over heating, and overload in
Hybrid Servo Controller and over heating, overload, and abnormal speed in
Hybrid Servo Motor.
Working Medium HL-HLP DIN51 524 Part1/2 R68,R46
Operation Temperature °C -20 to 100
@40 °C 67.83
Actuation Oil Viscosity @100 °C 8.62
Miscellaneous Safety, Reactor, and EMI filter are optional.
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Chapter 1 Use and Installation|HES Series
1-4
460V Series Specifications HES____43A
Model Number 063G 063H 080G 080H 100G 100H 100Z 125G 125H 160G 160H 200G
Oil Pump Capacity cc/rev 25 32 40 50 64 80
Flow Rate L/min 63 80 100 125 160 200
Maximum Flow
Rate* L/min 75 96 120 150 192 240
Linear % Below 1% F.S.
Flow rate
Specifications
Magnetic
Hysteresis % Below 1% F.S.
Maximum
Pressure Mpa 14 18 14 18 14 18 14 18 14 18 14
Minimum
Pressure Mpa 0.1
Linear % Below 1% F.S.
Pressure
Specifications
Magnetic
Hysteresis % Below 1% F.S.
Power kW 11 15 20
Insulation Grade A grade (UL)
Cooling Method Forced Air Cooling
Environment
Temperature 0 ~ 40 °C
Environment Humidity 20 ~ 90 RH(No condensation)
Servo Oil
Pump
Specifications
Weight of Servo
Oil Pump kg 82 83 95 108 110 144
Model
NumberVFD-___VL43A-J 110 150 185 220 300 370
Voltage of Power Supply Three-Phase Power Supply 200 ~ 240V, 50/60Hz
Rated Output
Capacity KVA 19 25 29 34 46 56
Weight kg 10 13 13 13 36 36
Brake Unit Built-in Plugged-in
Speed Inspector Resolver(Revolving Transformer)
Pressure Command Input 0~10V Support three-point calibration
Flow Rate Command
Input 0~10V Support three-point calibration
Multi-functional Input
Terminal 5ch DC24V 8mA
Multi-functional Output
Terminal 2 ch DC24V 50mA, 1 ch Relay output
Analog Output Voltage 1 ch dc 0~10V
Cooling Method Forced Air Cooling
Environment
Temperature -10 ~ 45 °C
Environment Humidity Below 90 RH(No condensation)
Servo
Controller
Specifications
Protection Functions Over current, over voltage, low voltage, over heating, and overload in Hybrid Servo
Controller and over heating, overload, and abnormal speed in Hybrid Servo Motor.
Working Medium HL-HLP DIN51 524 Part1/2 R68,R46
Operation
Temperature °C -20 to 100
@40 °C 67.83
Actuation Oil
Viscosity @100 °C 8.62
Miscellaneous Safety, Reactor, and EMI filter are optional.
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Chapter 1 Use and Installation|HES Series
1-5
1-3 Introduction of Hybrid Energy
System
Flow Rate Command
(0~10V)
PressureCommand
(0~10V)
PGCard
RST
U V W
Encoder signal
Oil Pump
Brakeresistance/
Brake Unit
PowerTerminal
A
C
FAN
220V
Over heat protection
switch
Servo motor
Servo oil pump
Injector
Controller
Delta Hybrid
Servo
Controller Pressure
Sensor
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Chapter 1 Use and Installation|HES Series
1-6
1-4 Installation
Servo Oil Pump
Please install the servo oil pump in an environment with the following conditions to ensure safe
product operation:
Conditions of Operation
Environment Environment Temperature Relative Humidity
Oil Temperature
0°C~ 40°C
20%~90%, No condensation
0°C~ 60°C (15°C~ 50°C is recommended)
The figure below shows that HES is installed on the machine. The screws must be secured to the
rubber mat to fixate the servo oil pump. It is recommended to add iron bars as the support of the
hybrid servo motor.
Rubber Mat*4
Iron bar
Installation Space
Installation Distanc
e
10cm
[4inch] 10cm
[4inch]
10cm
[4inch]
Since heat is generated as the hybrid servo motor is running, certain space must be reserved to
ensure good circulation of the cooling air as shown in the figure above.
When the hybrid servo motor is running, the temperature of the external cover will reach to about
100°C. Please do not touch it with hand to avoid burns.
NOTE
Please do not let any foreign objects such as fiber, paper pieces, wood chips or metal pieces to adhere to the cooling fan
of the hybrid servo motor.
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Chapter 1 Use and Installation|HES Series
1-7
Pipelines & Connections
Remove all protection caps on the pump
Choose suitable oil tube and connectors (Maximum intake flow rate 1m/s)
Recommended Specifications of intake oil tube
Flow Rate(L/min) Tube Diameter (inch) Length (m)
63 Above 1.25 Within 1.5
80 Above 1.5 Within 1.5
100 Above 1.75 Within 1.5
125 Above 2 Within 1.5
160 Above 2.25 Within 1.5
200 Above 2.5 Within 1.5
Absolute intake oil pressure: Maximum 2 bar
Prior to assembly, the iron dusts in the connectors and oil tubes must be removed.
The filter for the oil inlet must be above 150mesh.
NOTE
For safety, please install safety valvein the oil line loop.
Do not add check valve to the oil outlet of the oil pump to avoid poor response of Hybrid Energy System.
Hybrid Servo Controller
Please install the Hybrid Servo Controller in an environment with the following conditions to ensure
safe product operation:
Conditions of
Operation
Environment
Environment Temperature
Relative Humidity
Pressure
Installation heights
Vibration
-10°C~ +45°C
<90%，No condensation
86 ~ 106 kPa
<1000m
<20Hz: 9.80 m/s2(1G) max; 20~50H:5.88 m/s2(0.6G) max
Conditions of
Storage and
Shipping
Environment
Environment Temperature
Relative Humidity
Pressure
Vibration
-20°C~ +60°C (-4°F ~ 140°F)
<90%，No condensation
86 ~ 106 kPa
<20Hz: 9.80 m/s2(1G) max; 20 ~ 50Hz: 5.88 m/s2(0.6G) max
Contamination
Protection Grade 2nd Grade: suitable for factory environments with medium to low contamination
Installation Space
HAir Flow
H
WW
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Chapter 1 Use and Installation|HES Series
1-8
HP W
mm (inch) H mm (inch)
7.5-20HP 75 (3) 175 (7)
25-75HP 75 (3) 200 (8)
100HP 75 (3) 250 (10)
;The Hybrid Servo Controller must be installed vertically with screws to sturdy structures. Do not
install it upside down, tilted, or horizontally.
;Since heat is generated when Hybrid Servo Controller is running, good circulation of the
cooling air must be provided as shown in the figure above. Certain space is reserved in the
design to allow the heat generated to dissipate upwards.As a result, do not install the machine
below any equipment that cannot stand excessive heat. If the machine is installed in the control
plate, special care must be given to maintain good air flow for cooling so that the surrounding
temperature of Hybrid Servo Controller won’t exceed the regulated values. Do not install Hybrid
Servo Controller in any closed box with poor air flow and cooling, which will lead to machine
malfunction.
;As the Hybrid Servo Controller is running, the temperature of the cooling plate will change with
the environment temperature and the load, with the maximum temperature reaching to about
90°C. Therefore, the backside of installation materials for Hybrid Servo Controller must be able
to sustain high temperature.
;When multiple Servo Controllers are installed in one single control plate, it is recommended to
install them with laterally to avoid heat interference among each other. If stacking installation is
needed, spacers must be installed to minimize the effect of the heat from the lower machine on
the upper machine.
NOTE
Do not add check valve to the oil outlet of the oil pump to avoid poor response of Hybrid Energy System.
The product should be installed in a control plate made of inflammable materials such as metal to avoid the risk of fire.
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Chapter 1 Use and Installation|HES Series
1-9
1-5 Dimensions
Servo Oil Pump
HES063H23A, HES063G43A, HES063H43A,
HES080G23A, HES080H23A, HES080G43A, HES080H43A
HES100G23A, HES100H23A, HES100G43A, HES100H43A
HES125G23A, HES125H23A, HES125G43A, HES125H43A
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Chapter 1 Use and Installation|HES Series
1-10
HES160G23A, HES160G43A, HES160H43A
HES160H43A
HES200G43A
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Chapter 1 Use and Installation|HES Series
1-11
Hybrid Servo Controller
Frame C
W
W1
H1
H
D
S1
S1
Unit: mm[inch]
Frame W W1 H H1 H2 H3 D Ø Ø1 Ø2 Ø3
C235
[9.25]
204
[8.03]
350
[13.78]
337
[13.27]
320
[12.60] - 136 [5.35]
6.5
[0.26] - 34 [1.34]
22
[0.87]
NOTE
Frame C: VFD110VL23A/43A-J,
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Chapter 1 Use and Installation|HES Series
1-12
Frame D
DW1
W
H1
H
S1S1
Unit: mm[inch]
Frame W W1 H H1 H2 H3 D Ø Ø1 Ø2 Ø3
D 255.0
[10.04]
226.0
[8.90]
403.8
[15.90]
384.0
[15.12]
360.0
[14.17]
21.9
[0.86]
168.0
[6.61]
8.5
[0.33]
44
[1.73]
34
[1.34]
22
[0.87]
NOTE
Frame D: VFD150VL23A/43A-J, VFD185VL23A/43A-J, VFD220VL23A/43A-J,
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Chapter 1 Use and Installation|HES Series
1-13
Frame E
W1
W D
H1
H2
S2
H
D1
S1
D2
S3
Unit: mm[inch]
Frame W W1 H H1 H2 D D1 D2 S1 S2 S3
E1 370.0
[14.57]
335.0
[13.19] - 589.0 [23.19]
560.0
[22.05]
260.0
[10.24]
132.5
[5.22]
18.0
[0.71]
13.0
[0.51]
13.0
[0.51]
18.0
[0.71]
E2 370.0
[14.57]
335.0
[13.19]
595.0
[23.43]
589.0
[23.19]
560.0
[22.05]
260.0
[10.24]
132.5
[5.22]
18.0
[0.71]
13.0
[0.51]
13.0
[0.51]
18.0
[0.71]
NOTE
Frame E1: VFD300VL43A-J, VFD370VL43A-J, VFD450VL43A-J,
Frame E2: VFD300VL23A-J, VFD370VL23A-J,
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Chapter 2 Wiring|HES Series
2-1
Chapter 2 Wiring
2-1 Wiring
2-2 Wiring of Servo Oil Pump
2-3 Descriptions of Main circuit Terminals
2-4 Descriptions of Control Loop Terminals
Upon opening the top cover of the Hybrid Servo Controller and reveal the wiring terminal bus, check if
the terminals of each Main circuit circuit and control loop circuit are labeled clearly. Pay attention to the
following wiring descriptions to avoid any incorrect connection.
;The Main circuit power terminals R/L1, S/L2, and T/L3 of the Hybrid Servo Controller are for power
input. If the power supply is connected by accident to other terminals, the Hybrid Servo Controller
will be damaged. In addition, it is necessary to verify that the voltage/current rating of power supply
is within the numbers listed on the name plate.
;The ground terminal must be grounded well, which can avoid being stricken by lightning or
occurrence of electrocution and minimize interference by noise.
;The screw between each connection terminal and the wire must be tightened securely to avoid
sparking by getting loose from vibration.
DANGER
;If the wiring is to be changed, first step is to turn off the power of the Hybrid Servo
Controller, for it takes time for the DC filter capacitor in the internal loop to
completely discharge. To avoid any danger, the customer can wait for the charging
indicator (READY light) to be of completely and measure the voltage with a DC
voltmeter. Make sure the measured voltage is below the safety value of 25Vdc
before starting the wiring task. If the user fails to let the Hybrid Servo Controller
completely discharge, residual voltage will build up internally, which will cause
short circuit and spark if wiring is conducted. Therefore, it is recommended that the
user should only conduct the wiring when there is no voltage to ensure his/her
safety.
;The wiring task must be conducted only by professional personnel. Make sure that
the power is off before starting to avoid incidence such as electrocution.
;During wiring, please follow the requirements of the electrical regulations to select
proper gauges and conduct wiring accordingly to ensure safety.
;Check the following items after finishing the wiring:
1. Are all connections correct?
2. No loose wires?
3. No short-circuits between terminals or to ground?
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Chapter 2 Wiring|HES Series
2-2
2-1 Wiring
The wiring of the hybrid energy system consists of that for the servo oil pump and that for the Hybrid
Servo Controller. The user must follow the wiring loop below for all wire connections.
Standard Wiring Diagram
RC
RA
RB
MO1
MO2
SON
RES
MI3
MI4
MI5
COM
PI
ACM
QI
ACM
Output terminal
input terminal
Controller
L1
L2
L3
R
S
T
MalfunctionIndicator
Start Oil
Pump
Reset
U
V
W
PG Card Encoder
Connector
1
2
+24V
ACM
3
PO
Pressure Sensor
Unused
A
C
FAN
220V
Pressure
Command
Flow Rate
Comman
d
M
3~
U
V
W
MCM
Blowairtothe
electromotor
AFM
ACM
Set as output frequency
as manufactured
0~10Vdc/2mA
Feedback
Signal
+1 +2/B1 B2
Brake Resistor (optional)
-
Note 1*
Correct Wiring Method
If wirin
g
is conducted before settin
g
parameters, error messa
g
e will be displa
y
ed
COM
EMG
Protection
switch for
electromotor
overheating
Note 2*
Please use the
enclosed clips
Unused
Call 1(800)985-6929 for Sales
deltaacdrives.com
[email protected]
Call 1(800)985-6929 for Sales
deltaacdrives.com
[email protected]