Delta VFD-VJ Series User manual

9-(

Preface
Thank you for choosing Delta’s high-performance Hybrid servo drive VFD-VJ Series
dedicated to plastic injection molding machine. The VFD-VJ series products are made of
high quality components and materials that incorporate the latest microcontroller
technology.
This manual is to be used for the installation, parameter setting, troubleshooting, and daily
maintenance of the Hybrid servo drive. To guarantee safe operation of the equipment, read
the following safety guidelines before connecting power to the Hybrid servo drive. Keep this
operating manual at hand and distribute to all users for reference.
To ensure the safety of operators and equipment, only qualified personnel familiar with
Hybrid servo drive are to do installation, start-up and maintenance. Always read this
manual thoroughly before using VFD-VJ series Hybrid Servo Drive, especially the
WARNING, DANGER and CAUTION notes. Failure to comply may result in personal injury
and equipment damage. If you have any questions, please contact your dealer.
Firmware version: V2.03
PLEASE READ PRIOR TO INSTALLATION FOR SAFETY.
DANGER
;AC input power must be disconnected before any wiring to the Hybrid
servo drive is made.
;Even if the power has been turned off, a charge may still remain in the
DC-link capacitors with hazardous voltages before the POWER LED is
OFF. Please do not touch the internal circuit and components. For safe
maintenance, use a multimeter to measure the voltage across the +1
and – terminals. The measured value should be lower than 25Vdc for the
system to operate normally.
;There are highly sensitive MOS components on the printed circuit boards.
These components are especially sensitive to static electricity. Please do
not touch these components or the circuit boards before taking anti-static
measures. Never reassemble internal components or wiring.
;Ground the Hybrid servo drive using the ground terminal. The grounding
method must comply with the laws of the country where theAC motor
drive is to be installed.
;This series of products is used to control the three-phase induction motors
and permanent magnet synchronous motors. It cannot be used for
single-phase motors or for other purposes.
;This series of products cannot be used on occasions that may endanger
personal safety.
;Please prevent children or unauthorized personnel from approaching the
Hybrid servo drive.

;Never connect the Hybrid servo drive output terminals U/T1, V/T2 and
W/T3 directly to the AC mains circuit power supply.
;DO NOT use Hi-pot test for internal components. The semi-conductor
used in Hybrid servo drive easily damage by high-voltage.
;Even if the 3-phase AC motor is stop, a charge may still remain in the
main circuit terminals of theAC motor drive with hazardous voltages.
;Only qualified persons are allowed to install, wire and maintain AC motor
drives.
;When the Hybrid servo drive uses an external terminal as its source of
operation commands, the motor may start running immediately after the
power is supplied. In this case, it may be dangerous to any on-site
personnel.
;DO NOT install the Hybrid servo drive in a place subjected to high
temperature, direct sunlight, high humidity, excessive vibration, corrosive
gases or liquids, or airborne dust or metallic particles.
;Only use Hybrid servo drives within specification. Failure to comply may result in
fire, explosion or electric shock.
;When the motor cable between Hybrid servo drive and motor is too long,
the layer insulation of the motor may be damaged. Please add an AC
output reactor to prevent damage to the motor. Refer to appendixA
Reactor for details.
;The rated voltage for Hybrid servo drive must be ≤240V (≤480V for 460V
models) and the mains supply current capacity must be ≤5000A RMS
(≤10000A RMS for the ≥40hp (30kW) models).
NOTE
The content of this manual may be revised without prior notice. Please consult our distributors or download the most
updated version at http://www.delta.com.tw/industrialautomation

Table of Contents
1. Use and Installation
1-1 Receiving and Inspection 1-2
1-2 Product Specifications 1-3
1-3 Selection of Hybrid Servo Drives and Motors 1-4
1-4 Product Installation 1-6
1-5 Product Dimensions 1-11
2. Wiring
2-1 Description of Wiring 2-2
2-2 Description of Terminals on Main Circuit 2-7
2-3 Description of Terminals on Control Circuit 2-11
3. Machine Adjustment Procedure
3-1 Description of Control Panel 3-2
3-2 Machine Adjustment Procedure 3-4
4. Description of Parameters
4-1 Summary of Parameters 4-2
4-2 Detailed Description of Parameters 4-9
5. Fault Diagnostic Methods
5-1 Error Messages 5-2
5-2 Over Current OC 5-7
5-3 Ground Fault Factor GFF 5-7
5-4 Over Voltage OV 5-8
5-5 Low Voltage Lv 5-8
5-6 Over Heat OH1 5-9
5-7 Overload OL 5-9
5-8 Phase Loss PHL 5-10
5-9 Electromagnetic/Induction Noise 5-11
5-10 Environmental Condition 5-12
6. Suggestions and Error Corrections for Hybrid Servo Drives
6-1 Maintenance and Inspections 6-2

6-2 Greasy Dirt Problem 6-2
6-3 Fiber Dust Problem 6-5
6-4 Erosion Problem 6-6
6-5 Industrial Dust Problem 6-7
6-6 Wiring and Installation Problem 6-8
6-7 Multi-function Input/Output Terminals Problem 6-9
7. Recommended Operations for Customers and Troubleshooting
7-1 Regular Maintenance and Check 7-2
7-2 Oil Contamination 7-6
7-3 Lint Issue 7-7
7-4 Corrosion Issue 7-9
7-5 Dust Issue 7-10
7-6 Installation and Wiring/Connection Issue 7-11
7-7 Multi-function Input/Output Terminal Application Issue 7-12
AppendixA Optional Accessories
A-1 Braking Resistor Selection Chart A-2
A-2 Non-fuse Circuit Breaker A-6
A-3 Fuse Specification A-6
A-4 Reactor A-7
A-4-1 AC Input Reactor Recommended Value A-7
A-4-2 AC Output Reactor Recommended Value A-7
A-4-3 Zero Phase Reactor A-9
A-4-4 DC Reactor A-10
A-5 Digital Keypad KPV-CE01 A-11
A-6 Speed Feedback PG Card Selection A-15
A-7 Communication Card A-19
A-8 EMI Filter A-20

1. Use and Installation
1-1
1. Description of Hybrid Servo Drives
1-1 Receiving and Inspection
1-2 Product Specifications
1-3 Overview of Hybrid Servo Systems
1-4 Product Installation
1-5 Product Dimensions
The Hybrid servo drive should be kept in the shipping carton or crate before installation. In order to retain
the warranty coverage, the Hybrid servo drive should be stored properly when it is not to be used for an
extended period of time. Storage conditions are:
;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 an environment containing corrosive gases and liquids.
;DO NOT place on the ground directly. It should be stored properly. Moreover, if the
surrounding environment is humid, you should put exsiccator in the package.
;DO NOT store in an area with rapid changes in temperature. It may cause
condensation and frost.
;If the Hybrid servo drive is stored for more than 3 months, the temperature should
not be higher than 30 °C. Storage longer than one year is not recommended, it could
result in the degradation of the electrolytic capacitors.
;When the Hybrid servo drive is not used for longer time after installation on building
sites or places with humidity and dust, it’s best to move the Hybrid servo drive to an
environment as stated above.

1-2
1-1 Receiving and Inspection
This VFD-VJ Hybrid servo drive has gone through rigorous quality control tests at the factory before
shipment. After receiving the Hybrid servo drive, please check for the following:
;Inspect the unit to assure it was not damaged during shipment.
;Make sure that the part number indicated on the nameplate corresponds with the part number of
your order.
If the registered information does not match your purchase order, or if the product has any problem,
please contact the dealer or distributor.
Nameplate Information
Let us take the 15HP/11kW 230V 3-Phase model as an example.
MODEL
INPUT
OUTPUT
Freq.Range
Version:1.00
:VFD110VL23A-J
:3PH180-264V50/60Hz43A
:3PH0-230V41.1A
11kW/15HP
:0~600Hz
110VL23AJT9310002
AC DriveModel
Input Spec.
OutputSpec.
OutputFrequencyRange
Software version
BarCode
SerialNumber
Model Explanation
VFD VL -110 23 A J
Version Type
MainsInputVoltage
185:25HP(18.5kW)
220:30HP(22kW)
300:40HP(30kW)
370:50HP(37kW)
450:60HP(45kW)
550:75HP(55kW)
750:100HP(75kW)
23:230V3-PHASE
43:460V 3-PHASE
Applicable motor capacity
055:7.5HP(5.5kW)
075:10HP(7.5kW)
110:15HP(11kW)
150:20HP(15kW)
Delta's high-performance Hybrid servo drive
Series Number Explanation
319T110VL23AJ
Production number
Production year 2009
Production factory
Production week
(T: Taoyuan, W: Wujian)
Model
230V 3-phase 15HP(11kW)

1. Use and Installation
1-3
1-2 Product Specifications
Specifications of 230V Series
Frame No. CDE2
Model No. VFD-_ _VL_ _A-J 055 075 110 150 185 220 300 370
Power (KW) 5.5 7.5 11 15 18.5 22 30 37
Horse Power (HP) 7.5 10 15 20 25 30 40 50
Output Current for
Continuous Operation
Over 60 sec (A) 33 46 62 90 119 119 180 248
Output Output Current for
Continuous Operation
Over 20 sec (A) 37 54 70 106 140 140 204 292
Input Current (A) 25 31 47 60 80 90 106 126
Tolerable Input
Voltage Variation Three-phase 200~240V 50/60Hz
Tolerable Supply
Voltage Variation ±10% (180~264V)
Power
Supply Tolerable Supply
Frequency Variation ±5% (47~63Hz)
Weight (kg) 8 10 10 13 13 13 36 36
Specifications of 460V Series
Frame No. CDE1 E2
Model No. VFD-_ _VL_ _A-J 055 075 110 150 185 220 300 370 450 550 750
Power (KW) 5.5 7.5 11 15 18.5 22 30 37 45 55 75
Horse Power (HP) 7.5 10 15 20 25 30 40 50 60 75 100
Output Current for
Continuous Operation
Over 60 sec (A) 21 27 36 46 58 62 102 124 155 187 255
Output Output Current for
Continuous Operation
Over 20 sec (A) 25 32 42 54 68 78 120 146 182 220 300
Input Current (A) 14 18 24 31 39 47 56 67 87 101 122
Tolerable Input
Voltage Variation Three-phase 380~480V, 50/60Hz
Tolerable Supply
Voltage Variation ±10% (342~528V)
Power
Supply Tolerable Supply
Frequency Variation ±5% (47~63Hz)
Weight (kg) 8 10 10 13 13 13 36 36 36 50 50
Common Features
Control method SVPWM
Speed Detector Resolver / Incremental Encoder
Speed Command Input DC 0~10V, 3-point calibration of analog input is supported
Pressure Command Input DC 0~10V, 3-point calibration of analog input is supported
Pressure Feedback Input DC 0~10V
General Purpose Input Signal 5 ch DC24V 8mA
General Purpose Output Signal 2 ch DC24V 50mA, 1 ch Relay output
Analog Output Voltage 1 ch dc 0~10V
Optional
Peripheral Speed Feedback PG Card Mandatory (Refer to Appendix A-5)

1-4
Braking Resistor Mandatory (Refer to Appendix A-1)
Pressure Sensor
Mandatory (It must has an output signal ranging within 0~10V, which can be configured
by Parameters 03-10~03-11;
The maximum pressure can be configured by Parameter 00-08)
Accessories
EMI Filter Optional (Refer to Appendix A-7)
Motor Protection Electronic thermal relay protection
Over Current
Protection Over current protection is activated at 300% of the rated current
Ground Leakage
Current Protection Activated when the leakage current is higher than 50% of the drive’s rated current
Voltage Protection Over Voltage Level: Vdc>400/800 V; Low Voltage Level: Vdc<200/400 V
Input Power Supply
Over Voltage
Protection Metal Oxide Varistor (MOV)
Protection
Feature
Over Temperature
Protection Built-in temperature sensor
Protection Level NEMA 1/IP20
Operation
Temperature -10°C~45°C
Storage Temperature -20°C~60°C
Humidity Below 90% RH (non-condensing)
Vibration 1.0G below 20Hz, 0,6G at 20~60 Hz
Cooling System Forced air cooling
Environment
Installation Altitude Altitude below 1,000m, keep from corrosive gasses, liquid and dust
International Certification

1. Use and Installation
1-5
1-3 Overview of Hybrid Servo Systems
PGCard
RST U V W
AC
FAN
220V/380V
Delta Hybrid
Servo
Drive
Flow Rate Command
(0~10V)
Pressure Command
(0~10V)
Pressure
Feedback
(0~10V)
Injector
Controller
Encoder signal
Brake resistance/
Brake Unit
Power
Terminal
Pressure
Sensor
Oil
Pump
1-3-1 Selection of Hybrid Servo Drives and Motors
Due to the differences in the hydraulic system in practical applications, the following choice of
drives and motors is provided as a reference.
In the following example, a flow of 64L/min and maximum holding pressure of 175Bar are
used.
1. Pump Displacement per Revolution
Based on the maximum flow of the system (L/min), the pump displacement per revolution
(cc/rev) can be calculated.
Example: If the maximum flow of the system is 64L/min and the highest rotation speed of
the motor is 2000rpm, the displacement per revolution is 64/2000*1000 = 32
cc/rev.
2. Maximum Torque of the Motor
Based on the maximum pressure (Mpa) and pump displacement per revolution (cc/rev),
the maximum torque can be calculated.
Example: For the required maximum pressure of 17.5 Mpa and pump displacement per
revolution of 32cc/rev
Torque = 17.5*32*1.3/(2*pi) = 116 N-m, where the factor 1.3 is used to compensate the
total loss in the system.
3. Rated Torque and Rated Power of the Motor
At the maximum pressure for the holding pressure, the required torque should be 1.5
times of the motor’s rated torque or less (depending on the data provided by the motor’s

1-6
manufacturer). Over such an operating condition, the over-temperature of the motor may
easily occur. Let us take the factor 1.5 as an example, if the rated torque of the motor is 77
N-m, the motor with a power of 12kW* and a rated speed of 1500 rpm can be chosen.
*The power of the motor is calculated by using )60/2()()(
π
ω
××
−
=
rpmmNTWP
4. Maximum Current of the Motor
Example: Check the parameter kt (Torque/A) in the motor’s specifications, if kt = 3.37, the
maximum current is approximately 116/3.37 = 34A at the maximum torque of
116 N-m.
5. Selection of Matched Hybrid Servo Drive
Example: Look up the over-load capability for each Hybrid servo drive in the product
specification chart
If the holding pressure is at the maximum pressure of 17.5 Mpa, and a pump of
32cc/rev is used, the required motor current is approximately 34A
For such a current value, the following models can be chosen
VFD075VL43A-J, the overload may occur within 20 sec.
VFD110VL43A-J, the overload may occur approximately after 60 sec.
NOTE
If there is no suitable motor that meets the specifications, a motor with a higher rated value can be used instead.
For any information about the Hybrid servo drives or any assistance in detailed configuration of your company's
products, please contact the manufacturer.
1-3-2 Selection of Pump for Hybrid Servo Motor
Select a pump with a suitable displacement based on the required flow rate and motor speed;
If low noise is required, you can choose the screw pump or internal gear type.If a high
volumetric efficiency is required, you can choose the piston pump or dual displacement
piston pump.
Comparison of Commonly Used Pump (This may vary for different pump manufacturers).
Type of Oil Pump Volumetric
Efficiency Flow Pulsation Rotation Speed Noise
Internal Gear Pump Low Medium Medium Low
Piston Pump High Low Low High
Screw Pump Medium High High Medium

1. Use and Installation
1-7
1-4 Product Installation
Please install the Hybrid servo drive under the following environmental conditions to ensure safety of
use:
Environmental
Condition for
Operation
Ambient temperature
Relative Humidity
Pressure
Installation Altitude
Vibration
-10°C~ +45°C
<90% (non-condensing)
86 ~ 106 kPa
<1000m
<20Hz: 9.80 m/s2(1G) max; 20~50H:5.88 m/s2(0.6G)
max
Environmental
Condition for Storage
and Transportation
Ambient temperature
Relative Humidity
Pressure
Vibration
-20°C~ +60°C (-4°F ~ 140°F)
<90% (non-condensing)
86 ~ 106 kPa
<20Hz: 9.80 m/s2(1G) max; 20 ~ 50Hz: 5.88 m/s2
(0.6G) max
Contamination
Protection Level Level 2: Applicable to factory environment with low-to-medium contamination
Space for Installation
HAir Flow
H
WW
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)
1. Mount the Hybrid servo drive vertically on a flat vertical surface object by screws. Other directions are
not allowed.
2. The Hybrid servo drive will generate heat during operation. Allow sufficient space around the unit for
heat dissipation.

1-8
3. The heat sink temperature may rise to 90°C when running. The material on which the Hybrid servo
drive is mounted must be noncombustible and be able to withstand this high temperature.
4. When Hybrid servo drive is installed in a confined space (e.g. cabinet), the surrounding temperature
must be within -10 ~ 40°C with good ventilation. DO NOT install the Hybrid servo drive in a space with
bad ventilation.
5. When installing multiple Hybrid servo drives in the same cabinet, they should be adjacent in a row with
enough space in-between. When installing one Hybrid servo drive below another one, use a metal
separation between the Hybrid servo drives to prevent mutual heating.
;Prevent fiber particles, scraps of paper, saw dust, metal particles, etc. from adhering to the heat
sink.

1. Use and Installation
1-9
Lifting
Please carry only fully assembled Hybrid servo drives as shown in the following. Lift the Hybrid servo
drive by hooking the lifting hole.
40-100HP (Frame No. E)
Step 1
Step 2
Step 3 Step 4

1-10
Flange Mounting
Step 1:
Please take out the 16 screws (8
screws for each top and bottom side of
the drive) and remove the fixed plate 1
and fixed plate 2) as shown in the
following figures.
3
4
1
2
7
8
5
6
fixed plate 1
1
2
5
6
3
4
7
8
fixed plate 2
Step 2:
place the 8 screws back in to secure
the fixed plate 1 and fixed plate 2 (as
shown in the following figures) with the
following torque.
Frame No. C: 14-17kgf-cm
[12.2-14.8in-lbf]
Frame No. D: 20-25kgf-cm
[17.4-21.7in-lbf]
Frame No. E: 20-25kgf-cm
[17.4-21.7in-lbf]
1
2
3
4
fixed plate 1

1. Use and Installation
1-11
1
2
3
4
fixedplate2
Step 3:
Please notice that it doesn’t need to
put those 8 screws shown in
the following figures back to
the drive. Moreover, please
make sure that these 2
different fixed plates are put in
the correct side as shown in
the figures.

1-12
1-5 Product Dimensions
Frame No. C
W
W1
H1
H
D
S1
S1
Unit: mm [inch]
Frame No. WW1 HH1 H2 H3 DØØ1 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 No. C: VFD055VL23A/43A-J, VFD075VL23A/43A-J, VFD110VL23A/43A-J,

1. Use and Installation
1-13
Frame No. D
DW1
W
H1
H
S1S1
Unit: mm [inch]
Frame No. WW1 HH1 H2 H3 DØØ1 Ø2 Ø3
D255.0
[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 No. D: VFD150VL23A/43A-J, VFD185VL23A/43A-J, VFD220VL23A/43A-J,