INVT CHV110 Series Instruction Manual

1
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.

2
Table of Contents
1. Energy Saving Principle………………………………………..………………………..1
2. Product Features……………………………………….………..………..……………..2
3. Application Environment………………………………………..…..………….………..3
4. Installation and Configuration………………………………….………………………..4
4.1 Environmental Requirements…………………………….…………………………5
4.2 Outside Dimensions of Energy Saver………………………………………………6
4.3 Connection of Injection Molding Machine with Energy Saver……………………7
4.4 Operation Instructions for Current Signal Acquisition Card…………………….10
4.5 Signal Acquisition Method of Injection Molding
Machine…………………….….11
4.6 Description 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 and Maintenance……………………………………………………….….…...36
7.1 Daily Check………………………………………………………………….………36
7.2 Periodic Check…………………………………………………………….….…….36
8. Warranty…………………………………………………………………….……………38
9. Additional Information……………………………………………………….………….39
Attachment 1: List of Functional Parameters……………………………………………40
Attachment 2: Standard Wiring Diagram………………………………………………...50
Attachment 3: Warranty Card……………………………………………………………..52

Energy Saving Principle
For 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.
1

Product Features
CHV110 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;
2

Application Environment
To 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.
3

Installation and Configuration
4
WARNING
Safety Instructions
Please 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”.
Indicates potential hazards that, if not avoided, could result in loss of
life or serious injury.
Indicates 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.
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 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 Mark

•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.
•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 45ºC; overheat may
result in file or damage to the equipment.
WARNING
Caution
4.1 Environmental Requirements
Energy 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 -10°C to 40°C.
Excessively high or extremely low temperature may lead to equipment fault.
5

• 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 Saver
6

A (mm) B(mm) C(mm)
Model and Power
Range Outside Dimensions
CHV110-(07R5-015)T3 300 685 250
CHV110-(018-030)T3 350 846 270
CHV110-(037-055)T3 390 935 285
CHV110-075T3 431 985 360
•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 100Ωor lower;
Grounding resistance for 400V grade shall be 10Ωor lower;
Grounding resistance for 660V grade shall be 5Ωor 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.
7
Warning
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 Saver
4.3.1 Schematic diagram of connection of injection 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 Diagram of Connection of Injection Molding Machine to Energy Saver
WARNING
8

•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 100Ωor lower;
Grounding resistance for 400V grade shall be 10Ωor lower;
Grounding resistance for 660V grade shall be 5Ωor 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.
•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.
CAUTION
4.3.2 Main loop terminals consist of:
1) Three-phase AC power input terminals: R, S, T
2) Ground wiring terminal:
3) Motor wiring terminals: U, V, W
Distribution of main loop terminals is shown in Figure 4.3.2
RSTUVW
Figure 4.3.2 Main Loop Terminal Block of the Energy Saver for Injection Molding Machine
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4.3.3 Terminals of control loop:

Figure 4.3.3 Wiring Terminals of Control Loop
Terminal
Name
Purpose and Description
S1∼S5
Digital input terminals, forming optical coupling isolation input with PW and
COM;
Input voltage range: 9~30V
Input impedance: 3.3 KΩ
HDI1 (HDI2)
High-speed pulse or digital input, forming optical coupling isolation input with
PW and COM;
Range of pulse input frequency: 0-50 KHz
Input voltage range: 9~30V
Input impedance: 1.1 KΩ
PW
External 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 mA
COM Common terminal for +24V or external power supply
AI1 (AI3, AI4) Analog input, voltage range: 0V~10V
Input impedance: 10 kΩ
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 for open collector output
HDO
High-speed pulse output terminal, with the corresponding common terminal
as COM;
Output frequency range: 0~50 KHz
AO1 (AO2)
Analog output terminal: optional voltage or current output through jumper
J19;
Output range: voltage (0~10V)/current (0~20 mA)
PE Grounding terminal
RO1A, RO1B,
RO1C
RO1 relay output, RO1A common terminal, RO1B normally close, RO1C
normally open
Contact capacity: AC 250V/3A, DC 30V/1A
RO2A, RO2B,
RO2C
RO2 relay output, RO2A common terminal, RO2B normally close, RO2C
normally open
Contact capacity: AC 250V/3A, DC 30V/1A
RO3A, RO3B,
RO3C
RO3 relay output, RO3A common terminal, RO3B normally close, RO3C
normally open
Contact capacity: AC 250V/3A, DC 30V/1A
10

4.3.4 Composition of pressure and flow signal input terminals
The composition of pressure and flow signal input terminals of the energy saver for
injection molding machine is shown in Figure 4.3.4
1) Current signal channel 1, 1IA, 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.
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1IA 1IB 2IA 2IB
Figure 4..4.4-1 Appearance of Current Signal Acquisition Card
The card has four wiring terminals, as shown in Figure 4.4.4-2.
1IA 1IB 2IA 2IB

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Figure 4.4.4-2 Wiring Terminals
Where, 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 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
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 Ammeter
Method 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 also determine whether it is
proportional pressure or proportional flow signal by the current scale of a multimeter.
Method 3: Collecting signals on the proportional pressure and proportional flow solenoid
valves. On the oil way block on the both ends of an injection molding machine, there are a
number of solenoid valves, most of which are directional valves. Unlike directional valves,
the proportional pressure and proportional flow solenoid valves are often combined
together and looks much bigger than flow valves. The user can also determine whether
they are proportional pressure and proportional flow solenoid valves by the current scale
13

of a multimeter.
Note: Proportional pressure and flow signals must be 0-1A current signals, and the signal
acquisition card must be connected in series with such signals. Proportional pressure and
flow signals flow into the signal acquisition card from 1IA/2IA, and flow out from 1IB/2IB. If
the signal acquisition card is reversely connected, it cannot collect any signals and the
injection molding machine has no action signal.
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 exits the level-1 menu; deletes
shortcut parameter
DATA
ENT
Confirmation
key
Enters menus level by level; conforms
parameter setting
UP key Increase of data or functional code
DOWN key Decrease of data or functional code
14

Key
Symbol Name Function Description
>>
SHIFT SHIFT key
Displays parameters cyclically in the stop
display interface and operation display
interface; select the bit to be modified
when modifying a parameter
RUN
RUN key Used for operation in keypad operation
mode
STOP
RST
STOP/RESE
T key
In operation state, press this key to stop
the operation; restricted by the functional
code P7.04. In fault alarm state, press this
key to reset any control mode.
QUICK
JOG
Multifunctiona
l shortcut key
Function of this key is determined by the
functional code P7.03:
0: Quick function of shortcut menus;
enters or exits level-1 menu.
1: Switching between forward rotation and
reverse rotation; the changeover key
2. JOG operation, forward rotation JOG
key
3. Clearing UP/DOWN settings: Clears
frequency values set by UP/DOWN keys
RUN
+
STOP
RST
Combination
Press the <RUN> key and the
<STOP/RST> key at the 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: If the indicator
is off, it means the inverter is in the forward rotation
state; if the indicator is on, it means the inverter is
in the reverse rotation state.
LOCAL/REM
OT
Keypad operation, terminal operation, and remote
communication control indicator:
If the indicator is off, it indicates the inverter is in the
keypad operation control mode; if the indicator
flickers, it indicates the inverter is in the operation
control state; if the indicator is on, it indicates the
inverter is in the remote operation control state.
TRIP
Overload alarm indicator:
If it is in the overload alarm state, the indicator
flickers; otherwise, the indicator is off.
2) Description of unit indicators
15

16
Symbol Description
Hz Frequency unit
A Current unit
V Voltage unit
RPM Rotation speed unit
% Percent
3) Digital display area
The 5-digit LED display can display various monitoring data such as set frequency and
output frequency as well as alarm code.
4.7 Operation Procedures
4.7.1 Parameter setting
Three-level menus:
1) Functional code group number (level-1 menu);
2) Functional code 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-2 menu without saving the parameter, and still stays at the current functional
code.
For example, change the value of the functional code P1.01 from 00.00 Hz to 01.05 Hz.
Stop/Run

Figure 4.7.1 Level-3 Menu Operation Flow Diagram
In the level-3 menu, if no bit of parameters flickers, it indicates the functional code cannot
be modified. The possible causes include:
1) The functional code cannot be modified, for example, actually measured
parameters and operation record parameters.
2) The functional code cannot be modified in the operation state; you have to stop
the 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 the shortcut
menu has the same effect as modifying the parameter in the common programming state.
A maximum of 16 functional parameters can be added t the shortcut menu. The user can
17

18
add or delete 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: