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.

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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
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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.
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• 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
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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.
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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
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