SYRUNS SY6000-Z Series User manual

Contents
PREFACE...............................................................................................1
CHAPTER 1 PRINCIPLE OF ENERGY SAVING...............................2
CHAPTER 2 FEATURES......................................................................4
2.2 INSTRUCTION OF MODEL NO.............................................................4
2.3 SPECIFICATIONS ................................................................................4
2.4 OVERALL DIMENSIONS......................................................................5
CHAPTER 3 INSTALLATION..............................................................6
3.1 INSTALLATION SITE ...........................................................................6
3.2 PRECAUTIONS:..................................................................................6
3.3 MAIN CIRCUIT AND CONTROL CIRCUIT .............................................7
CHAPTER 4 OPERATION....................................................................8
4.1 SWITCHOVER BETWEEN POWER FREQUENCYAND ENERGY-SAVING.8
4.1.1 Running at energy-saving switching to power frequency......8
4.1.2 Running at power frequency switching to energy saving......8
4.2 TESTING STAGE OF THE CABINET......................................................9
4.3 NORMAL USING STAGE......................................................................9
4.4 KEYPAD OPERATION.................................................................10
4.4.1 KEYPAD FUNCTION ......................................................................10
4.4.2 KEYPAD BASIC OPERATION ..........................................................10
4.4.2.1 Direct display status..........................................................10
4.4.2.2 Switchover of display parameter.......................................10
CHAPTER 5 PARAMETERS..............................................................12
CHAPTER 6 TROUBLESHOOTING.................................................18
6.1 FAULT CODE AND REASON ANALYSIS ..............................................18
6.2ADJUSTMENT OF DEFECTIONS.........................................................20
CHAPTER 7 MAINTENANCE...........................................................22
7.1 DAILY INSPECTION..........................................................................22
7.2 REGULAR MAINTENANCE................................................................22
7.3 PERIODIC MAINTENANCE................................................................23
7.4 STORAGE.........................................................................................23
0

User Manual of SY6000-Z series Preface
1
PREFACE
Thanks for choosing SY6000-Z series moulding injection
energy saving cabinet.
SY6000-Z series cabinet is high quality moulding injection
energy saving drive which is designed according to
IEC618000/IEC610000. The cabinet owns protection functions of
phase-loss, over voltage, under voltage, over current, etc.
SY6000-Z series cabinet is suitable for kinds of moulding
injection machine with hydraulic control proportional pump. It
controls output power of motor according to pressure signal and
flow signal of moulding injection machine to reach the objective
of energy saving. The energy saving rate may get 25%~65%.
SY6000-Z series cabinet can work for pump motors which
power ratings are from 11KW~55KW. It also can apply for one
moulding injection machine with multiple pump motors.
Before using SY6000-Z series cabinet, in order to keep
people in safe and acquire better energy-saving effect, please read
the manual thoroughly. If you meet with tough problems when
using, please contact us in time.
Please retain this manual and you will use it if necessary in
future.

User Manual of SY6000-Z series Principle of energy-saving
Chapter 1 Principle of energy saving
Power consumption of moulding injection machine
mainly in the following sections:
①Power consumption of hydraulic pump system;
②Power consumption of heaters;
③Power consumption of circulating cooling water pump
Electricity consumption of hydraulic pump accounts for
80% energy consumption of the injection molding machine, so
reducing the power consumption is the key to save energy for
molding injection machine.
The pressure and flow are changing when molding
injection machine is in matching mould, cross locking,
injection, material storing, cooling and other stages.
When oil need of the injection molding machine changes,
the relief valve in pump outlet will adjust pressure and flow of
the load, while the output motor power is the same, thus results
in waste of energy.
According to requirements of pressure and speed at the
current work status of moulding injection machine, such as
stages of mold, lock cross, shooting rubber, material storage
and cooling, SY6000-Z series cabinet can adjust automatically
the pump speed the fuel supply to make actual fuel supply be
consistent with actual load flow at any working stage.
Thus it eliminates overflowing of hydraulic oil, reduces
pump output, and saves electricity consumption of pump motor,
so as to achieve the best energy-saving state of moulding
injection machine.
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User Manual of SY6000-Z series Principle of energy-saving
3

User Manual of SY6000-Z series Features
Chapter 2 Features
2.1 SY6000-Z series cabinet is suitable for quantitative pump
moulding injection machine. Its features are as follows:
zAdopt advanced space voltage vector PWM control algorithm, with
advanced technology and low output current harmonic content, without
power supply pollution
zWith timing functions, cumulative working time can be recorded
under energy saving state.
zAdopt high-quality imported components, product quality assured
zExcellent fault management and protection features make cabinet and
motor away from damage under no circumstance
zLarge capacity of instantaneous impact current, up to 250%; overload
capacity 180% per minute
zNo trip when the moulding injection machine is under high pressure
plastic injection and heavy load, so as do not affect production, ensure
product quality
zAdvanced integrated cabinet, with switchover of power frequency /
energy saving, with dedicated air channel, compact structure, easy to
install
2.2 Instruction of model no.
2.3 Specifications
Voltage
class Model no. Power rating (kW) Rated output current (A)
SY6000-Z01140Y 11.0 243PH
380V SY6000-Z01540Y 15.0 33
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User Manual of SY6000-Z series Features
Voltage
class Model no. Power rating Rated output current (kW) (A)
SY6000-Z01840Y 18.5 39
SY6000-Z02240Y 22.0 44
SY6000-Z03040Y 30.0 60
SY6000-Z03740Y 37.0 75
SY6000-Z04540Y 45.0 90
SY6000-Z05540Y 55.0 110
2.4 Overall dimensions
Installation dimensions of SY6000-Z series AC Drives (unit: mm)
Voltage
class Model no. W H H1 D D1
SY6000-Z01140Y
SY6000-Z01540Y 320 630 660 200 225
SY6000-Z01840Y
SY6000-Z02240Y
SY6000-Z03040Y 390 780 810 300 325
SY6000-Z03740Y
SY6000-Z04540Y
3PH
380V
SY6000-Z05540Y 500 850 880 350 375
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User Manual of SY6000-Z series Installation
Chapter 3 Installation
3.1 Installation site:
In order to get good performance and long lifespan, the installation
site should meet the following conditions:
zGood indoor ventilation.
zAmbient temperature-10 ~40 .℃℃
zHumidity less than 90%RH, without dew.
zDon’t install in the combustibles such as woods.
zAvoid direct sunlight.
zNo combustible, explosive, corrosive gases and liquids.
zNo ash dust, oil dust, floatable fibers and metal particles.
zStrong installation base, no vibration.
zNo electromagnetic interference.
3.2 ★Precautions:
1. The cabinet applies for injection equipment which is dragged by
general three-phase AC induction motor or inverter motor. Motor
insulation class is B or above.
2. General three phase induction motor, which is driven by the
cabinet, can not run in long term at low speed.
3. Capacitor, VDR and other RC absorbing devices are not allowed
to connect with output terminals of the cabinets.
4. If there are contactors between the cabinet and the motor, must
ensure that the cabinet doesn’t output when the contact switches,
otherwise the cabinet may be damaged.
5. Installation environment should be well ventilated.
6. The cabinet should be used derating if the altitude is higher
than1000 meters. Derate using 10% when the altitude rises 1500 meters.
7. Compare with running at power frequency, temperature rise and
noise of the motor will increase slightly when use the cabinet. This is
6

User Manual of SY6000-Z series Installation
normal phenomenon.
8. The cabinet will be as industrial waste when scrap it, so please
be careful:
(1) Inner polyester capacitors probably explode if set it on fire.
(2) Plastic pieces may produce toxic gases when burn it.
3.3 Main circuit and control circuit
7

User Manual of SY6000-Z series Operation
Chapter 4 Operation
4.1 Switchover between power frequency and energy-saving
4.1.1 Running at energy-saving switching to power frequency
1. The cabinet runs at the state of energy-saving, and the indicator lights.
2. Turn off pump motor of moulding injection machine, and make sure
the motor has stopped.
3. Rotate changeover switch, the indicator of power frequency running
lights at this time, then the cabinet starts running at the state of power
frequency running.
4. Start main motor of moulding injection machine, and start normal
operation
4.1.2 Running at power frequency switching to energy saving
1. The cabinet runs at the state of power frequency, and the indicator of
power frequency running lights.
2. Turn off pump motor of moulding injection machine, and make sure
the motor has stopped.
3. Rotate changeover switch, the indicator of energy saving running
lights at this time, then the cabinet starts running at the state of energy
saving running.
4. Start main motor of moulding injection machine, and start normal
operation.
★Key point:
Turn off the motor of moulding injection motor before switchover
between power frequency and energy saving running, then start switching
between power frequency and energy-saving.
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User Manual of SY6000-Z series Operation
4.2 Testing stage of the cabinet
Under circumstance of same mould and raw material, measure
electricity consumptions of moulding injection machine at two running
states of power frequency and energy saving during the same time, and
calculate energy saving rate.
When switch power frequency and energy saving, technician should
adjust timely parameters of moulding injection machine and the cabinet
until it produces qualified products.
For some types injection molding machines, don’t need change
parameters of moulding injection machine after adjustment of the cabinet,
as switchover between power frequency and energy saving doesn’t effect
product quality.
4.3 Normal using stage
After installation and adjustment of the cabinet, please run the cabinet
at the state of energy saving in normal use.
When users need replace moulds, technician only need adjust the
parameters of flow and pressure until it produces qualified products.
Precautions:★
1. Shunting changeover switch is forbidden during running. Otherwise
it will cause malfunction to the cabinet.
2. Do not convert running of power frequency/ energy saving, so as to
avoid protection action of the cabinet.
Warning:★
Do not connect AC power supply to output terminals (U, V, W),
otherwise will lead to damage the cabinet, and even cause fires!
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User Manual of SY6000-Z series Operation
4.4 Keypad operation
4.4.1 Keypad function
Control panel keypad of SY6000-Z series energy saving cabinet
consists of LED digital monitor, LED indicator, operation keys and panel
potentiometer, as shown in Figure 4-1.
Figure 4-1 Name and instruction of keypad
4.4.2 Keypad basic operation
4.4.2.1 Direct display status
Direct display status of SY6000-Z series cabinet refers to initial
display mode after power on, which is used for displaying output
frequency of the cabinet.
4.4.2.2 Switchover of display parameter
In the status of direct display, we can view or modify function
10

User Manual of SY6000-Z series Operation
parameters by keypad operations.
Figure 4-2 Operation procedure of parameter setting
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User Manual of SY6000-Z series Parameters
Chapter 5 Parameters
Basic functions of molding injection machines
Function
code Description Setting range Default Model No.
Group F0 Basic function
F0.00 Running setting
selection
0:keypad running
1:terminal running
2:communication
running
0 ◎0
F0.01 Max output
frequency F0.02～600.00Hz 50.00Hz ◎1
F0.02 Upper limit
frequency F0.03～F0.01 50.00Hz ◎2
F0.03 Lower limit
frequency 0.00 Hz～F0.02 0.00Hz ◎3
F0.04 Acceleration time
0 0.1～3600.0s Depend on models ○4
F0.05 Deceleration time
0 0.1～3600.0s Depend on models ○5
F0.06 Rated power
rating 1.5～400.0kW Depend on models ●6
F0.07 Rated current 0.0～760.0A Depend
on models ●7
F0.08 Parameter
initiation
0: No operation
1: Restore default
2: Clear fault record 0 ◎8
Group F1 Frequency setting
F1.00 Keypad setting
frequency 0.00 Hz～F0.01 50.00Hz ○9
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User Manual of SY6000-Z series Parameters
13
Function
code Description Setting range Default Model No.
F1.01 Main frequency
command
0: Keypad
1: AI1
2: AI2
3: HDI
4: Simple PLC
5: Multi-step speed
6: PID
7: Communication
8: Potentiometer
0
○
10
F1.02 Auxiliary frequency
command
0: AI1
1: AI2
2: HDI 0 ○11
F1.03 Auxiliary
frequency
reference
0: Max output
frequency
1: Main frequency
command
0
○
12
F1.04 Frequency command
selection
0: Main
1: Auxiliary
2: Main + auxiliary
3: Max (main,
auxiliary)
0
○
13
F1.05 UP/DOWN
setting
0: Valid, save
UP/DOWN value
when power off
1: Valid, do not save
UP/DOWN value
when power off
2: Invalid
0 ○14
Group F2 Start/stop control
F2.06 Stop mode 0: Coast to stop
1: Free stop 0 ○28
F2.12 Lower limit
frequency mode 0: Run at lower limit frequency 0 ◎34

User Manual of SY6000-Z series Parameters
14
Function
code Description Setting range Default Model No.
(valid when
frequency lower
limit >0)
1: Stop
2: Sleep standby
F2.15 Power-on terminal
running protection
0: Disabled when
power on
1: Enabled when
power on
0 ○37
Group F6 enhanced function
F6.10 No. of fault auto
reset 0～9 0 ○117
F6.11 Interval time of
fault auto reset 0.1～100.0s 1.0s ○118
Group FA enhanced function
FA.14 Third latest fault
type ●212
FA.15 Second latest fault
type
0: No failure
1:Inverter unit
p
rotection (FLT)
2: Reserved
3: Reserved
4: Acc over-current
(OC1)
5: Dec over-current
(OC2)
6: Constant speed
over-current (OC3)
7: Acc over voltage
(OE1)
8: Dec over voltage
(OE2)
9: Constant speed ove
r
voltage (OE3)
10:Bus under-voltage
failure (Uv)
●213

User Manual of SY6000-Z series Parameters
15
Function
code Description Setting range Default Model No.
FA.16 Latest fault
Purpose
11:Motor overload
(OL1)
12: Over load (OL2)
13: Reserved
14: Output phase
failure (SPO)
15: Over heat (Ot)
16: Reserved
17: External fault (EF)
18:Communication
error (CE)
19:Current detection
error (ItE)
20: Moto
r
self-learning error (tE)
21: EEPROM
operation error (Err)
22:PID feedbac
k
disconnection erro
r
(PIDE)
23: Braking unit faul
t
(bCE)
24: Reserved
●214
Group Fd Molding injection
Fd.00 Model selection
0: G purpose
1: P purpose
2: Molding injection
purpose
0 ◎238
Fd.01 Max input of proportional flow
control valve 0.0%~100.0% 100.0% ◎239
Fd.02 Max input frequency of
proportional flow 0.00Hz~F0.01 50.00Hz ◎240

User Manual of SY6000-Z series Parameters
16
Function
code Description Setting range Default Model No.
control valve
Fd.03 Min input current of proportional
flow control valve 0.0%~Fd.01 0.0% ◎241
Fd.04
Min input
frequency of
proportional flow
control valve
0.00Hz~F0.01 0.00Hz ◎242
Fd.05
Input current
weighting
coefficient of
proportional flow
control valve
0.00~1.00 0.10 ◎243
Fd.06 Reserved 244
Fd.07 Reserved 245
Fd.08 Reserved 246
Fd.09 Reserved 247
Fd.10 Reserved 248
Fd.11 Max input current of proportional
flow control valve 0.0%~100.0% 100.0% ◎249
Fd.12
Max input
frequency of
proportional flow
control valve
0.00Hz~F0.01 50.00Hz ◎250
Fd.13 Min input of
proportional flow
control valve 0.0%~Fd.11 0.0% ◎251
Fd.14 Min input
frequency of 0.00Hz~F0.01 0.00Hz ◎252

User Manual of SY6000-Z series Parameters
17
Function
code Description Setting range Default Model No.
proportional flow
control valve
Fd.15
Input weighting
coefficient of
proportional flow
control valve
0.00~1.00 0.90 ◎253
Fd.16 Reserved 254
Fd.17 Reserved 255
Fd.18 Reserved 256
Fd.19 Reserved 257
Fd.20 Reserved 258
For more details, please reference to Chapter 5 of User Manual of
SY5000 series AC Drives.

User Manual of SY6000-Z series Troubleshooting
Chapter 6 Troubleshooting
6.1 Fault code and reason analysis
The protection circuit and fault output relay activates, and stop the
machine and show failure, after the cabinet detects abnormal situations.
Make sure to find the failure causes and countermeasures, and run the
cabinet after troubleshooting.
The cabinet will record last 3 times causes of the malfunction. After
fault reset, you can check records any time in group E in viewing
functional parameters (Parameters FA.14~FA.16). For fault codes
description, please check Table 6-1.
Table 6-1 Fault name and reason analysis
Fault
code Name Reason Troubleshooting
oC1
oC2
oC3
Over-current
in operation Output short circuit or mutation load
Please identify reasons,
and reset after taking
approximate measures. If
this is still on, please ask
for technical support.
oC2 Over-current
in accel
1. The setting value
of accel time is too
small; 2. Torque
compensation
voltage value is set
in an error.
1. increase accel time
value;
2. increase or decrease
torque compensation
voltage value
oC3 Over-current
in decel
1. The setting value
of decel time is too
small;
2. Output short or
load mutation.
1. increase decel time
value;
2. eliminate short-circuit or
load mutation
oE1 Over-voltage
in accel
oE3 Over-voltage
in operation
1.Power voltage is
too high; 2.load
speed has fluctuated
1.Make sure that the power
voltage is in the normal
range;
2. Decrease fluctuation of
load speed.
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User Manual of SY6000-Z series Troubleshooting
19
oE2 Over-voltage
in decel Load inertia (GD2) is too big
1. To change the decel time
so that it is suitable for the
load inertia;
2. connect braking unit
FLt
Intelligent
power
module
(IPM)
protection
1. Short-circuit
happens in the
upper and lower
bridge arms of IPM;
2. Other reason
causes oversized
transient current.
Please identify reasons,
and reset after taking
approximate measures. If
this is still on, please ask
for technical support.
Poff
Transient
power-cut or
under-voltage
fault
The power voltage
declines or transient
power failure
occurs in operation.
Please check power status
and wiring of input side.
ot Over-heat of
inverter
1. Cooling fan is
abnormal; 2.
Ambient
temperature is too
high; 3. Air vent is
blocked
1. Check fan operation;
2.Make inverter operating
environment meet the
requirements;
3. Eliminate dust of the air
vent.
oL Over load
1. motor over-load;
2. V/F feature or
torque
compensation
capacity is
uncertain.
1. Decrease load or replace
larger capacity inverter;
2. Increase or decrease
torque compensation
voltage
Err E2PROM write data
error
Errors happen when
E2PROM stores
data.
Please store this parameter
again by using SET key, or
initialize by using E-059
parameter, cut off the
power and then power on.
EF Emergency
stop Terminal input, EMS acts Confirm the signal connection.
Remark: E2PROM errors of wiring data, just display anomaly and don’t trip.