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DACHENG

DCSF-C Series Servo Driver


5.5~75KW(Corresponding 30T~3600T)

User

Manual

(Ver8.88)

Zhejiang Dacheng Electric Co., Ltd


Catalogue
Preface… … … … … … … … … … … … … … … … … … … … … … … … … … … … .4

Chapter 1 Product information… … … … … … … … … … … … … … … … … … … 5

1.1 DCSF-C servo driver naming rule… … … … … … … … … … … … ................................. 5

1.2 DCSF-C servo driver series… … … … … … … … … … … … … … … … … … … ..............5


1.3 Product dimension and installation drawing… … … … … … … … … … … … … … … 6
Chapter 2 Wiring … … … … … … … … … … … … … … … … … … … … … … … ...7

2.1 Wiring type… … … … … … … … … … … … … … … … … … … … … … … … … … … … … 7

2.2 The main loop terminals and wiring… … … … … … … … … … … … … … … … … … … ..7


2.2.1: Wiring Specification… … … … … … … … … … … … … … … … … … … … … … … … ..8
2.2.2 Wiring Method… … … … … … … … … … … … … … … … … … … … … … … … … … … 8
2.2.3 Cautions … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .8
2.3 Terminal … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 8
2.3.1 The main loop terminals… … … … … … … … … … … … … … … … … … … … … … … 8
2.3.2 Encoder Signal Input Terminal CN1(15 cores) … … … … … … … … … … … … … … .9
2.3.3 AI/ AO Terminal CN2(44cores)… … … … … … … … … … … … … … … … … … … … ..9
2.3.4 Telecommunication Terminal CN3(9 cores)… … … … … … … … … … … … … … … ..10
2.3.5 Input/Output Interface Type… … … … … … … … … … … … … … … … … … … … … ....11
2.3.6 Analog input terminal instructions… … … … … … … … … … … … … … … … … … .....11
2.4 Wiring safety information and notice… … … … … … … … … … … … … … … … … … ...12
2.4.1 Wiring… … … … … … … … … … … … … … … … … … … … … … … … … . … … … … ..12
2.4.2 Before electricity… … … … … … … … … … … … … … … … … … … … … … … … … ..12
2.4.3 After electricity..........................................................................................................13
2.4.4 In operation… … … … … … … … … … … … … … … … … … … … … … … … … … … ...13
2.4.5 Maintenance… … … … … … … … … … … … … … … … … … … … … … … … … … … ..13
2.5 Motor insulation inspection… … … … … … … … … … … … … … … ...… … … … … … ..13
2.6 Thermal protection of motor… … … … … … … … … … … … … … … . … … … … … . … 13
2.7 About motor heating and noise… … … … … … … … … … … … … … . … … … … … … ..13
2.8 About adapter motor… … … … … … … … … … … … … … … … … … .… … … … … … ...14
2.9 The daily maintenance and safeguard of servo driver… … … … … .… … … … … … ..15
2.10 Regular inspection… … … … … … … … … … … … … … … … … … … … … … … … … ..15
2.11 Wearing parts replacement Servo drive… … … … … … … … .… … ...… … … … … .… 15
2.12 The storage of servo drive… … … … … … … … … … … … … .… … … ..… … … … … ...16
2.13 Servo driver's warranty instructions… … … … … … … … … .… … .… .… … … … … .....16
2.14 Selection guidance… … … … … … … … … … … … … … … … ..… … .… … … … … … ...16
2.15 Brake component selection guide................................................................................17
2.15.1 Resistance value choice… … … … … … … … … … … … … .… … … … … … … … .… .17
2.15.2 The power choice of braking resistance… … … … … … … … … … … … … … … … ..17

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Chapter 3 Parameters and display of Keyboard… … … … … … … ..18
3.1 Panel Description..........................................................................................................18
3.2 Menu operating instructions… … … … … … … … … … … … … … … … … .....................18
3.3 The operating instructions… … … … … … … … … … … … … … … … … … … … … … … 20
3.4 Control parameters… … … … … … … … … … … … … … … … … … … … … … … … … ...20
3.5 Alarm parameters… … … … … … … … … … … … … … … ...… … … … … … … … … .… ..38
3.6 PID Adjust introductions… … … … … … … … … … … … … … … … … … … … … … … ..39
3.7 PID Adjusting method… … … … … … … … … … … … … … … … … … … … … … … … .40

Chapter 4 Installation and adjustment for injection machine… … ...41


4.1 Notice… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … ...41
4.2 Notice for sensor installation… … … … … … … … … … … … … … … … … … … … … . .41
4.3 About unload… … … … … … … … … … … … … … … … … … … … … … … … … … … ..41
4.4 Computer knowledge… … … … … … … … … … … … … … … … … … … … … … … … ...41
4.5 About wiring instructions for servo to injection molding machine… … … … … … … 43
4.6 Fast commissioning explanation… … … … … … … … … … … … … … … … … … … … .44
4.7 About pressure volume linear proofreading… … … … … … … … … … … … … … … … 44
4.8 Need to adjust related parameters for servo injection molding machine… … … … … 46
4.9 The specification for “Dacheng ”servo motor and servo drive… … … … … … … … ...46
4.10 Servo for multiple pump… … … … … … … … … … … … … … … … … … … … … … … 47
4.11 Master-slave multiple pump… … … … … … … … … … … … … … … … .. … … … … … 48
4.12 Jumper instruction for DSP5 board… … … … … … … … … … … … … . … … … … … .48
4.13 About explanations for internal pressure usage and flow function… … … … … … .49
4.14 About commissioning fault and treatments for injection machine… .. … … … … … 50

Chapter 5 Wiring diagram drawing… … … … … … … … … … … … 50

Chapter 6 Selection and calculation for servo… … … … … … … ...53


6.1 The selection for servo oil pump parts… … … … … … … … … … … … … … … … … … 53
6.1.1 Oil pump selection… … … … … … … … … … … … … … … … … … … … … … … … ...53
6.1.2 The selection for servo motor type… … … … … … … … … … … … … … … … … … ..53
6.1.3 The selection for servo drive type… … … … … … … … … … … … … … … … … … … 53

Chapter 7 Introduction of servo motor… … … … … … … … … … ...54


7.1 Servo motor naming rule… … … … … … … … … … … … … … … … … … ..................54
7.2 Servo motor dimension… … … … … … … … … … … … … … … … … … … … … … … … 54
Appendix 1… … … … … … … … … … … … … … … … … … … … … … … … … … 55

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Preface
DCSF-C series servo drivers are the products that we have co-developed with
Harbin Institute of Technology and we have the proprietary intellectual property rights.
The series of servo drivers adopt the latest Digital Signal Processing Chips of American
TI company and CPLD as core control chip. The implement of the advanced vector
algorithms together with our successful experience in automatic control field has helped
realize the design optimization of servo driver’ s software and hardware. Adaptive
control algorithm can adapt parameters dynamically and improve the accuracy and
speed of system control according to the change of controlled objects. Besides, we use
the imported IPM to ensure the perfect protection, reliable operation and stable
performance.
Our company has proved the reliability of our servo drivers through a large number
of product application, thus to guarantee you use our DCSF-C series servo drivers in a
safe and reliable way. DCSF-C series servo driver is the right system developed for
driving permanent magnet synchronous (PMSM) servo motor. The range of DCSF-C
series servo driver is wide (rated current (15A-600A), to achieve servo oil pump control,
also to realize the general servo function demand. It is the good performance of high
power servo drive for market.
The manual is the handbook for DCSF-C series servo driver operation. It is for selection,
installation, parameters setting, commissioning and diagnosis.
To correct sure the servo driver, please prior read this manual before operation, and
save it for future reference. Equipment supporting customers will send this manual with
good to final user.
Goods inspection:
Please confirm when unpacking:
1)Whether it is same for the model and rated value of this driver. It is including
machine, product certification, user manual and warranty bill.
2)If there is any breakage phenomenon during transportation; Please contact with your
supplier if missing or damaged.
Initial use:
Please read this manual carefully before first use. Please contact with my technical
support staff for help if there are some doubts for function and performance. It is
useful for us.
Due to the constant improvement of the servo drive and innovation, so the data we
offered are subject to change without prior notice.
DCSF-C series servo driver meet the above international standard, some of products
have been get the CE certification:
IEC/EN 61800-5-1:2003 Adjustable electric transmission system safety requirements;
IEC/EN 61800-3:2004 Adjustable electric transmission system;
Third part:The electromagnetic compatibility product standard and its specific test
method.

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Chapter 1 Product information
1.1 DCSF-C servo driver naming rule:

1.2 DCSF-C servo driver series


Rated
Power Input
output Adaptable system pressure of
Servo driver model Input voltage capacity current
current injection molding machine(kgf)
(kVA) (A)
(A)
DCSF-C550S380V8.86 9 13.0 12.0

DCSF-C750S380V8.86 12 18.0 16.0

DCSF-C900S380V8.86 15 22.0 20.0

DCSF-C1100S380V8.86 18 25.5 24.0


Three-phase
380V 175
DCSF-C1500S380V8.86 25 38.0 35.0
rang:-15%~20%
DCSF-C1850S380V8.86 30 45.0 42.0
DCSF-C2200S380V8.86 42 52.0 50.0

DCSF-C3000S380V8.86 50 76.0 71.0

DCSF-C4500S380V8.86 60 112.0 100.0

DCSF-C5500S380V8.86 75 150.0 140.0

DCSF-C7500S380V8.86 100 182.0 175.0

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1.3 Product dimension and installation drawing

5.5kW-11kW servo driver dimension drawing

13kW-30kW servo driver dimension drawing

37kW-55kW servo driver dimension drawing

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Chapter 2 Wiring
2.1 Wiring type

Internal terminal drawing of Servo driver for injection molding machine


2.2 The main loop terminals and wiring

2.2.1: Wiring Specification


1. We suggest you to use insulating cold pressure terminals and make sure firm

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connection.
2.We suggest you to use three phase isolation transformer for power supply.
2.2.2: Wiring Method
1. For the input and output signal wire and encoder wire, please use the shielded one.
The length should be: input wire: within 10m; encoder signal wire: within 10m.
Condition permitting, the shorter the wire is, the better.
2. One end of the grounding wire should be earthed. And the diameter of the wire must
be no less than 2.5mm.
3. In the environment with serious disturbance, noise filter is suggested to be installed.
While installing, pay attention to the following items:
● Try to install the noise filter, the servo driver and the supervisory controller as
close as possible.
● Don’t make the main circuit and the signal wires go through the same pipeline,
nor tie them together.
4. Please fit a no-melt circuit breaker(NFB) to cut off the external power supply when
there’ s a trouble in running., for example, air switch.
2.2.3 Cautions
1.match the wiring of U、V、W with terminal U,V,W respectively. You can not make
the motor run backward by changing the wiring of three phase terminals.
2. Because of a lot of electrolyte and capacitance in the servo drivers, there is still high
voltage in the internal circuit even if the power is off. So please electrify servo drivers
five minutes later.
3. Please cut off the power supply if you don’t use the machine for a long time.
4. Definition of rotating direction: Facing the machine shaft, rotating shaft rotating in an
anticlockwise direction is called Forward Rotation; on the other hand, it is Backward
Rotation.
2.3 Terminal
2.3.1: The main loop terminals
Terminal mark Signal name Function
L1
Main circuit
L2 Three phase AC220V 50Hz
power
L3
Rectify anode
P
output Braking output , connect braking devices between P and PB
PB Brake output
Output machine
U U phase
power
Output machine
V V phase
power
Output machine
W W phase
power

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PG Grounding Grounding
Match the wiring of U、V、W with terminal U,V,W respectively, never cross
Special Attention needed: P,PB are terminals of external braking resistors. Because P
and PB are connected with internal high voltage circuit, so please don’t touch the
Terminal P and Terminal P B in case of electric shock., and avoid collision between
Terminal P and PB, terminal P ,PB and other terminals to prevent damage to drivers
because of short circuit.
2.3.2: Encoder Signal Input Terminal CN1(15 cores)
Terminal
Symbol Signal Name Remark
No.
1 Ref+ Variable Exc signal+ Connect with Photoelectric Encoder A+
2 Ref- Variable Exc signal _ R2 White
3 sin- Variable output sine - S4 Blue
4 sin+ Variable output sine + S2 Yellow
5 cos+ Variable output cosine + S1Red
6 cos- Variable output cosine - S3 Black
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8
9
10
11
12
14
15
16 PG PG Shielding layer
2.3.3: AI/ AO Terminal CN2(44cores)
Terminal No. Symbol Signal Name Function
1 Z+ Rotary Z+ Output
2 Z- Rotary Z- Output
3 CZ Z Collector Open-drain Output
4 GND
5 IN1 Digital Input Port 1 Servo forward enable
6 IN2 Digital Input Port 2 Servo reverse enable(only affect by
speed function
7 IN3 Digital Input Port 3 Internal pressure selection
8 IN4 Digital Input Port 4 Motor temperature alarm output
9 IN5 Digital Input Port 5 Server mode selection(internal flow
selection0
10 IN6 Digital Input Port 6
11 IN7 Digital Input Port 6
12 COM+ Digital Output Common Anode

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13 GND Digital Grounding
14 +24V 24v Power Output Max:300mA
15 DA Analog Output Terminals 0-10V
output
16 A+ Rotary A+ Output

17 A- Rotary A- Output
18 OUT1 Digital Output Port 1
19 OUT2 Digital Output Port 2
20 OUT3 Digital Output Port 3
21 OUT4- Digital Output Port 4 Alarm output
22 COM- Digital Output common anode
23 AD1 Analog Speed Input
24 AGND Analog Ground
25 AD2 Analog Torque Output
26 AGND Analog Ground
27 +15V Internal +15V Analog power Max:100mA
supply
28 Reserve
29 -15V Internal -15V Analog power Max:100mA
supply
30 Reserve
31 B+
32 B-
33 PLUS+
34 PLUS-
35 PDIR+
36 PDIR-
37 PCLR+
38 PCLR-
39 Reserve
40 Reserve
41 Reserve
42 +15V Pressure Sensor Power Only apply to Injection machine
43 AGND Pressure Sensor Power Ground Only apply to Injection machine
44 AD3 Pressure Sensor Signal Only apply to Injection machine
2.3.4: Telecommunication Terminal CN3(9 cores)
1 Reserve

2 TXD Send
3 RXD Accept
4 Reserve

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5 GND Ground wire
6 Reserve
7 Reserve
8 Reserve
9 Reserve
2.3.5:Input/Output Interface Type

Switch Signal Input

Switch Signal Output


1、 OUT1,OUT2,OUT3,OUT4 Max. load current: 100mA,Max. working voltage:
32V。
2、Customers can provide the external power source. Pay special attention to the power
polarity while wiring. Wrong polarity connection can cause damage to drivers.
3、In case of lagging load such as relays, connect anti-parallel freewheel diodes at the
two ends. Attention: inverse wiring can cause damage to the drivers.
2.3.6:Analog input terminal instructions :
Because of the weak simulation voltage signals are particularly vulnerable to
external interference, double shielded wire for connecting is preferred, and wiring
distance as far as possible short, not more than 20 m In some simulation signal serious
interference occasions, the additional filter capacitor and ferrite magnetic cores , as
shown below:

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Analogue input terminals wiring diagram

Analog input terminal handling the wiring diagram


2.4 Wiring safety information and notice
2.4.1:Wiring:
Should by professional electrical engineering staff construction, or get an electric
shock risk!
Servo drive, and there should be a separate power circuit breaker, or get an electric
risk!
Please confirm that the power supply before connection in shut off the state, or get
an electric shock risk!
Grounding terminals must be reliable grounding, or get an electric shock risk.
Can't the input power even to the output U V W, otherwise it will cause damage to
the servo drive
2.4.2:Before power:
Please confirm whether the power supply voltage level and servo driver rated
voltage consistent;whether Input/output of wiring position is correct,and check
whether any buffer circuit for short circuit phenomenon,Even if the line to tighten Or it
may cause a servo driver damage!
Servo driver must cover to cover the electricity, or it may cause a shock
Servo driver need not to carry on pressure test, the factory has done when the product
testing, users to test or it may cause accidents

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All peripheral accessories are provided in this manual circuit correct connection or it
may cause accidents
2.4.3:After power:
 Do not open the cover plate after power up or get an electric shock risk!
 Do not use wet hand touch servo driver and the surrounding circuit, or get an electric
shock risk!
 Do not touch the servo driver terminals (including control terminals), or get an
electric shock risk!
At the beginning of the electricity, servo drive system in high voltage automatic
external safety testing, at this time, please do not touch the servo driver U V W
terminals or motor terminals, or get an electric shock risk!
If you need to test run, please pay attention to the motor rotation the danger of hurt,
or it may cause accidents!
Please do not optional change servo driver manufacturer parameters, otherwise may
cause equipment damage!
2.4.4: In operation:
 Please do not touch the cooling fans and discharge resistance to test temperature, or
it may cause burns!
Amateur technicians do not in operation of testing signals, or it may cause a
personal injury or damage to the equipment!
Servo driver operation, to avoid things fall into the equipment otherwise it will cause
damage to the equipment!
It is forbidden for you to use the contactor off methods to control servo drive rev.
Stop otherwise it will cause damage to the equipment
2.4.5: Maintenance
Please do not charged for equipment repair and maintenance or get an electric shock
risk!
Confirm in servo drive after 10 minutes of power to servo driver implementation
maintenance and repair or capacitance on residual charge to people cause harm!
Without professional training personnel do not to servo driver implement repair and
maintenance or can cause injury or damage to the equipment
2.5: Motor insulation inspection
Motor first used in long placed the before and after again use regular check, should
do motor insulation inspection, due to the failure of the motor winding insulation and
damage the servo driver insulation inspection must will motor servo driver apart from
attachment, suggested the 500 V ohmmeter , should guarantee the insulation resistance
not less than 5 M Ω
2.6: Thermal protection of motor
If choose motor servo driver and rated capacity is not matching, especially servo
driver rated power greater than the motor power rating, be sure to adjust the servo drive
motor protection in the related parameters value or in motor with thermal relay to
before to motor protection
2.7: About motor heating and noise
Because of input voltage of servo driver is PWM waves, it contains certain harmonic

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and, therefore, the rise of temperature of the motor, noise and vibration frequency will
run the same work than a little increase.
1):The output side has pressure sensitive devices or improve the power factor of
capacitance
Servo driver output is PWM waves, the output side such as the installation of electrical
power factor improve with maybe the lightning protection with pressure sensitive
resistance, easy cause servo drive moment even damage over current servo drive, not
dot use.
2): Servo drive the input and output devices such as switching device used contact
If you should input in the contactor between power and servo drive, we are not
allowed to use this contact device control stop with servo drive. Need to use, not less
than an hour interval
Frequent fall easily charge and discharge in servo drive the service life of the capacitor
If the output and motor with contact between the switch device, shall ensure that no
output servo driver in the operation, or easy cause servo driver module in damage
3): Outside use of rated voltage value
Not suitable for manual by the allowed to work outside the scope of voltage use, easy
cause servo drive device in damage. If necessary, please use the corresponding or step
down device in the variable pressure processing
4): Three phase input change into two-phase
Do not change DCSF-C series three-phase of ac servo drive to two phase use,
otherwise will lead to failure or servo driver damage
5): Lightning shock protection
This series of servo drive in a lightning over current protection device, for induction
lightning have certain ability of self-protection. For frequent lightning in the client, also
you shall put protection in servo driver front
6): Elevation and de-rating use
At an altitude of more than 1000 m area, because thin air cause poor loose hot effect of
servo driver, it is necessary to drop the forehead Please contact with my technical staff
for this situation,
7): Some special usage
If customers ask us to provide us other methods outside wiring diagram in this manual
in use, such as with dc bus, etc, please consult with my technical department, the
telephone number is 86-0575-82168285。
8): The scrap attention of servo drive
Maybe it can explode if it was burned between the main loop and the electrolytic
capacitors on printed circuit board. Plastics can produce the poisonous gas burn ,you
can treat them as industrial waste please.
2.8: About adapter motor
1)Suitable for permanent magnet synchronous servo motor;
2)Servo drive motor has the default standard parameters, according to the actual
situation of the necessary for motor parameter identification or modify the default value
to try to conform to the actual value, otherwise, it will affect the effect of operation and

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protection performance.
3)Due to appear a short circuit of cable or on the internal motor ,it will cause servo
driver servo driver alarm, and even fry machine. Therefore, please do insulation
short-circuit test before first initial installation of electrical and cable, in daily
maintenance, you should do this test regularly.Note, it is necessary for you to
disconnect the servo driver and test part
2.9: The daily maintenance and safeguard of servo driver
1) Daily maintenance
Due to the environmental temperature, humidity, dust and vibration, can cause aging
of internal servo drive device, lead to potential failure or reduce service life of servo
driver. Therefore, it is necessary for us to implement daily and regular maintenance and
safeguard of servo driver
After the power off, because here are still high voltage of the filter capacitance, so it is
forbidden to immediately repair or maintenance on servo drive,
Must wait until the bus voltage no more than 36V of lights off charging with multi-
meter after charging
2)Daily inspection item
Check if an abnormal voice changes in the operation of motor voice;
Check there was a vibration in the motor running;
Check whether the installation environment of servo driver is changing;
Check if cooling fan is normal working of servo drive;
Check whether servo driver is overheating.
3)Daily cleaning:
Should always keep servo driver in a clean condition;
Effectively eliminates the dust of servo driver table area, prevent dust access internal
of servo driver. Especially metal powder; effectively eliminates grease of a cooling fan
in servo driver
2.10: Regular inspection
Please regularly check place difficult to check during operation
1)Regular inspection project:
Check the duct, and regularly clean;
Check whether there is a screw loose;
Check whether the servo drive from corrosion;
Check Whether there is a arc trace for terminals;
The main loop insulation testing
In measuring insulation resistance with (please use dc 500 V meg ohmmeter, you will
disconnect main return route and servo driver with meg ohmmeter .Do not test control
return route insulation with insulation resistance meter it is not necessary for do high
pressure test (completed before factory)
2.11: Wearing parts replacement Servo drive
The main wearing parts including cooling fan and electrolytic capacitor for filter, the
life have closely related with environment and maintain status in use. General life time:
Device life time:fan 2~3 year;electrolytic capacitor 4~5 year
Users can determine the exact date according to running time

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1) Cooling fan
May damage reason: bearing wear, leaf aging
Judging standard:whether there are crack for fan blades, and there are abnormal
vibration at startup
2)Filtering electrolytic capacitors
May damage reason:the poor quality for input power、higher、higher environmental
temperature,frequent load jump、Electrolyte aging
Judging standard:Check if liquid leaks out, the relief valve is already bulge, the
measurement for electrostatic capacitive, the determination of insulation resistance.
2.12: The storage of servo drive
Users must pay attention to following points for temporary storage and long-term after
buying:
1)Please ensure to pack into box with original package as far as possible .
2)Long time storage can lead to the degradation of electrolytic capacitor, must ensure
do a electricity within two years, at least five hours, input voltage regulator must be
slowly rise to ratings
2.13 Servo driver's warranty instructions
Warranty refers to only servo drive itself
1)In normal use, fault or damage, my company is responsible for the 12 months
warranty
(From the factory date , subject to laser labels on machine),our company will answer
for the maintain and will charge reasonable maintain costs generated by this more
than 12 months;
2)In the 12 months, if has the following circumstance, should charge some maintenance
cost :
The man-made damage for users who do not operate according to manual’s
instructions;
The damage due to flood, fire damage and abnormal voltage;
The damage for use driver to abnormal function;
The service fees according to manufacturer uniform standard calculation, such as a
contract, processing with priority to contract
2.14 Selection guidance
When choosing servo driver, first must be clear about the technical requirements of the
servo drive system, the application occasion and the specific situation of the load
characteristics, and depend on output voltage, rated current factors of adapter motor,
then choose the model, and operation mode
Basic rule:Rated load current motor servo driver can't more than a rated output
current.. There are short-term overload in the running, can cause changes in the velocity
of the load If you have higher demand of speed precision, please consider a higher class

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2.15 Brake component selection guide
Adapter
Adapter Magnet Module Adapter Adapter Input/output wiring Adapter braking
servo
motor ring current reactor filter mm2 resistance
driver
7.5kW 11kW Small 75A 30A 30A 4 ≥ 1kW/20Ω
9kW 15kW Small 75A 30A 42A 6 ≥ 1kW/20Ω
11kW 18.5kW Small 100A 40A 42A 6 ≥ 1.5kW/20Ω
13kW 18.5kW Big 100A 40A 50A 6 ≥ 1.5kW/20Ω
15kW 18.5kw Big 100A 40A 50A 10 ≥ 1.5kW/16Ω
17kW 22kW Big 150A 60A 50A 10 ≥ 1.5kW/16Ω
18.5kW 22kW Big 150A 60A 65A 10 ≥ 1.5kw/10Ω
22kW 30kW Big 150A 60A 65A 10 ≥ 2.0kW/10Ω
25kW 37 kW Big 150A 60A 65A 16 ≥ 2.0kW/10Ω
27kW 37kW Big 200A 80A 65A 16 ≥ 2.0kW/20Ω×2
30kW 37kW Big 200A 80A 65A 16 ≥ 2.0kW/20Ω×2
33kW 37kW Big 200A 80A 80A 16 ≥ 2.0kW/20Ω×2
37kW 45kW Big 200A 90A 100A 25 ≥ 2.0kW/20Ω×2
45kW 55kW Big 300A 110A 160A 25 ≥ 2.0kW/20Ω×3
Note:1:*The form is only for reference, specific depend on the working conditions of
different injection molding machine
2:×2 Said two braking resistance is used in parallel,×3 Said three braking resistance
is used in parallel
The above is the guide data, user can choose different resistance tolerance and power
according to the actual situation,(But resistance must not less than recommended value
in the table, can be more than power. The choice of braking resistance determine motor
power in actual application system, also related with system inertial, deceleration time,
the potential load energy, customers need to choose according to the practical situation.
The amount of system inertia is greater, the time to decrease is shorter, the number for
braking frequent is bigger, and the power of braking resistance need to greater, the
power resistance is smaller.
2.15.1 Resistance value choice
Braking, the renewable energy of motor almost consumed in the braking resistance
According this formula:U*U/R=Pb
U in formula----braking voltage for stabilize system braking(different value for
different system,for380VAC system, you can choose 690V),Pb----braking power。
2.15.2 The power choice of braking resistance
In theory, it is same value between braking resistance power and braking power, but
considering the de-rating is 70%。
Can according to this formula:0.7*Pr=Pb*D
Pr----resistance power;D----braking frequency(the proportion for braking process of
the whole process)
Injection molding machine braking load ----10%

17
Chapter 3 The parameters and display of Keyboard
3.1 Panel Description
The panel consists of six LED displays and 5 keys:

MENU ↑ ↓ ● OK

Key Name Meaning


Menu key:For choose the mode of the first floor or from another
MENU
layer return to the first layer.

Add key: said increase serial number or numerical


Reduce key: said reduce serial number or numerical


Commissioning button: to start motor


OK
Determine key: used to determine into the next layer or set of
parameters
3.2 Menu operating instructions
Enter or quit menu or back to the previous menu by pushing MENU button
The first level menu :
There are five kinds of mode:
DSP---:Display mode (showing speed, pulse information)
PRG---:Parameter setting mode (Set parameters for driver)
JOG---:Commissioning mode (It is useful for first time, you do not connect lead
wire, the motor will work)
AUT---:Zeroing mode(It is useful before factory or after repair)
EEP--- : Parameter management mode(For example, A factory value, backup
parameters, restore parameters)
The second level menu:
1、DSP Show Selection
1:SPd Display Speed (r/min)
2:Cod Display Encode (Pulse Count)
3:dCU Bus Voltage (V)
4:--tr Motor torque (digital value)
5:CoJ Pole Position
6:I-q q Shaft Current
7:I-d d Shaft Current
8:I-A A Phase Current
9:PdL Control pulse low 5
10:PdH Control pulse high 5
11:CdL Feedback pulse low 5

18
12:CdH Feedback pulse high 5
13:Cnt Position curve segment
14:Ad1 Analog signal 1(the digital quantity of simulation collection)
15:Ad2 Analog signal 2(the digital quantity of simulation collection)
16:Ad3 Analog signal 3(the digital quantity of simulation collection)
17:Iod Terminator input state

Display 1 for high level signal, do not show for low level signal
2、PRG Parameter setting selection:Pr01-Pr198

3、JOG Commissioning:(pushing ● button,the motor sets up,pushing

OK button,then stop working)

4、AUT((the second level menu) zeroing:

Press ● button,automatic measuring zero angles


of magnetic pole

AJ Automatic measuring angles Click OK button,the motor stop measuring zero

angles of magnetic pole

Press ● button, motor sets up, click ↓ ↑

button adjust zeroing angle


LJ measuring angle by hand
click OK button,the motor stop measuring zero
angles of magnetic pole

OK
AL Zeroing of Current Sensor Click button,the motor stop adjusting zero
angles of Current Sensor automatically

io Digital output testing click OK button,automatic output test

19
5、EEP backup and restore::SA Storing,LF default value,bF backup,HF restore,
Er software version(see8.80)
Parameter management method Details
EEP-SA In parameter Write parameters of EEPROM parameter zone
EEP-BF Parameter backup Write parameters of EEPROM backup zone
EEP-HF Parameter restore Read EEPROM backup data in the parameter table
EEP-LF The default value restore Read the default values of parameter in the parameter
table
EEP-Er Software version Show software version
3.3 The operating instructions
In the first level menu, click ↓ ↑ button,Choose any kinds of 5 modes.
Click OK button by enter the second menu, And then press
↓ ↑

button again to choose parameter modifies or function


.
Click OK button when finished. If modification completed,

please MENU button,and return to the previous page,Then click

↓ ↑ button to choose ERP,click OK button then

↓ ↑
press button to choose EEP-SA again,click OK button to write
parameter in EEPROM parameter zone, in order to save the parameter after power
failure.
↓ ↑
The digitals have changed more rapidly if clicking button again and
again when modification. It helps to modify big numbers quickly.
3.4 Control parameter (it is useful if tick”*”)
Serial Default
Name Unit Range Notes
number value

Commissioning
Pr-01 r/min 200 0-5000 The value of speed is always 200 when trial running
speed
Maximum
Pr-02 r/min 3000 0-5000 *Alarming over speed data
speed limit
Encoder *The encoder zeroing angle can measure automatically
Pr-03 1 600 0-2500
electrical angle through AUT-AJ of menu
U phase current The zero point of U phase current sensor can measure
Pr-04 0 ±5000
zero automatically through AUT-AJ of menu
V phase current The zero point of V phase current sensor can measure
Pr-05 0 ±5000
zero automatically through AUT-AJ of menu
Analog signal1 AD1 analog signal 1gain(corresponding the 23d foot of
Pr-06 2000 1-5000
gain CN2
Analog signal1 AD1analog signal 1zero (corresponding the 23rd foot of
Pr-07 0 ±5000
zero CN2

20
Analog signal2 AD2 analog signal 2gain(corresponding the 25th foot of
Pr-08 150 0-5000
gain CN2
Analog signal2 AD2 analog signal 2zero (corresponding the 25th foot of
Pr-09 0 ±5000
zero CN2
Pr-10 Internal speed 1 r/min 100 ±5000 *The first internal speed when internal speed control
Pr-11 Internal speed 2 r/min 200 ±5000 * The second internal speed when internal speed control
Pr-12 Internal speed 3 r/min 300 ±5000 * The third internal speed when internal speed control
Pr-13 Internal speed 4 r/min 400 ±5000 * The fourth internal speed when internal speed control
Analog signal 1
Pr-14 0.1ms 10 1-50 Smooth filtering of external analog signal 1
filtering
Analog signal 2
Pr-15 0.1ms 10 1-50 Smooth filtering of external analog signal 2
filtering
Pr-16 internal speed 5 r/min 500 ±5000 * The fifth internal speed when internal speed control
Pr-17 Internal speed 6 r/min 600 ±5000 * The sixth internal speed when internal speed control
Pr-18 Internal speed 7 r/min 700 ±5000 * The seventh internal speed when internal speed control
Pr-19 Internal speed 8 r/min 800 ±5000 * The eighth internal speed when internal speed control
Speed control gain, bigger value, sooner speed response.
Pr-20 Speed loop Kp 0.001 300 0-5000 bigger gain will cause oscillation easily, recommended
value is about 500-1500, value bigger for big load
Speed control points, bigger parameter, higher speed
points, to eliminate offset, the value should be smaller for
Pr-21 Speed loop ki 0.0001 100 0-5000
big inertia .The recommended value is within
1-200,smaller value, bigger load
Speed control feed- forward , bigger value to reach quicker
Pr-22 Speed loop kc 0.001 0 0-5000 response of little position deviation, especially in the high
speed response occasion.
Speed control differential, in general ,the value is about
Pr-23 Speed loop kd 0.001 0 0-1000
0-10
Torque positive
Pr-24 1 100 0-500 Torque positive maximum limit
limit
Torque negative
Pr-25 1 -100 -500-0 Torque negative maximum limit
limit
Response
Response frequency of speed loop 10kHZ/pr26,value will
Pr-26 frequency of 1 10 1-50
bigger for big load
speed loop
Acceleration The acceleration time, to increase this value to reach the
Pr-27 ms 1 0-30000
time soft start
Deceleration The deceleration time, to increase this value to reach the
Pr-28 ms 1 0-30000
time soft deceleration
The minimum
Analog the min speed limit when \ speed control, it is help
Pr-29 limit of analog r/min 0 ±100
for eliminate deviation of the analog signal,0 unrestricted
speed
Current control gain, the value is bigger, the quicker torque
Pr-30 Current loop kp 0.001 2500 0-5000
response, better rigidity. But overlarge gain will cause

21
oscillation easily, so the recommended value is within
1500-3000
Current control integral , the value is bigger ,the quicker
torque integral, eliminate offset, better rigidity for
Pr-31 Current loop ki 0.0001 100 0-5000
low-speed, value should be small for bigger inertia, he
recommended value is within 50-200
Current feed-forward function is to shorten setting time.
Instruction control unit will differential speed instruction
and sending current feed-forward command, and these two
Pr-32 Current loop kc 0.001 0 0-5000 commands will be sent to servo unit. If excessively use
current feed-forward, will appear overrun and undershoot
phenomenon, so adopt the optimum setting considering
response
Pr-33 Current loop kd 0.001 0 0-1000 C Current control differentiation, the value is about 0-10
The power
Pr-34 positive 850 0-5000 The positive maximum limit for power
maximum limit
The power
Pr-35 negative -850 -5000-0 The negative maximum limit for power
maximum limit
The positive
maximum limit
Pr-36 400 0-5000 The positive maximum limit of current loop weak magnet
of current loop
weak magnet
The negative
maximum limit
Pr-37 -400 -5000-0 The negative maximum limit of current loop weak magnet
of current loop
weak magnet
Encoder output
Pr-38 1 1-4096 It will run after power failure
frequency
Carrier
frequency0-10k The modulating frequency of power module, preference is
Pr-39 Hz 3 0-3
hz 1-8khz 4kHZ,please adjust if special load
2-6khz 3-4khz
Driver current
Pr-40 class 8 1-15 Current warning level including 15 levels
protection class
Positioning Error pulse number for position control(If increase this
Pr-41 accuracy for 1 pulse 1 1-100 value can eliminate oscillator occurrences for big-inertia
position control overload
Maximum
-5000-+500
Pr-42 speed for 1500 *The max speed limit for position control
0
position control
Speed for
-5000-+500
Pr-43 position change 200 *The automatically change zero for position curve control
0
curve

22
The return time
*The return positioning time for automatically change
Pr-44 for position 0.1s 10 0-1000
zero for position curve control
change curve
Nixie tube
Pr-45 1 1-16 The details seen 4.2
default display
Maximum
The max speed limit for torque control
Pr-46 speed limit of 1500 -3000-3000
torque
DC bus voltage
Pr-47 100 1-200 DC bus voltage gain
gain
DC bus voltage
Pr-48 0 -3000-3000 DC bus voltage zero
zero
Current
Pr-49 625 0-2000 Normal users are forbidden
feedback factor
The goal of
Pr-50 speed curved 100 0-5000 *
section 1
The
add-subtract
Pr-51 10ms 100 0-30000 *
time of speed
curved section 1
The goal of
Pr-52 speed curved 200 0-5000 *
section 2
The
add-subtract
Pr-53 10ms 100 0-30000 *
time of speed
curved section 2
The goal of
Pr-54 speed curved 300 0-5000 *
section 3
The
add-subtract
Pr-55 10ms 100 0-30000 *
time of speed
curved section 3
The goal of
Pr-56 speed curved 400 0-5000 *
section 4
The
add-subtract
Pr-57 10ms 100 0-30000 *
time of speed
curved section 4
The goal of
Pr-58 speed curved 500 0-5000 *
section 5

23
The
add-subtract
Pr-59 10ms 100 0-30000 *
time of speed
curved section 5
The holding
Pr-60 time of speed 10ms 100 0-30000 *
curved section 1
The holding
Pr-61 time of speed 10ms 100 0-30000 *
curved section 2
The holding
Pr-62 time of speed 10ms 100 0-30000 *
curved section 3
The holding
Pr-63 time of speed 10ms 100 0-30000 *
curved section 4
The holding
Pr-64 time of speed 10ms 100 0-30000 *
curved section 5
Injection
molding
Pr-65 machine 1 100 0-200 Used for Injection molding machine synchronous
synchronous
parameters
Filtering
the value is about 15-120,can reduce mechanical vibration
Pr-66 constant for low 1hz 180 1-200
for little adjustment
speed
Switching value
The value is 10,decrease this value can cut down speed
Pr-67 of speed control 1 10 0-1000
overshoot
PI-I-P
Switching value
Please choose value is 500,to decrease the value can cut
Pr-68 for current 1 500 0-1000
down current overshoot
control PI-I-P
The first and
Gain switching speed position for the position location,
second gain
200 decrease this value for increase position control gain1,2,but
Pr-69 switching 100 0-1000
(*100) too small gain cause oscillation easily, the value between
positioning for
100-500
position control
The first gain Position control gain, to increase this value can improve
Pr-70 Kp of position 10 1-100 position control rigidity. But the overlarge gain will cause
location oscillation easily, the value between 1-20 is better
Position control feed forward gain, increase value can
Position
improve positioning advanced speed of position control,
Pr-71 location feed 10 1-100
but the overlarge gain will cause oscillation easily, the
forward kc
value between 1-50

24
Electronic gear You must restart your system to take effect after power
Pr-72 1 1-30000
numerator failure
Electronic gear You must restart your system to take effect after power
Pr-73 2 1-30000
denominator failure
Input pulse
type:
1:OrthogonalA
B pulse
(positive)
2:Pulse+directio
n (positive)
3:Positive pulse
+ reverse pulse
You must restart your system to take effect after power
Pr-74 (positive) 1 1-6
failure
4:Orthogonal
AB pulse
(negative)
5:Pulse +
direction
(negative)
6:Positive pulse
+ reverse pulse
(negative)
The type of the
encoder output
pulse
0:Orthogonal
AB pulse
dividing
frequency
1:Pulse +
You must restart your system to take effect after power
Pr-75 direction 0 0-3
failure
channels
2:Orthogonal
AB pulse
synchronization
3:Orthogonal
pulse + back
pulse
synchronization
Current alarm
Pr-76 1 1 1-100 *The number of current alarm filtering
filtering

25
The gain factor proportion of position control, can enlarge
The second gain this value to improve quickness of position, but
Pr-77 1 5 1-100
of position overlarge the value can lead oscillation, we recommend
the better value about 20
The position
acceleration
Pr-78 time and 0.1ms 1 0-1000 Recommend 0.1ms
deceleration
time
Hydraulic
control mode
Pr-79 1 0-1 *Designed for injection molding machine
0 normal mode
1fast mode
The pressure closed loop gain for injection machine, the
Pressure closed
Pr-80 1 5 1-1000 bigger value to increase pressure inhibition efficiency, but
loop Kp1
easily oscillation, we recommend range about 50-30

The pressure closed loop points for injection machine, the


Pressure closed
Pr-81 1 5 1-1000 bigger value will Increase pressure tracking speed, we
loop Ki
recommend range about 10-50
Pressure Sensor Pressure Sensor gain,the unit of pressure is bar/MPa, we
Pr-82 1 800 1-8000
gain recommend the value about 800 when input signal 4-20mA
Pressure sensor
Pr-83 1 0 -2000-2000 The zero value of pressure sensor
zero
Pressure sensor
Pr-84 1 10 1-50 The number of smooth filtering for pressure sensor
filtering
Pressure closed
Pressure closed loop unloading speed
Pr-85 loop unloading 1 -500 -500-500
speed
Pressure closed Pressure closed loop feed forward, increase this value to
Pr-86 1 30 0-200
loop Kc reach rapid response
Speed
Pr-87- instruction 1 100 1000 0 Don't filter
smoothing filter
Current
Pr-88 instruction 1 100 1000 0 Don't filter
smoothing filter
Positioning complete range, positioning complete output
Pr-89 1 20 0-10000
condition value
Control mode Control mode selection(0 internal speed control
selection(0 1 Analog torque/ speed control 2 Analogue quantity
internal speed control 3 Torque control 4Default curve speed control 5
Pr-90 0 0 0-9
control Position curve control 6 Position control 7 Position
1 Analog controlled by computer 8 Speed controlled by computer 9、
torque/ speed 10、11 Pressure closed loop control(used for injection

26
control molding machine)
2 Analogue
quantity control
3 Torque control
4 Default curve
speed control
5 Position curve
control
6 Position
control
7 Position
controlled by
computer
8 Speed
controlled by
computer
9 Pressure
closed loop
control(used for
Plastic Injection
Machine)
10 Synchronous
speed mode,
used for
multiple pump
system for
injection
molding
machines
11 CAN direct
digital
communication
for injection
molding
machine
The min
synchronous
running speed
Pr-91 0 0 0-1 Special for injection molding machine
for injection
molding
machine

Pr-92 Motor pole 2 8 2-24 For manufacturer use

0:The maximal Recommend 3,if need high-speed(>2000rpm,please set the


Pr-93 0 0 0-3
efficiency value is 0

27
control
1 The maximum
power control
2 Combination
control
3 Automatic
tracking
0:pc do not
Pr-94 on-line 0 0 0-1 *Whether it is always connect with PC *
1:pc on-line
0 Encoder
Pr-95 1Rotating 0 1 0-1 The choice of feedback encoder
transformer
The negation of
Pr-96 0-1 0 The negation of alarm signal output
Alarm output
Stop mode
0:Free stop Stop mode 0:Free stop
Pr-97 0-1 0
1:Deceleration 1:Deceleration stop
stop
The target speed
Pr-98 of deceleration 0-5000 0 The target speed of deceleration stop
stop
Pr-99 Reserve 0 1 0-4 Used for manufacturer
The cycles of
Pr-100 the position 1 0-30000 0 The whole rotating cycle for motor
curve 0
The cycles
Pr-101 deviation of the 1 0-10000 0 Rotating decimal cycle of motor
position curve 0
The speed of
Pr-102 position curved 1 0-2000 0 Running speed limit for motor
section 0
Acceleration-de
celeration speed
Pr-103 1ms 0-1000 1 Curve time of acceleration and deceleration
of position
curved section 0
The cycles of
Pr-104 the position 1 0-30000 0 Motor running whole cycle
curved section 1
The cycles
deviation of the
Pr-105 1 0-10000 0 Motor rotating decimal cycle
position curved
section 1

28
The speed of the
Pr-106 position curved 1 0-2000 0 Motor running speed limit
section 1
Acceleration-de
celeration speed
Pr-107 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 1
The cycles of
Pr-108 the position 1 0-30000 0 Motor running whole cycle
curved section 2
The cycles
deviation of the
Pr-109 1 0-10000 0 Motor rotating decimal cycle
position curved
section 2
The speed of the
Pr-110 position curved 1 0-2000 0 Motor running speed limit
section 2
Acceleration-de
celeration speed
Pr-111 1ms 0-1000 1 *Curve acceleration and deceleration time
of position
curved section 2
The cycles of
Pr-112 the position 1 0-30000 0 Motor running whole cycle
curved section 3
The cycles
deviation of the
Pr-113 1 0-10000 0 Motor rotating decimal cycle
position curved
section 3
The speed of the
Pr-114 position curved 1 0-2000 0 Motor running speed limit
section 3
Acceleration-de
celeration speed
Pr-115 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 3
The cycles of
Pr-116 the position 1 0-30000 0 Motor running whole cycle
curved section 4
The cycles
deviation of the
Pr-117 1 0-10000 0 Motor rotating decimal cycle
position curved
section 4
The speed of the
Pr-118 position curved 1 0-2000 0 Motor running speed limit
section 4

29
Acceleration-de
celeration speed
Pr-119 1ms 0-1000 1 Curve t acceleration and deceleration time
of position
curved section 4
The cycles of
Pr-120 the position Motor running whole cycle
1 0-10000 0
curved section 5
The cycles
deviation of the
Pr-121 0-1000 Motor rotating decimal cycle
position curved 1 0
0
section 5
The speed of the
Pr-122 position curved Motor running speed limit
1 0-2000 0
section 5
Acceleration-de
celeration speed
Pr-123 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 5
The cycles of
Pr-124 the position 0-3000 Motor running whole cycle
1 0
curved section 6 0
The cycles
deviation of the
Pr-125
position curved 1 0-10000 0 Motor rotating decimal cycle
section 6
The speed of the
Pr-126 position curved Motor running speed limit
1 0-2000 0
section 6
Acceleration-de
celeration speed
Pr-127 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 6
The cycles of
Pr-128 the position 0-3000 Motor running whole cycle
1 0
curved section 7 0
The cycles
deviation of the
Pr-129
position curved 1 0-10000 0 Motor rotating decimal cycle
section 7
The speed of the
Pr-130 position curved Motor running speed limit
1 0-2000 0
section 7

30
Acceleration-de
celeration speed
Pr-131 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 7
The cycles of
Pr-132 the position 0-3000 Motor running whole cycle
1 0
curved section 8 0
The cycles
deviation of the
Pr-133 Motor rotating decimal cycle
position curved 1 0-10000 0
section 8
The speed of the
Pr-134 position curved Motor Running speed limit
1 0-2000 0
section 8
Acceleration-de
celeration speed
Pr-135 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 8
The cycles of
Pr-136 the position Motor running whole cycle
1 0-30000 0
curved section 9
The cycles
deviation of the
Pr-137 Motor rotating decimal cycle
position curved 1 0-10000 0
section 9
The speed of the
Pr-138 position curved Motor running speed limit
1 0-2000 0
section 9
Acceleration-de
celeration speed
Pr-139 1ms 0-1000 1 Curve acceleration and deceleration time
of position
curved section 9
The cycles of
the position
Pr-140 Motor running whole cycle
curved section 1 0-30000 0
10
The cycles
deviation of the
Pr-141 Motor rotating decimal cycle
position curved 1 0-10000 0
section 10
The speed of the
Pr-142 position curved Motor running speed limit
1 0-2000 0
section 10

31
Acceleration-de
celeration speed
Pr-143 of position 1ms 0-1000 1 Curve acceleration and deceleration time
curved section
10
The cycles of
the position
Pr-144 Motor running whole cycle
curved section 1 0-30000 0
11
The cycles
deviation of the
Pr-145 Motor rotating decimal cycle
position curved 1 0-10000 0
section 11
The speed of the
Pr-146 position curved 1 0-2000 0 Motor running speed limit
section 11
Acceleration-de
celeration speed
Pr-147 of position 1ms 0-1000 1 Curve acceleration and deceleration time
curved section
11
The cycles of
the position
Pr-148 1 0-30000 0 Motor running whole cycle
curved section
12
The cycles
deviation of the
Pr-149 1 0-10000 0 Motor rotating decimal cycle
position curved
section 12
The speed of the
Pr-150 position curved 1 0-2000 0 Running speed limit for motor
section 12
Acceleration-de
celeration speed
Pr-151 of position 1ms 0-2000 1 Curve acceleration and deceleration time
curved section
12
The cycles of
the position
Pr-152 1 0-30000 0 Motor running whole cycle
curved section
13
The cycles
deviation of the
Pr-153 1 0-10000 0 Rotating decimal cycle of motor
position curved
section 13

32
The speed of the
Pr-154 position curved 1 0-2000 0 Motor running speed limit
section 13
Acceleration-de
celeration speed
Pr-155 of position 1ms 0-1000 1 Curve acceleration and deceleration time
curved section
13
The cycles of
the position
Pr-156 1 0-30000 0 Motor running whole cycle
curved section
14
The cycles
deviation of the
Pr-157 1 0-10000 0 Motor rotating decimal cycle
position curved
section 14
The speed of the
Pr-158 position curved 1 0-2000 0 Motor running speed limit
section 14
Acceleration-de
celeration speed
Pr-159 of position 1ms 0-1000 1 Curve acceleration and deceleration time
curved section
14
The cycles of
the position
Pr-160 1 0-30000 0 Motor running whole cycle
curved section
15
The cycles
deviation of the
Pr-161 1 0-10000 0 Motor Rotating decimal cycle
position curved
section 15
The speed of the
Pr-162 position curved 1 0-2000 0 Motor running speed limit
section 15
Acceleration-de
celeration speed
Pr-163 of position 1ms 0-1000 1 Curve acceleration and deceleration time
curved section
15
The cycles of
the position
Pr-164 1 0-30000 0 Motor running whole cycle
curved section
16

33
The cycles
deviation of the
Pr-165 1 0-10000 0 Motor rotating decimal cycle
position curved
section 16
The speed of the
Pr-166 position curved 1 0-2000 0 Motor running speed limit
section 16
Acceleration-de
celeration speed
Pr-167 of position 1ms 0-1000 1 Curve acceleration and deceleration time
curved section
16
Low voltage
Pr-168 Kg 0-200 5 Only for used for injection molding machine
setting
Bottom flow
Pr-169 1 0-5000 20 Only for used for injection molding machine
setting

Pr-170 1 0-1000 15 Fixed point for 15kg pressure

Fixed point for 30kg pressure


Pr-171 1 0-1000 30

Fixed point for45kg pressure


Pr-172 1 0-1000 45

Fixed point for 60kg pressure


Pr-173 1 0-1000 60

Fixed point for 75kg pressure


Pr-174 1 0-1000 0

Fixed point for 90kg pressure


Pr-175 1 0-1000 1

Fixed point for 105kg pressure


Pr-176 1 0-1000 0

Fixed point for 120kg pressure


Pr-177 1 0-1000 0

Fixed point for 135kg pressure


Pr-178 1 0-1000 0

Fixed point for 150kg pressure


Pr-179 1 0-1000 1

The choice of
Pr-180 control 0-1 0 Used by manufacturer
algorithm
Mechanical
resonance wave
Pr-181 0.01% 0-80 0 Gain attenuation factor of mechanical resonance wave
attenuation
factor

34
Mechanical
Pr-182 resonance wave 1RPM 0-4000 0 Mechanical resonance wave speed
speed
Automatic gain
attenuation
factor
Pr-183 0.01% 0-80 0 Attenuation factor of speed gain from 1000cycle to 0cycle
(inhibit
low-speed
vibration)
Local
Pr-184 communication 0 0-254 Mod bus Protocol address
address
The choice of 0:Customize
Pr-185 communication 100 0-1000 1:mod bus-RTU
protocol 2: Injection molding machine monitoring
Time delay for
Pr-186 flat machine 10ms 100 1-1000 Used for flat machine
stops

The selection of communication baud rate


The selection of
0:57600
Pr-187 communication 0 0-2 0
1:28800
baud rate
2:38400

Positive and
negative limit
Pr-188 speed for Rpm 700 1-2000 Positive and negative limit speed for stocking machine
stocking
machine
The min speed
Pr-189 Rpm 0 0-50 Less than this speed, the torque is not exist
of torque limit
Inverted
restricting
The high or low selector of positive and counter torque
Pr-190 signal of Level 0 0-1
restricting signal
positive-
counter torque
Judge filtering
number of
Pr-191 200 1-2000 Only used for stocking machine
stocking mode
stops
The output
Pr-192 0-1 0 0-50 0 With electricity 1without electricity
mode of braking

35
Often open and
closed choice of
Pr-193 0 0-1 1 often open 2 often closed
direct pressure
flow
The min alarm
Pr-194 limit of low V 0-1000 0 0 unrestricted
pressure
The max torque
Pr-195 1 800 0-2000 Used by manufacturer
measuring limit
The switch of
Pr-196 writing 0 0-1 0 to close;1 to open
computer data
Administrator
Pr-197 1 123 1000 Password is 123
Password

36
The use of
default load
parameters
0 normal mode
1Numerical
Control System
mode
2Big inertia
load mode
3Socking
machine mode
4 Reserve
mode
5 Flat machine
6 injection
molding
Pr-198 machine The choice of default parameters mode
7 injection
molding
machine
synchronous
mode
8 injection
molding
machine CAN
direct digital
communication
mode
9 Injection
molding
machine
master-slave
switch mode
Change
Pr-199 password of 1 0 1000 Password is 111
Parameters

37
3.5 Alarm parameters
Name Introductions Note
1:Too heavy load Check oil pump of motor is jammed
2:Abnormal encoder Check whetjer it is normal forcod
3:The value of Pr20,Pr21,too big Reduce parameters
4:The value of Pr24,Pr25,too big Reduce parameters
Module overheating
AL-01 5:Damaged module or overheated Fan does not turn, Planted wave is too high
protection
6:There are no earth cable for driver The bad grounding contacts,with oil
7:Improper wiring connection The wrong wriing sequence for UVW
8:Bad insulation of generate power Electric leakage
9:The main CPU board was damaged Replace main CPU board(attention jumper)
1:Abnormal encoder Check it is normail for cod
AL-02 Over speed Protection 2:Zeroing angle deviate Re-correct zero
3:Pr02 is too small Increase value Pr02
1:Abnormal encoder
Check it is normail for cod
2:Loose encoder plug
AL-03 wiring error of encoder Tighten plug
3:The length of encoder cable exceed 40
Shorten encoder cable
meters
1:Wrong connection between U V W of
Rewiring
the wiring error of motor
AL-04 Decrease value Pr02
motors 2:In JOG mode, the value of Pr20is too big
Check it is normail for cod
3: Abnormal encoder
1:Three power voltage is more than 490V Measuring input voltage,and to lower
2:Small or damaged braking resistance Replace braking resistance or increase
AL-05 overvoltage protection
3: The detectiono fault for drive high powwr of resistance,and replace driver
pressure board

1:Too heavy load Check pump motor if jammed


2:Abnormal encoder Check it is normal for cod
AL-06 over-current protection
3:The value of Pr20,Pr21,too big Decrease Pr20,Pr21
4:The value of Pr24,Pr25,too big Decrease Pr24,Pr25
1:Abnormal encoder Check it is normal for cod
AL-07 zero-coding error 2:Loose encoder plug Tighten plug
3:The length of encoder cable exceed 40m Shorten encoder cable
1:Abnormal encoder wiring
2:Loose encoder plug Check it is normal for cod
3:The length of encoder cable exceed 40 Tighten plug
zero error for the motor
AL-08 meters Shorten encoder cable
wiring
4:Wrong connection between U V W of Rewiring
motor Replace board
5:Damaged driver board PWM wave
Motor renewable
-bbrr- Renewable braking showing Said braking resistance in the work
braking r
The power voltage is too low Measuring input line
AL-09 Low voltage alarming
Refer to Pr194 Reset Pr194

38
The bad connection for RS232
AL-10 Wrong communication Check the connection
communication cable
Replace fan
Motor temperature 1:Motor fan error
AL-11 Shorten load time or reduce load(check load
alarm 2: Long -time overload use for motor
connection)
AL-12 current Abnormity Driver phase missing Check if powwr is missing phase
AL-13 Error current sensor Bad current sensor or bad connection Check plug in driver
CAN communication
AL-14 Bad Can connection Check can communication cable
overtime alarom
3.6 PID Adjust introductions:
1 Speed Kp:the greater the value, the higher the gain, the greater the rigidity, the
determination Of parameter calculating according to specific type and load of the servo
drivers. Under normal circumstances, the greater e load inertia, the greater the value.
There are no shocks in the system, the larger setting as much as possible.
2、Speed Ki:the greater the value, the faster the rate, the greater the rigidity, the
determination Of parameter calculating according to specific type and load of the servo
drivers. Under normal circumstances, the greater load inertia, the smaller the value.
There are no shocks in this system ,the larger setting as much as possible.。
3、Location Kp:the greater the value, the higher the gain, the greater the rigidity. Under
the same frequency instruction pulse,the smaller the position lag. There are no shocks in
this system, the larger set as much as possible.
4、Current Kp:the greater the value, the higher the gain, the smaller the current tracking
error. However, the higher the gain, will have noise or vibration. This parameter has
something to do with servo driver and mnotors, having nothing to do with
loading.There are no shocks in this system, the larger setting as much as possible.
5、Current Ki:the greater the value, the faster the rate, the smaller the current tracking
error. However, the higher the gain, will cause the noise or vibration. This parameter
has something to do with servo driver and mnotors, having nothing to do with loading.
Under normal circumstances, the smaller the electromagnetic motor constant, the
smaller the integration time constant. There are no shocks in this system, the larger
setting as much as possible.
6、Feed forward set Methods: The speed can be fed through the open-loop control of the
servo system to accelerate the speed of response, when speeding up the feed forward
gain to reduce the accumulation of position loop error, thus speeding up the error rate of
compensation .In theory analysis, the current speed gain increases, the smaller the total
error value of location loop, that is, the smaller the integral role. But too much feed
forward gain easily lead to oscillations and location overshoot, In addition, the actual
system in the ideal differential link doesn’t exist, so the link can not gain too much, at
the same time, in order to ensure accuracy of the positioning servo system, integral
control is essential points

39
PI Adjusting Schematic Diagram
3.7 PID adjusting method:
1)First of all don't rush to modification parameter,it is the first step for judge what state
now through careful judgment I for above chart.
2)After confirm,then adjust Kp from small to large, adjust a time to see a phenomenon,
until take the best data.
3)After adjusting Kp,then adjust Kifrom small to large,adjust a time to see a
phenomenon, until take the best data.
4) Adjust Kp Ki a little again help ign to keep them in optimal condition.
5)It is forbidden to adjust many parameters at the same time.

40
Chapter 4 Installation and adjustment for injection machine
4.1 Notice
To ensure stabilize work for servo pump, please attention to these following notice.
Servo motor working process will be repeated on the state of the high-speed stop, easy
to cause the motor shaking and vibration, please ensure that motor fixed installation,
reasonable firm, can use block rubber pad to fix.
4.2 Notice for sensor installation
It appears repeated sucker-oil filling condition during servo pump running,it easily
cause instantaneous no oil for tubin, on this basis, to ensure internal of pressure sensor
always keep hydraulic oil, please ensure oilmouth vertical installation for pressure
sensor.
4.3 About unload
Related parameters: Pr85.(Discharging pressure reverse speed)
Notice:
Pr85.(Discharging pressure reverse speed)Because discharging pressure too fast, it will
cause reversal noise for oil pump.
Experience point:
Pr85.(Discharging pressure reverse speed)=-300
About lowest pressure and the bottom flow
Related parameters:Pr168=5.(lowest pressure without work)、Pr169=20.(the bottom
flow)
In general, you need to keep the lowest pressure and the bottom flow, in order to ensure
that the oil ircuit filled with charge oil, prevent oil filling or putting repeatedly, leads
unstable running for injection molding machine
4.4 Computer knowledge
There are two kinds of pressure flow signal output by computer for machine:1:The
output signal of injection machine by computer is PQ valve signal, that is the output
current signal,and it needs current and voltage transfer board, namely “Valve signal
segregation board”,because servo only accept voltage signal.
2: The output signal is 0-10V voltage signal by computer for machine, so you can direct
connect with servo drive or through signal segregation board to eliminate interference .
4.5 About wiring instructions for servo to injection molding machine
1) Whether single or multiple pump system, a system can be divided into major loop
and control circuit parts.We suggest you install interlayer between two parts, because
the major loop will cause noise radiation
2)Servo driver and filter must be installed in the same installation board And must be
installed with the board at the area of as far as possible the metal to metal good contact
3)The attachment of interference suppression filter to servo driver must be on both
sides of the shield connection, usually no more than 50 cm length.Servo drive board
must be accepted as neutral connection of the whole machine system grounding and
shieldin connection
If the motor or other system components cause interference, so the high frequency
connection of these parts is not good. In this case, you must implement equipotential

41
connection
4)For connected screen layer of motor junction box ,we usually use metal cable pipe,
shielding layer must through the cable wiring unit directly connected to earth point
The leakage current will increase for use of interference suppression filter.Due to the
value more than 3.5mA, so we should have all the following measurements:
5)The minimum protect conductor sectional area was 10mm2 copper wire.
6)If use into line reactor, so must be installed in the power supply side of interference
suppression filter.
7)Shielding layer must connected to shielding row, so as to reduce shielding
impedance
8)If shield layer through wire grounding, the effect of eliminating interference will
poor70%
9)When using the shielding signal lines,always connect with twisted-pair cable
according to drawn into pairs
10)The premise of safety operation of driver must be strictly according to the following
instructions
The phenomenon of operation fault and damage might arises from improper
installation wiring
*Attention to voltage abd motor rated voltage.
* Don't connect power lien and motor power line by mistake;
* Main circuit wiring and control circuit wiring should separate (distance > 15 cm)
* The control line is shielded/wire.Shielding layer must be grounded in the signel side
of driver
* Logic and analog input is only applicable to low voltage circuit, please use
appropriate control components;
* Confirm servo driver and motor shell are good grounding. motor cable shielding layer
should connect both ends of between inverter and motor, when necessary, can cut off
paint
*Connection of braking resistance should use shielding/twisted-pair cable (The
grounding of shielding layer should in the single side of servo driver
* Connect electric cabinet or system neutral with shortest cable to total ground end (to
prevent ground loop)
*In order to achieve a low impedance high frequency connection, and ground, shielding
layer and other metal connection (for example: install board, install parts) must install
with the metal to metal contact in good condition, contact surfaces as far as possible big,
the usage of grounding cable section area as far as possible big (minimum 10 mm2) or
use thick grounding row
* Shielding layer for copper or tin shielding line of shielding network because steel
braided line is not suitable for high frequency range. Usually the shielding layer
pressure against with clip or cable, and fixed in potential row or PE grounding. It is
forbidden to use wired extend shield, and shall be directly connect shield layer to the
appropriate contacts.
*If use external interference suppression filter, it is better for install closed interference

42
place(<30cm),and keep large metal areas with installation board as far as possible.
* All wiring try to short, grounding try to close, and keep active for activities cable.
Keep wiring flat (don't pierced), to protect two sides installation of conductor without a
designated wire
* Please use glue line for outer shielding wire to prevent general interference
4.6 Fast commissioning explanation for servo injection machine
Refer to wiring diagram in chapter 5, according to the following rapid steps:
Note: Drive is installed in the electrical box of injection molding machine, to ensure
that there are enough heat dissipation space, there are 6 fan for power more than 50W, 3
for into wind, 3 only for output. Filter grounding must be connected to filter ground
terminal, don't connect to filter housing. Strictly follow one-point earth principle
1):Connected power incoming inline L1,L2,L3,reactor,filter,braking resistance,
the main line from motor to driver, insert encoder line, signal transfer board, measure
voltage for L1,L2,L3 with the multi meter.
2):Recheck whether the line connected
3):On the power supply, pay attention to see if there is abnormal phenomenon
4):Set value of Pr198=6
5):Invoke default value EEP-LF
6):Save EEP-SA
7):Setting:
Pr06=2000(Changed with customer’ s demands of speed (flow))Flow gain
Pr08=140O Pressure gain (changed with customer’ s pressure requirement)
Pr82=800 Sensor gain(according to different pressure sensor requirement:current type
800,voltage type 450)
Pr24=100 Torque forward upper limit(to increase pressure a little , less than 300 when
cannot get on )
Pr25=-100 Torque reverse upper limit
Pr39=3(recommend 3 for 15kW and above, driver not easy fever)carrier frequency
Pr40=5 Current protection class(can enlarge this value when normal work)
9):Save EEP-SA
10):The display through keyboard
AD1 Flow signal
AD2Pressure signal
AD3 Sensor signal
Show and record the value
Then set:Pr07=-( AD1+10)Flow zero
Pr09=-AD2 Pressure zero
Pr83=-AD3 Sensor zero
11):Save EEP-SA
12):Check AD1should less than -5,AD2 should equal 0, AD3should equal0
13):Set Pr01=-10,JOG commissioning, if drive shows value about-10,itmeans motor

43
can work, so the setting is successful.
14):Enable, let machine work, turrets move around 10 times to row air
15):Manual injection to pressurize 50kg 100kg 140kg and check machine pressure
gage,if gage shaking, it means torque is not big enough, you should set a bit more for
Pr24,Pr25 until pointer fixed about 140kg.Annention do not set big enough for
pr24,pr25,the max value less than 380.,otherwise any problem arise. If appear AL-06
when commissioning, oversize Pr40,but less than12,if more than 12,trouble also arise.
16):Recheck whether wire is connected,driver fan,motor fan is running.
17):Test temperature for motor and driver, the driver temperature should less than55
degree during 30 minutes working time. The max motor temperature is not more than
75 degree.
18): Introduce note, use standard, power supply condition to users.
4.7 About pressure flow linear proofreading
If rapid debugging, normally injection molding machine can work, but pressure flow is
a deviation, at this moment you need to adjust signal linear, general computer has the
output signal linear correction function(note:Old computer can be adjusted by
potentiometer),to revise the preset through injection machine computer, the following
steps as follows:
1:Determine how many maximum flow for users, also is the how many turn of motor
and oil pump, for example, the more appropriate turn is about 1500-1700 RPM for
“Chengjie” gear pump, imported pump is about 1800-2100 RPM, then set the max
speed Pr06 after confirmation
2:Confirm the max pressure you need, also how many kilograms of max pressure for
injection machine, general pressure is 140kg 160kg,175kg,and modify the max
pressure for Pr08 after confirmation.
3:Save EEP-SA
4:Recheck whether AD1,AD2 are zero,if not, please modify Pr07,Pr09 until
AD1,AD2is zero.(note:please save EEP-SA after modification,otherwise it is no
valid)
5: Make driver shows AD1,driver unable enable,let injection machine computer
send 20% 40% 60% 80% 99% flow,see whether AD1 increase speed accordingly,it is
ok for error <50RPM,if AD1 fails, then you can modify flow output until get data in
proportion in computer pre setter for machine.
5:Let driver shows AD2 , driver unable enable, let injection machine computer
send 20kg, 40kg, 60kg, 80kg, 100kg,120kg,140kg(175kg),see whether AD2 shows
corresponding data,it is ok for error ≤1kg,if AD2 fails, then you can modify pressure
output until get data in proportion in computer pre setter of machine.
4.8 Need to adjust related parameters for servo injection molding machine
Pr03=300-1200(600) Select the best Angle according to motor(Transformer is 600,
Encoder is 1200,our product is 600)
Pr06=0-5000(2000)Flow signal flow
Pr07=0-1000(0)Flow signal zero
Pr08=0-1000(150)Pressure signal gain

44
Pr09=0-1000(0)Pressure signal zero
Pr14=0-50(10)Flow signal filter
Pr15=0-50(10)Pressure signal filter
Pr20=600-2000(300) Bigger value, quicker response ( Too big will cause motor
vibration)
Pr21=10-200(100) Bigger value, quicker response(Too big will cause motor vibration)
Pr24=100-300(100) Bigger value, bigger torque(torque limit, too big will cause current
alarm)
Pr25=-100--300(-100) Bigger value, bigger counter- torque (counter -torque limit, too
big will cause current alarm)
Pr26=1-100(10)Speed loop response frequency, smaller value, higher response
Pr30=1500-3000(4000) Bigger value, quicker response(too big will cause motor
vibration)
Pr31=80-200(100) Bigger value, quicker response(too big will cause motor vibration)
Pr34=100-900(850) Power limit
Pr35=-100--900(-800) Power limit
Pr39=1-3(3)bigger value, lower driver fever, recommend 3
Pr40=5-14(8) Current alarm class
Pr49=50-2000(625)Current feedback coefficient,generally do not change, keep default
Pr65=100 Multiple pump synchronous coefficient(used for multiple pump)
Pr66= (180) Speed loop filter coefficients, inhibit resonance
Pr79=0-1(1)Hydraulic control mode 0 soft 1 quick
Pr80=1-30(5) Bigger value, quicker response(too big will cause motor vibration)
Pr81=1-100(5) Bigger value, quicker response, smaller pressure, more difficult for
overshoot(too big will cause motor vibration)
Pr82=0-2000(800)Pressure sensor gain(current type sensor is 800;pressure type sensor
is 450)
Pr83=0-1000(0)Pressure sensor zero
Pr84=0-50(10)Pressure sensor signal filter
Pr85=0-1000(-500)Unloading reverse speed
Pr86=0-100(20)Pressure feed forward, bigger pressure, more difficult for overshoot
pr91=5 Beginning speed for multiple pump system
Pr93=3 The best power control mode
Pr168=5 Low pressure
Pr169=20bottom flow
Pr198=6 Main pump mode for injection machine 7 Synchronous master-slave mode
for injection machine 8 CAN direct digital communication mode for injection machine
9 Master-slave switch mode for injection molding machine
Pr170-Pr179=15kg,30kg,45kg,60kg,75kg,90kg,105kg,120kg,135kg,150kg The fixed
point for pressure value of injection molding machine model given value fixed point
pressure(AD2).(Do not recommend for commonly use)

45
4.9 The specification for “Dacheng ”servo motor and servo drive
Our aviation socket signal forrotating transformer:
1:-----(Ref+)-----R1 Orange(Shanghai)Red and White(Tamagawa)
2:-----(Ref-)-----R2 White Yellow and White
3:-----(sin-)-----S4 Blue Blue
4:-----(sin+)-----S2 Yellow Yellow
5:-----(cos+)-----S1 Red Red
6:-----(cos-)-----S3 Black Black
Motor power:U V W PG Corresponding U V W PG in driver
The number of motor pole:8 pole
15-core plug signal of our driver encoder:
1:-----(Ref+)-----R1 Orange(Shanghai)Red and White(Tamagawa)
2:-----(Ref-)-----R2 White Yellow and White
3:-----(sin-)-----S4 Blue Blue
4:-----(sin+)-----S2 Yellow Yellow
5:-----(cos+)-----S1 Red Red
6:-----(cos-)-----S3 Black Black
Driver:U V W PG Correspodning U V W PG in motor
4.10 Servo for multiple pump

Please send computer pressureand and flow signal to manin drive,manind rive also send
sync signal to secondary drive,then to reach same sync rotationfor them,the adjustment
of sync parameter should through Pr65,the fault value Pr65=100%,it meansit is same
rotation for main and secondary motor.The min beginning speed of secondary pump
ispr91,dafault value pr91=100 means manin pump can work for speed >100rp.During
practical usage for injection machine,secondary motor’ s speed is lower than mani,so
there are only main motor is working when pressure,it is energy-saving and stabilize.
Please set main drive to normal mode for injection machine, pr198=6,then adjust

46
parameters according to 4.6,4.7 instructions.
Please set secondary driver to normal mode for injection machine, pr198=7, then invoke
default value to complete.
The specific of wiring Sync signal of manin driver to secondary driveras above picture:
The advantage is: simple, can multilevel series for the use of servo synchronous pulse.
4.11 Master-slave multiple pump(double trigger)

Please send computer pressureand and flow signal to manin drive,manind rive also send
sync signal to secondary drive,then to reach same sync rotationfor them,the adjustment
of sync parameter should through Pr65,the fault value Pr65=100%,it meansit is same
rotation for main and secondary motor.The min beginning speed of secondary pump
ispr91,dafault value pr91=100 means manin pump can work for speed >100rp.
There is one signal distribution board, “enable signal”and “master-slave choice”on
board, secondary pump can use as main pump, also cut or connect connection between
pump and manin oil circuit through “enable signal”.
The scheme wiring a little bit more complicated, but high freedom,can use a sensor or
many sensors, multiple throttle valve, especially suitable for large machine multiple
pump system
The specif setting as follows:
Please set main drive to normal mode for injection machine, pr198=6,then adjust
parameters according to 4.6,4.7 instructions.
Please set secondary driver to normal mode for injection machine, pr198=7, then invoke
default value to complete.
Please set main drive to normal mode for injection machine, pr198=9,then adjust
parameters according to 4.6,4.7 instructions.

47
The master-slave choice see in5 of 2.1 connection terminals drawing (corresponding the
ninth feet of 44-core plug)
4.12 Jumper instruction for DSP5 board
Note: this instruction is only for debugging or maintenance staff of equipment
manufacturers, users is not need to know
There are three kinds of sensor available for us;
Nanjing 50A_100A 、Honeywell 50A、Honeywell 125A。
For fit with the above three types sensor, Special setting jumpers as follows
Of DSP5 version
In the back of the dsp5 board

1:If current seonsor of drive is Nanjing pressure type 50A_100A,and J7、J8、J9 do not
need jumper
2:If current sensor of driver is Honeywell 50A, J7jumper,J8、J9jumper one the right
side.
3:if current sensorof drive is Honeywell 125A, J7jumper,J8、J9jumper on the left side.
4.13 About explanations for internal pressure usage and flow function
There are special signal for imported injection machine,some of them no pressure
flowsignal output,so we can use terminals to choose internal pressure and flow signal
for drive.
1): When you give a signal for the seventh feet of servo driver 44-core plug, machine
pressure will work according to pressure setting in pr10, the default is 100 kg pressure
(see below drawing)
2): When you give a signal for the ninth feet of servo driver 44-core plugmachine flow
will run accordinto flow setting in pr11,the default is 200rpm。(see above drawing)
3):The role of article 1、2 with under positive enabled circumstances.

48
4):Function paramerters preference
Pr193=0 Don't use special internal pressure flow function
Pr193=1 Special internal pressure flow function,the role of 7、9、10 feet should often
open
Pr193=2 Special internal pressure flow function,the role of 7、9、10 feet should often
close
The default is Pr193=1 for injection machine mode

Wiring diagram of internal pressure and flow function


4.14 About commissioning fault and treatments for injection machine
Fault
Fault cause Treatments
phenomenon
1:PG line didn't connect
from motor to drive
2:There are air in machine Connect PG line rom motor and drive
wobble for 3:Thelength of sensor Check whether the oil-in mouth of pump is air leakage, eliminate
machine cableis is too long air through seat moving back and forth
pressure Shorten sensor cable and connect with0.1uF anti-interference
4:Have electromagnetic
gauge capacitance and wear magnet ring
interference
Adjust Pr20 Pr80 Pr81
5:parameters do not
adjusted
overshoot
1: Pressure flow linear is
for machine Preset linear for machine computer pressure
not good
pressure Increase value Pr80,decrease value Pr81
gauge 2:The parameters do not set
1:There is air for oil pump Check whether oil pump is air leakage,eliminate air through seat
Oil pump 2:The ban connection for moving back and forth
noise motor pump Check connection parts for motor pump,wnen necessary,youcan
loosen connecting screw

49
1:The parameters have not
been set Little reduce value Pr24,Pr25,Pr20,Pr80
Frequent
2:UVW line short circuit There are touch line phenomenon from motor to drive ,check again
AL01 or
3: oil pump lock Check there are dirty stuck in oil pump
AL06 alarm
4:The bad connection for Connect PG line between motor to drive
PG line
1:The pressure flow signal Check if it is ormal for output signal of machine computer,whether
The slow
is wrong it is same between showing value AD1 AD2 in driver and
action for
2:There are leakage for computer output value
machine
injection machine Check if valve is stuck or bad of injection machine valve

Chapter 5 Wiring diagram

50
Motor fan
AC220V
Servo driver
44-core plug 15- core plug servo motor
L1 L2 L3 P PB U V W W V U
use metal

to 44-core plug for servo motor

encoder plug
L1 L1 L1

temperature switch
AC380V Line

L1

17-core encoder plug


breaker

reactor

filter
L2 L2 L2 L2
W W W
L3 L3 L3 L3
V V V
U U U

magnet ring 1
magnet ring 2
wire around 2 laps wire around 3 laps
encoder cable
To injection molding machine

Braking resistance
0--10V Flow signal+ AD1 Flow out motor temperature switch cable
coil filter plate

1 1
0--10V Flow signal- AD2 Pressure out motor temperature switch cable
2 2
0--10V Pressure + AD3 Pressure sensor out
3 3
0--10V Pressure - 4 15V
4 +15V
5
5 6 -15V
6 Enable signal connect to normally
YC+Pressure sensor
7
YC-Pressure sensor 8

Input voltage signal from l injection molding machine

51
The electric control cabinet diagram up to EMC standard

52
Chapter 6 Selection and calculation for servo
6.1 The selection for servo oil pump parts
Note: The speed characteristics of DCM series servo motor used to injection machine:
The max no-load is 2000rpm for rated speed of motor is 1500rpm, load is about
2700-1800
The max no-load is 2500rpm for rated speed ofmotor is 2000rpm, load is about
2200-2300
Dispalcement is q(ml/rev),system pressure is p(kgf/cm2);motor/pumpratedspeedis Vn
(rpm)。
Flow is Q(L/min)=displacement is q(ml/r)×motor/ max pump speed is Vmax(rpm)
/1000;
6.1.1 Oil pump selection
The selection ofoil pump pressure:
Rated pressure of oil pump shall be equal or greater than system pressure
p(kgf/cm2)。
The selection of pump dispalcement:
Pump displacement/turn of each revolution l(ml/rev)=Q(L/min)×1000(ml/L)/
Vn(rpm).
For example:one set of 120t injection flow is 66L/min,rated speed for motor is
2000rpm
Then displacement=66*1000/2000=33 ml/rev
So the pump displacement should be:32 ml/rev,and turn to 2062rpm can meet flow
requirement.
The selection of pump type:
Pressure
Pump Volume Impulse Speed
Price Noise Rrealibity (single
type efficiency (stability)
clasee)
Gear
Low Low Medium Medium High Low Medium
pump
Piston
Medium High High High Low Medium Low
pump
Screw
High Medium Low Low Medium High High
pump
Oil pump characteristics comparison
6.1.2 The selection for servo motor type
Torque for oil:
T=system pressure is p(kgf/cm2)×displacement is q(ml/rev)/62.8
The power of oil pump
P=T×pump rated speed Vmax(rpm)/9550
Considering pump,motrt power,and strong overload capacityof servo motor,so the
motor power should be:
Ps=P/1.62 (1.62 is conversion favtor)
Fox example:one set of 120 displacement of machine is 66L/min,choosetherated speed
for motor is 2000rpm,pressure is175kg,displacement is 32 ml/rev,the max speed
2062 can meet flow requirement.
Pump torque is:T=175×32/62.8=89.2Nm
Pump power is:P=89.2×2000/9550=18.6kW
Servo motor power is:Ps=18.6/1.62 =11.5kW
6.1.3 The selection of servo drive type

53
The selection of servo drive volume:
After confirm the servo motor,you can ask motor supplier for giving torque comstant
value for corresponding motor Kt(Nm/A)
Note:torque constants Kt(Nm/A)is related with servo motor technique,material and
rated speed Vn(rpm).
The holding- pressure current for servo drive (conversion according to energy
transformation efficiency 93% (including servo driver efficiency、 motor power
factor)):
Imax(A)=Tmax(Nm)/ Kt(Nm/A)/93%
According to principle which the numerical value less than rated output current 150%
of servo drive, and to obtain the required model and surrounding parts model of servo
drive

Chapter 7 Introduction of servo motor


7.1 Servo motor naming rule

Voltage Class: C: 220V/3000rpm, D: 220V/2500rpm E: 220V/2000rpm


F: 220V/1500rpm,G: 220V/1000rpm
H:380V/3000rpm,G:380V/2500rpm,L:380V/2000rpm,
M:380V/1500rpm,N:380V/1000rpm
Frame size: 60mm、85mm、110mm、130mm、150 mm、190mm、250mm
Shaft type: A: circular shaft with key B: circular shaft non-key
Standard specification: D: standard shaft E: XX special shaft size
DCM-C: General servo motor
DCM-D High performance servo motor
DCM-U : Special type servo motor and driver (customer design)
DCM-Y: Special hydraulic servo motor

54
7.2 Servo motor dimension

250 series motor dimension(power range 15kW-55kW)

190 series motor diemsnion(power range 3.0kW-15kW)


Appendix 1:About EMC(The electromagnetic compatibility)instructions
1 Definition
The electromagnetic compatibility is refers to the operation of electrical equipment in
electromagnetic interference environment, no interference for electromagnetic
environment and can achieve its stable interference.
2 EMC standard introductions
According to the national standard GB/T12668.3 requirements, servo driver needs to
meet two requirements of electromagnetic interference and anti electromagnetic
interference.

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Our existing product execution is the latest international standards:IEC/EN61800-3:
2004 (Adjustable speed electrical power drive systems part 3:EMC requirements and
specific test methods),equal to national standard GB/T12668.3.
IEC/EN61800-3 investigates mainly from the electromagnetic interference and anti
electromagnetic interference in two aspects of the servo drive,the test of
electromagnetic interference, mainly to the servo driver radiation interference、
conducted interference and harmonic interference(corresponding to civilian servo drives
requirement). Anti-electromagnetism interference tests emphasize on testing of
transmission resistance、radiation resistance,surge flexibility,pulse flexibility of rapid
mutation ,ESD flexibility and low frequency flexibility of power (specific test project
are: 1 Immunity test for input voltage sag, interrupt and change; 2 Commutation gap
immunity test; 3 Immunity test for harmonic input; 4 change experiment for input
frequency; 5 Unbalance tests of input voltage; 6 fluctuation test of input voltage).
Strictly test according to the IEC/EN61800-3, Please operate the machines strictly
following 8.3,It has better electromagnetic compatibility in general industrial
environment
3 EMC guidance
3.1 Harmonic influence
The higher harmonic ofpower will damage servo drive. In some poor quality power grid,
we suggext you to install a ac input reactor
3.2 There are two kinds of electromagnetic compatibility and installation matters,
One interference is for electromagnetic noise surrounding environment to servo drive,
another interference is servo drive to surrounding equipment.
Install Caution
Servo 1)The drive and other electric products grounding wire should be well grounded;
2) Input and output power lines and weak electric signal lines for servo drive (such as:
control circuit) try not to parallel decoration, if necessary,using vertical layout ;
3)Output power lines of servo drive should use shielded cable, or use of steel e
shielding power lines, and it is reliable grounding, for interference lead,we suggest
using double ground shielding line, and reliable grounding;
4)For the length of motor cable is more than 100 m, requiring output filter or reactor
3.3 The treatments for surrounding electromagnetic equipment to servo drive
interferences
The general reason for driver to produce electromagnetic influence that there are
plenty of relay, contact device or electromagnetic brake nearby.If there are wrong action
for servo drive for this reason,please use the following methods to sove:
1)Install surge suppressor on the disturbance of the device;
2)Install filter on output side of servo driver,refer to 8.3.6,then operate;
3)For leads between servo driver control signal line and testing ling,suggest using
shield cable and reliable grounding.
3.4 The treatments for servo drive to surrounding equipments
This part of the noise is divided into two kinds: one kind is servo driver radiated
interference, and the other one is a servo driver ransmission interference The two
interference makes surrounding electrical equipment by electromagnetic or electrostatic
induction and cause false action for equipment

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According to several different kinds of interference, reference to the following methods
to solve:
For measuring instrument, receiver and sensor , 1)in general, signal are faint, if it is
close or in the same control od servo drive, easy to be disturbed and do false action
Please refer to the following suggestions:
As far as possible from interference sources; Don't decorate or equal bandingl signal
lines and power line; use shield cable for leads or power line, and reliable grounding;
install graviation ferrite in the output side of the servo drive(choose inhibition
frequency in 30 Hz ~ 1000 MHz range),and round 2~3 turns,For bad conditions, can
choose EMC output filter;
2 ) If interference equipment and servo driver using same power supply, cause
conducted interference, if above method also can't eliminate interference,you should
install EMC filter between servo driver and power supply (refer to 8.3.6 to select
operation);
3) Separate grounding of peripheral equipment, can eliminate leakage current
interference
for servo driver altogether grounding
3.5 Leakage current and processing
There are two types of drive current leakage: one kind is to the leakage current; ;
Another is leakage current between line to ine.
1) Influence factors and solutions of floor drain current
Distributed capacitance exists between wire and arth, greater capacitance, greater
current leakage; Effectively reduce distributed capacitance between servo driver and
motor distance
greater carrier frequency, greater leakage current.You can reduce leakage current
through redueing carrier frequency.But it will leads greater noise of motor by reducing
carrier frequenc, Please note that .The effective way by installingl a reactor for solving
current leakage.
Current leakage increases with increasing loop current, bigger motor, correspondingly
for greater leakage current.
2)Current leakage factor and solution between Lines
Output cabling of Servo driver has distributed capacitance, if circuit current contains
higher harmonic, it could cause resonance and produce leakage current, and if using
thermal relay may cause wrong action.
The solution is to reduce carrier frequency or add output reactor,It is recommended to
use electronic over-current protection function for servo drive
3.6 The attention for iinstalling EMC output filter in power output terminals
1)When installing input EMC filter in power output end,we recommend using “Jianli”
EMC filter
form Changzho;
2)Please use filter in strict accordance with ratings use; because filter is class 1 kind of
electric , filter metal houding should be good grouding of large area with metal electric
cabinet , and require good conductive continuity, or there will be to get an electric
shock risk and serious affect EMC effect;
3)Through EMC tests, found that filter grounding should connect with PE end for same

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public land , otherwise will seriously affect EMC effect;
4)Install the filter as close to output end of servo drive as possible

Zhejiang Dacheng Electric Co.,ltd Servo Industry Department

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