Inovance HC580 Series Injection Molding Machine Inverter User Guide: Operation Panel, Terminal Control and Fault Troubleshooting
The Inovance HC580 series is a specialized variable frequency drive engineered exclusively for injection molding machine applications. Unlike general-purpose inverters, the HC580 integrates hydraulic system control algorithms that directly manage the pressure and flow requirements of injection molding cycles, eliminating the need for a separate proportional valve controller. Covering power ratings from 11 kW to 160 kW, the HC580 is suitable for injection molding machines ranging from small precision molders to large-tonnage industrial systems. This guide covers the operation panel, terminal wiring and control, injection cycle control logic, pressure/flow analog control, PID tuning procedures, and fault code diagnostics to support comprehensive commissioning and maintenance.
Product Overview and Model Range
The HC580 model designation follows the format HC580T11 through HC580T160, where the numeric suffix indicates the rated power in kilowatts. All models feature three-phase 380V input and are designed to drive the hydraulic pump motor of an injection molding machine. The drive replaces the traditional fixed-speed motor plus proportional valve configuration with a variable-speed motor that directly controls hydraulic pressure and flow, delivering significant energy savings—typically 30% to 60% compared to conventional systems.
The core innovation of the HC580 lies in its dual-loop control architecture: a pressure control loop and a flow (speed) control loop that switch dynamically based on the injection molding cycle phase. During injection and holding phases, the drive operates in pressure control mode, maintaining precise hydraulic pressure. During plasticizing, cooling, and mold open/close phases, it switches to flow control mode, delivering the required hydraulic flow at lower pressure. This phase-based switching is managed entirely within the drive firmware, triggered by digital input signals from the injection molding machine controller.
Operation Panel and Keypad Functions
Keypad Layout
The HC580 is equipped with a detachable LED keypad that provides parameter access, status monitoring, and manual operation capability. The keypad features the following keys:
| Key | Function |
|---|---|
| PRG | Enter or exit the parameter programming menu |
| ENTER | Confirm parameter changes and save values |
| QUICK | Access the quick-setup menu for rapid commissioning |
| RUN | Start the motor manually from keypad command source |
| STOP | Stop the motor; also used for fault reset when pressed after a fault |
| RES | Reset faults |
| MF.K | Multi-function key; programmable for jog, direction change, or other functions |
| Up/Down arrows | Navigate parameter menus and adjust values |
Status Indicators
Four LED indicators on the keypad provide real-time status information:
| LED | Color | State | Meaning |
|---|---|---|---|
| RUN | Green | Steady on | Motor is running |
| RUN | Green | Blinking | Motor is in jog or deceleration mode |
| ALM | Red | Steady on | Fault condition active; motor stopped |
| ALM | Red | Blinking | Warning condition active; motor may still be running |
| LOCAL | Green | Steady on | Command source is the keypad (local control) |
| REMOTE | Green | Steady on | Command source is terminal or communication (remote control) |
Quick Setup Menu
The QUICK key provides direct access to the most commonly adjusted parameters during initial commissioning. This streamlined menu guides the technician through the essential setup sequence without navigating the full parameter tree. The quick-setup parameters include motor nameplate data, hydraulic control mode selection, maximum speed and pressure settings, and the primary PID gains for the pressure control loop.
Main Circuit Terminal Wiring
Power Input and Motor Output
| Terminal | Function | Notes |
|---|---|---|
| R, S, T | Three-phase AC input | Connect through circuit breaker and input contactor |
| U, V, W | Inverter output to motor | Connect to hydraulic pump motor |
| BR, + | Braking resistor connection | Connect external braking resistor for regenerative energy dissipation |
| +, − | DC bus positive and negative | For DC bus sharing or external braking unit |
| PE | Protective earth | Must be solidly grounded; separate from neutral |
The braking resistor connection (BR/+) is particularly important for injection molding applications because the deceleration from high-speed plasticizing to low-speed holding phases generates significant regenerative energy. Without a properly sized braking resistor, the DC bus voltage will rise and trigger overvoltage faults during phase transitions. The resistor should be selected based on the drive power rating and the duty cycle of the injection molding process.
Input Protection and Reactor
An AC input reactor is recommended for all HC580 models to reduce input harmonic distortion, improve power factor, and protect the DC bus capacitors. For installations where the supply transformer capacity exceeds ten times the drive rated power, or where the drive is connected to a supply with power factor correction capacitors, the input reactor becomes mandatory to prevent capacitor damage and nuisance tripping.
Control Terminal Wiring and Functions
Analog Inputs (AI1 through AI3)
The HC580 provides three analog inputs, each configurable for 0-10V or 0/4-20mA signals. These inputs are central to the injection molding machine interface:
| Terminal | Typical Signal | Application |
|---|---|---|
| AI1 | 0-10V from injection machine controller | Pressure command signal from the machine’s proportional valve output |
| AI2 | 0-10V from injection machine controller | Flow (speed) command signal from the machine’s proportional valve output |
| AI3 | 4-20mA from pressure transducer | Actual hydraulic pressure feedback for closed-loop control |
The injection molding machine controller typically provides two analog output signals: one for pressure command and one for flow command. In a conventional proportional valve system, these signals drive the pressure and flow control valves. In the HC580 retrofit, these same signals are connected to AI1 and AI2, where the drive interprets them as pressure and flow commands respectively. The drive then adjusts the motor speed to achieve the commanded pressure or flow, eliminating the need for the proportional valves and their associated energy losses.
Analog Outputs (AO1, AO2)
Two analog outputs provide monitoring signals that can be routed to external indicators or the injection machine controller:
- AO1 – Typically configured to output the actual motor frequency (running speed)
- AO2 – Typically configured to output the actual hydraulic pressure value or motor current
Digital Inputs (DI1 through DI5)
Five digital input terminals interface with the injection molding machine’s sequence control signals:
| Terminal | Typical Function | Machine Signal Source |
|---|---|---|
| DI1 | Forward run/stop command | Main motor contactor auxiliary or machine run signal |
| DI2 | Fault reset | Machine reset pushbutton |
| DI3 | Pressure/flow mode selection | Phase transition signal from machine controller |
| DI4 | Multi-pressure preset selection | Machine controller digital output |
| DI5 | External fault input or PTC protection | Motor thermistor or safety interlock |
Each DI terminal supports both PNP and NPN wiring through the shared COM terminal. The internal +24V supply (terminal OP, jumpered to +24V) provides power for external sensors. When wiring analog signals from the injection machine controller, use shielded twisted-pair cables and ground the shield at the drive end only. Keep analog signal cables physically separated from motor power cables by at least 200 mm to prevent electromagnetic interference.
Relay Outputs (T/A1, T/B1, T/C1 through T/A3, T/B3, T/C3)
The HC580 provides three programmable relay outputs, each with normally open (NO) and normally closed (NC) contacts:
| Relay | Terminals | Typical Assignment |
|---|---|---|
| Relay 1 | T/A1, T/B1, T/C1 | Fault alarm (trips on any fault) |
| Relay 2 | T/A2, T/B2, T/C2 | Run status indicator |
| Relay 3 | T/A3, T/B3, T/C3 | Pressure/flow mode status or ready signal |
Relay contacts are rated for 250 VAC at 3 A (resistive load) or 30 VDC at 1 A. For higher current loads, use an interposing relay. The relay function assignments are configured through the F4 parameter group.
Communication and PG Card Interface
The HC580 supports both CAN bus and RS485 Modbus RTU communication. The CAN interface enables high-speed deterministic communication with the injection machine controller or with multi-pump coordinated systems. The RS485 port provides standard Modbus RTU protocol for SCADA integration. Additionally, a PG (pulse generator) card slot accepts optional encoder interface cards for closed-loop speed control with motor-mounted encoders, providing the highest speed accuracy required for precision injection molding applications.
Injection Cycle Control Logic
Phase-Based Control Modes
The injection molding cycle consists of several distinct phases, each with different pressure and flow requirements. The HC580 manages these phases through automatic mode switching:
| Cycle Phase | Control Mode | Drive Behavior |
|---|---|---|
| Mold close | Flow control | Motor runs at moderate speed for fast mold closing; switches to low-pressure protection mode near closure |
| Injection | Pressure control | Maintains precise injection pressure; motor speed adjusts to hold pressure as cavity fills |
| Holding (pack) | Pressure control | Continues pressure maintenance at reduced level; compensates for material shrinkage |
| Plasticizing (screw rotation) | Flow control | Motor runs at high speed to drive hydraulic pump for screw rotation; back pressure maintained |
| Cooling / mold open | Standby or flow control | Motor slows or stops; minimal hydraulic demand |
| Ejection | Flow control | Short burst of flow for ejection action |
Mode Switching Mechanism
The transition between pressure control and flow control modes is triggered by the analog input signals from the injection machine controller. When the pressure command signal (AI1) exceeds a threshold while the flow command (AI2) drops, the drive enters pressure control mode. Conversely, when the flow command is dominant, the drive operates in flow control mode. The switching threshold and transition smoothing are configurable through parameters A3-22 through A3-28, which define the maximum flow during pressure control, minimum pressure during pressure control, output delay, and S-curve filter times for smooth transitions.
Multi-Pressure Preset Support
For injection molding machines that require different pressure settings for different cycle phases or product molds, the HC580 supports multiple pressure PID parameter sets. Up to four sets of pressure PID gains (kp, ti, td) can be configured and selected via digital input combinations, allowing the drive to optimize its control response for each phase of the molding cycle without manual retuning.
Pressure and Flow Analog Control
Pressure Closed-Loop PID Architecture
The HC580 implements a closed-loop PID controller for hydraulic pressure regulation. The pressure command (from AI1 or a preset value) serves as the setpoint, and the actual pressure feedback (from AI3, connected to a pressure transducer in the hydraulic system) serves as the process variable. The PID controller output adjusts the motor speed to minimize the error between the setpoint and the measured pressure.
The PID parameters are organized in the A3 parameter group and include separate gain sets for different operating conditions. The primary PID parameters are:
| Parameter | Name | Range | Default |
|---|---|---|---|
| A3-05 | Pressure loop proportional gain kp1 | 0.0 to 100.0 | Application-dependent |
| A3-06 | Pressure loop integral time ti1 | 0.001s to 10.000s | 0.100s |
| A3-07 | Pressure loop derivative time td1 | 0.000s to 1.000s | 0.000s |
Flow (Speed) Control
In flow control mode, the drive operates as a standard variable frequency drive, regulating motor speed based on the flow command signal from AI2. The speed command is scaled according to the maximum speed parameter (A3-01) and the motor frequency/voltage characteristics. Since flow control does not require pressure feedback, the pressure transducer is not actively used during this mode, though it continues to be monitored for protection purposes.
AI Zero Drift Self-Adjustment
Parameter A3-20 enables automatic zero drift compensation for the analog inputs. When enabled, the drive periodically samples the analog input values during known idle periods and subtracts any offset from the zero-point reading. This ensures that small DC offsets in the analog signal path do not accumulate as steady-state pressure errors. It is recommended to keep this function enabled for all injection molding applications.
PID Tuning Procedure
Initial Setup
Before tuning the PID parameters, ensure that the motor auto-tuning has been completed successfully and the hydraulic system is free of air bubbles. Set the pressure transducer range correctly in the drive parameters, and verify that the pressure feedback signal at AI3 reads zero when the hydraulic system is at atmospheric pressure.
Step-by-Step Tuning
- Set conservative initial values: Start with a low proportional gain (kp = 5-10), a moderate integral time (ti = 0.5s), and zero derivative (td = 0). This provides a stable but sluggish starting point.
- Apply a step pressure command: Command a pressure step of approximately 30% of maximum while the injection molding machine is in a controlled state (mold closed, no injection). Observe the pressure response on the drive’s analog output or through the communication interface.
- Adjust proportional gain: Gradually increase kp until the pressure response reaches the setpoint quickly but without excessive overshoot. If the pressure oscillates continuously, reduce kp by 20-30%.
- Adjust integral time: Reduce ti to eliminate steady-state error (the difference between the setpoint and the actual pressure after settling). Too small a ti value causes oscillation; too large a value leaves residual error.
- Add derivative action if needed: If the pressure response exhibits overshoot that cannot be eliminated by reducing kp, add a small td value (0.01-0.05s) to dampen the response. Derivative action is sensitive to noise, so use it sparingly.
- Verify across the full cycle: Run the injection molding machine through a complete cycle and monitor the pressure response during each phase. If different phases require different PID settings, configure the multi-pressure preset parameters.
Overshoot Suppression
The HC580 includes dedicated overshoot suppression parameters (A3-27 and A3-28) that provide an additional damping mechanism specifically designed for the pressure transitions in injection molding. The overshoot suppression detection factor (A3-27, default 200) defines the threshold at which the suppression algorithm activates, and the overshoot suppression factor (A3-28, default 0.200) controls the strength of the suppression action. These parameters work in conjunction with the standard PID gains to minimize pressure overshoot during rapid setpoint changes, such as the transition from injection to holding pressure.
Pressure Command S-Curve Filtering
Parameters A3-25 and A3-26 apply S-curve acceleration and deceleration filter times to the pressure command. These filters smooth out abrupt changes in the pressure command signal, which is particularly beneficial when the injection machine controller issues step changes in the pressure command. The default value of 0.030s provides a good balance between responsiveness and smoothness; increase the value if the pressure response is too aggressive or decrease it if the response feels laggy.
Key Parameter Groups
A0 Group: Field Weakening Control
The A0 group configures the field weakening (flux weakening) control, which allows the motor to operate above its base speed. This is relevant for injection molding machines that require high-speed plasticizing phases where the hydraulic pump motor may exceed its rated frequency. Proper field weakening settings ensure stable motor operation at extended speeds without excessive current draw.
A1 Group: PG Card Configuration
When an optional PG card is installed for closed-loop speed control, the A1 group configures the encoder type (incremental or absolute), pulse count per revolution, signal format, and direction. The PG card provides the speed feedback signal for the FVC (Full Vector Control) mode, which offers superior speed accuracy and dynamic response compared to sensorless vector control.
A2 Group: CAN Communication
The A2 group sets up the CAN bus communication parameters, including the node address, baud rate, and protocol mode. CAN communication is used for multi-pump coordinated systems where multiple HC580 drives share a common hydraulic manifold, and for high-speed data exchange with advanced injection machine controllers that support CAN-based protocols.
A3 Group: Basic Hydraulic Control
The A3 group is the heart of the injection molding machine control configuration. It contains the hydraulic control mode selection (A3-00), maximum motor speed (A3-01), system pressure settings (A3-02, A3-03), and the complete set of pressure PID parameters across multiple operating ranges. Key parameters in this group include:
| Parameter | Description | Significance |
|---|---|---|
| A3-00 | Hydraulic control mode | Selects between pressure/flow dual-loop, pressure-only, or flow-only modes |
| A3-01 | Maximum motor speed | Sets the upper speed limit for the hydraulic pump motor |
| A3-02 | System pressure | Defines the rated system pressure for scaling the pressure feedback signal |
| A3-03 | Maximum pressure | Sets the maximum allowable hydraulic pressure for protection |
| A3-05/06/07 | Pressure PID kp1/ti1/td1 | Primary pressure loop PID gains |
| A3-16/17/18/19 | Pressure PID kp4/ti4/td4 | Fourth pressure loop PID gain set for multi-phase optimization |
| A3-22 | Max flow in pressure control | Limits motor speed during pressure control mode to prevent runaway |
| A3-23 | Min pressure in pressure control | Sets minimum pressure threshold to prevent cavitation |
| A3-29 | Pressure loop gain factor | Overall scaling factor for the pressure loop output |
| A3-30 | Max torque during mode switch | Limits motor torque during transitions to prevent pressure spikes |
Fault Code Reference and Troubleshooting
Overcurrent Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| E02 | Overcurrent during acceleration | Acceleration time too short; motor parameters incorrect; short circuit in output | Extend acceleration time; verify motor parameters; check motor cable insulation |
| E03 | Overcurrent during deceleration | Deceleration time too short; regenerative energy without braking resistor | Extend deceleration time; install or upgrade braking resistor |
| E04 | Overcurrent at constant speed | Sudden load change; output short circuit; motor insulation failure | Inspect motor and cables; check for hydraulic system faults causing load surge |
Overvoltage Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| E05 | Overvoltage during acceleration | Input voltage too high; regeneration during acceleration | Check and stabilize input voltage; verify braking resistor installation |
| E06 | Overvoltage during deceleration | Deceleration time too short for the rotational inertia; insufficient braking capacity | Extend deceleration time; install larger braking resistor; check braking unit operation |
| E07 | Overvoltage at constant speed | Input voltage surge; load-driven regeneration | Stabilize power supply; investigate hydraulic system for energy return paths |
Overload and Overheat Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| E09 | Drive overload | Motor load exceeds drive rating; long-term overload operation | Reduce load; verify drive sizing; check hydraulic system efficiency |
| E10 | Motor overload | Motor running above rated current for extended period; blocked hydraulic circuit | Check hydraulic system for restrictions; verify motor cooling; adjust pressure settings |
| E11 | Motor overheat (PTC/KTY) | Motor temperature exceeded safe limit; sensor wiring fault | Reduce duty cycle; improve motor cooling; check PTC/KTY sensor wiring; verify F9-59 setting for KTY |
| E13 | Heatsink overheat | Ambient temperature too high; fan failure; blocked ventilation | Reduce ambient temperature below 45°C; replace cooling fan; clean heatsink fins |
Sensor and Feedback Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| Er45.0 | Protection signal fault (PTC) | PTC wiring loose; motor overheating; PG card fault | Check wiring; reduce load; short PTC-P and PTC-N to test; replace PG card if needed |
| Er45.3 | Protection signal fault (KTY) | KTY sensor wiring fault; motor overheating | Check KTY wiring; short KTY+ and KTY- to test; verify F9-59 parameter |
| E43 | Pressure sensor fault | Sensor wiring incorrect; power supply abnormal; sensor output failure | Check wiring; verify 24V supply; replace pressure transducer; test with PG card replacement |
| E28 | Speed sensor fault during auto tuning | Encoder mismatched with PG card; wiring incorrect; encoder mounting issue | Verify encoder/PG card compatibility; fix wiring; reinstall encoder; replace PG card |
| E31 | Speed error exceeds limit | Encoder wiring loose; UVW connection issue; PG card fault | Tighten encoder connections; check UVW motor wiring; replace PG card |
Auto-Tuning and System Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| E27 | Auto tuning fault | Motor parameters incorrect; drive-to-motor connection issue; auto-tuning timeout | Set motor parameters correctly; check motor cable connections; ensure motor is uncoupled for rotational tuning |
| E29 | Auto tuning speed feedback fault | Speed sensor mismatch; wiring error; sensor installation issue | Select correct encoder; fix wiring; reinstall sensor; replace PG card if needed |
| E30 | Back EMF fault during auto tuning | Motor parameters (F1 group) incorrect; motor defective | Verify F1 motor parameters; test with another motor to isolate the fault |
| E26 | User parameter restoring fault | New drive/firmware with no saved user parameters | Set and save user parameters; contact Inovance if issue persists |
Braking and Multi-Pump Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| E25 | Braking IGBT overtime | DC bus voltage persistently above braking threshold; F8-25 too small; braking resistor undersized | Install braking unit if not present; increase F8-25 if resistor not hot; upgrade to higher-rating resistor if hot |
| E47/E48 | Multi-pump related faults | Multi-pump coordination issues; slave pump enable/disable logic errors | Refer to multi-pump solution manual; verify A3-38 slave pump enable setting; check communication between master and slave drives |
| E24 | Reverse running timeout | Flow falling time too short; pressure command falling time too short | Increase flow falling down time; increase pressure command falling down time |
Communication and Time-Out Faults
| Code | Description | Common Causes | Solutions |
|---|---|---|---|
| E19 | Time out fault | F7-09 watch dog timer shorter than F8-17; communication interruption | Set F8-17 to a larger value or 0 (disable); check communication cable |
| E20 | Business time out fault | FA-08 shorter than FA-01/03/05/07; password or authorization issue | Set FA-08 to be no smaller than FA-01/03/05/07; obtain password FA-00/02/04/06 and increase timeout values |
| E22 | Overcurrent multi prevention fault | Output short circuit; auto-tuning not done; acceleration/deceleration too short; input voltage too low | Fix output wiring; perform auto-tuning; extend accel/decel time; adjust power supply; install braking resistor for shock loads |
Common Symptoms and Diagnostic Flow
No Display at Power-On
If the keypad shows no display when power is applied, check the following in order: (1) verify that the main power supply voltage is within range and actually reaching the R/S/T terminals; (2) check the DC bus voltage using the built-in measurement function if accessible; (3) verify that the 24V and +10V outputs on the control board are present; (4) re-seat the 8-pin and 40-pin ribbon cables between the control board and the drive board; (5) if all else fails, the pre-charge resistor, control board, or rectifier bridge may be damaged—contact Inovance support.
Motor Does Not Rotate After Run Command
When the drive receives a run command but the motor does not rotate: (1) check the wiring between the drive and motor; (2) verify that the motor parameters (encoder type, rated frequency, rated speed) are correctly set—restore factory defaults and reconfigure if necessary; (3) confirm that F0-01 (control mode) and F0-02 (command source) are correctly set; (4) check that the DI terminals are properly enabled in the F4 group; (5) verify the jumper between OP and +24V is secure; (6) if using V/F control with heavy-load start, check the torque boost setting (F3-01).
Frequent Overcurrent or Overvoltage Trips
If the drive frequently trips on overcurrent or overvoltage: (1) re-perform motor auto-tuning to ensure accurate motor parameters; (2) review and adjust acceleration/deceleration times to match the hydraulic system inertia; (3) check for load fluctuations in the hydraulic system such as valve sticking or pressure spikes; (4) verify that the braking resistor is properly sized and functional; (5) ensure the input voltage is stable and within the rated range.
Best Practices for Commissioning
Pre-Installation Verification
Before installing the HC580 on an injection molding machine, verify that the motor power rating is compatible with the drive rating. The drive should be rated at or slightly above the motor power. Check that the hydraulic system pressure transducer is functional and has a compatible output signal (4-20mA is preferred for noise immunity). Confirm that the injection machine controller provides analog pressure and flow command signals (0-10V or 4-20mA).
Retrofit Considerations
When retrofitting an existing injection molding machine from proportional valve control to variable-speed pump control, the proportional valves can typically remain in place but are set to fully open. The existing pressure and flow command signals from the machine controller are redirected to the HC580’s analog inputs. The hydraulic system may require minor adjustments to relief valve settings, and the machine’s cycle timing parameters may need optimization to take full advantage of the variable-speed response.
Safety Interlock Integration
Ensure that the injection molding machine’s safety interlock system is properly integrated with the HC580. The machine’s emergency stop circuit should cut power to the drive’s input contactor, and the drive’s fault relay should be wired into the machine’s safety circuit to prevent machine operation if the drive is in a fault state. Verify that the motor PTC or KTY temperature sensor is connected to the appropriate PG card terminals for motor thermal protection.
Conclusion
The Inovance HC580 series injection molding machine inverter represents a purpose-engineered solution that directly addresses the unique control requirements of hydraulic injection molding systems. Its dual-loop pressure/flow control architecture, multi-phase PID parameter sets, and comprehensive injection cycle management capabilities enable significant energy savings while maintaining or improving molding precision. By understanding the operation panel functions, correctly wiring the analog and digital control terminals, properly tuning the pressure PID parameters for the specific hydraulic system, and effectively diagnosing fault codes using the troubleshooting tables provided, technicians can achieve reliable and efficient operation. The HC580’s integration of injection molding control logic within the drive firmware simplifies system architecture while providing the flexibility needed to adapt to diverse molding applications and machine configurations.