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PIM-00004

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[Operation Manual]

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DAIKIN INDUSTRIES, LTD.

Oil cooler maintenance procedure

WARNING

[1] Before maintenance work, stop operation, and turn OFF the main power supply.

[2] During work, wear protective goggles and gloves.

i) The core fin has a sharp edge. Be careful not to hurt yourself.

ii) During air blow, be careful that foreign bodies will not touch your eyes.

CAUTION

[1] Be careful that strong force will not be applied to the AC fan power supply cable and connector during

work.

[2] During disassembly process, oil will flow out of the pipes and oil cooler.

1. Dismounting the oil cooler

[1] Loosen the cross recessed truss head machine screws (M5 L14, two pieces) in the full cover, and remove

the full cover.

The full cover has been fastened to the unit body with the claws (at six places in total: two at the front

of the unit, one on each side, and two at the top of the unit). Lift the cover vertically from the unit.

[2] Open the controller small cover, and remove the fan

connector and the fan ground cable.

[3] Cut the binding strap that ties the fan harness.

[4] Cut the binding strap that ties the hoses.

[5] Remove the hose bands (at two places), and disconnect the

hoses (two pieces) at the top of the oil cooler.

Note) In this step, oil may leak due to backward oil flow

from the tank. Before conducting this step, attach a

blind plug to each hose.

[6] Remove the hexagon socket head bolts (M5 L16: 2 pieces)

with washers, and dismount the oil cooler.

Fan connector

Fan ground cable

Содержание SUT10D80L21-10-F

Страница 1: ...PIM 00004 1 Operation Manual 1 61 Hybrid Hydraulic System Super Unit SUT10D80L21 10 F SUT16D80L21 10 F Operation Manual DAIKIN INDUSTRIES LTD Oil Hydraulics Division ...

Страница 2: ...AIKIN Hydraulic Unit In addition to this manual please prepare safety references for your machine to ensure safe operations and maintenance in accordance with various standards and norms Conventions of safety instructions in this manual In this manual safety instructions are classified into three categories DANGER WARNING and CAUTION DANGER Improper handling regardless of this indication causes an...

Страница 3: ...negligence in observing the instructions given in the operation manual or delivery specifications DAIKIN shall not be responsible for any damage attributable to malfunction caused by combinations of this unit and external equipment Limitations on Applications If a failure or malfunction of this unit may directly threaten human life or this unit is used for equipment that may cause injury to the hu...

Страница 4: ...stallation 13 Precautions for operation 13 Precautions for transportation 13 Precautions for installation 14 9 Preparations for Operation 16 Filling hydraulic oil 16 Electric wiring 17 I O signal cable specifications 24 10 Test Run 29 11 Operation Panel Operating Procedure 30 Outline of functions 30 Description on individual modes 30 Shift between individual modes 30 Operating procedure for each m...

Страница 5: ...rovides extremely high energy efficiency The Super Unit uses the autonomously switching dual pump system that enables autonomous control of combination mode single mode switching according to load pressure by using the dual fixed capacity pumps small capacity and large capacity pumps and the switching valve When a large flow rate is required the dual fixed capacity pumps small capacity and high ca...

Страница 6: ...nit can simplify the system configuration and reduce the cost for switching between high speed and low speed operations and multi stage pressure control of presses M M Conventional system configuration System configuration of Super Unit Controller General purpose solenoid valve Combination mode single mode switching valve Driver Special spool shockless solenoid valve Throttle valve Proportional re...

Страница 7: ...p g Optional function F 16 pattern P Q function and noise filter are used d Maximum pump discharge rate 80 83 0 L min h Non standard control No Item without a symbol Standard item MFG No i j k l i Hardware revision history j Software revision history k Serial No PQ represent characteristic chart 81 7 27 4 14 2 51 2 0 20 6 3 4 7 0 9 5 The above charts show the typical characteristics at an oil temp...

Страница 8: ...Adjustment Procedure Note 2 Power supply voltage fluctuation tolerance range is 10 Even if the power supply voltage fluctuations are within the tolerance range when the power supply voltage fluctuates in the positive direction the regenerative overload alarm stop may occur in response depending on the master machine operating conditions and load conditions Operating conditions Hydraulic oil Note 3...

Страница 9: ... stop the hydraulic unit repeatedly by turning ON OFF the power supply at intervals of 8 minutes or less use the start stop function using the start stop signal See page 24 When the hydraulic unit is started stopped with the start stop signal the time interval to restart the unit after stop command input should be at least 0 5 sec 5 This hydraulic unit incorporates a check valve that provides an o...

Страница 10: ...t front view When the full cover is removed Oil cooler Hydraulic pump Tank Motor Oil level gauge Valve block AC fan AC fan Return filter Controller Oil filling port Air breather Operation panel Return port Rc1 Discharge port Rc3 4 Drain port Rc3 4 Return port Rc1 1 2 Return port Rc1 1 4 Stop valve Option port Rc1 2 Option port Rc3 8 ...

Страница 11: ...c circuit diagram M M P Rc3 4 T1 T2 DR1 C R PL PH Rc1 2 Rc3 4 Rc1 Rc1 1 4 Rc1 1 2 1 3 2 5 4 8 7 6 1 6 2 M Components Part No Name 1 Tank 2 Suction strainer 3 Stop valve 4 Oil level gauge 5 Oil filling port Air breather 6 1 Inverter drive pump 6 2 Controller 7 Oil cooler 8 Return filter ...

Страница 12: ...ith reaction force of the hose The piping to the unit should be connected with a hose so that vibration of the motor pump unit will not be conveyed to the machine Note The return filter provides two ports One port is covered with a plug Rc3 4 and another port is covered with a taper plug vinyl cap Rc1 Note For details of the pipe positions refer to the model drawing on a separate sheet Note Tighte...

Страница 13: ... vibration suppressing rubber See the figure below DANGER If the hydraulic unit is lifted by any parts e g pump pipes other than the hook slots the unit may fall or turn over Check the weight of the hydraulic unit and make sure that it does not exceed the rated load capacity of each lifting sling WARNING During transportation make sure that the unit can be evenly lifted by the hook slots at four p...

Страница 14: ...ausing the hydraulic oil and equipment to become extremely hot If you accidentally touch the hot parts you may get burns CAUTION If the hydraulic unit is used in a place without an air intake exhaust space or where hot air is stuffed around the unit the motor and controller become hot causing the equipment service life to be remarkably shortened When the motor or controller becomes hot the tempera...

Страница 15: ...ng bracket separately sold see the delivery specification drawing model drawing WARNING Unless the hydraulic unit is fastened with bolts it may be turned over or moved by reaction force under the oil pressure in the pipe CAUTION If the hydraulic unit is installed on an inclined plane oil leak or air intrusion occurs resulting in abnormal sound or shortened service life of the equipment Be sure to ...

Страница 16: ... capacity L Yellow line upper limit Red line lower limit 100 100 L 85 L 160 165 L 141 L CAUTION 1 Operating the hydraulic unit with no oil in the tank causes pump seizure or wear which may result in pump damage 2 Make sure that the stop valve is opened If the stop valve is not opened the oil cannot be supplied into the pump This causes pump seizure or wear which may result in pump damage 3 During ...

Страница 17: ...nger contact distance for three electrodes in the OFF status Front view of the unit controller Bottom view of the unit controller Item Cable size Recommended cable Recommended crimp terminal Recommended cable clamp Power supply cable 6 0 mm2 or more AWG10 or larger size CE362 6 0 mm2 4 cores manufactured by KURAMO RBV5 5 5 manufactured by NICHIFU OA W2219 manufactured by OHM ELECTRIC Item Cable si...

Страница 18: ...the cables be sure to turn OFF the main power supply breaker and make sure that the power is interrupted Be sure not to connect the power supply cable to the I O signal terminals Do not apply an excessive power supply voltage higher than the power supply rating of the hydraulic unit CAUTION The hydraulic unit incorporates an overcurrent protection function Therefore it does not need an overcurrent...

Страница 19: ...rew in advance 2 Insert the cable into the controller through the controller s wiring hole 3 Tighten the controller fastening screw to fasten the cable clamp to the controller 4 Tighten the tightening cap to fasten the cable The cable sheath protrusion length should be approx 2 to 3 mm Controller fastening screw Tightening cap Wiring hole Controller fastening screw Sheath protrusion length 2 to 3 ...

Страница 20: ...Use an AC power supply conforming to the power supply specifications of this product Use a power supply cable conforming to the power supply capacity See the table below Do not connect the power supply cable to the ground terminal The ground terminal is connected with the motor frame Ensure Class D former Class 3 or higher grounding condition When unsheathing the cable be careful not to damage the...

Страница 21: ...mp the round crimp terminal with insulation sheath by using a dedicated tool 4 After looping each cable connect it to the terminal block CAUTION If the crimp tool is not suitable for the crimp terminal the cable will come off the terminal due to a crimp failure during operation This results in short circuiting or burnout of the circuit caused by abnormal heating 70 mm Approx 1 mm Connect a ground ...

Страница 22: ...areful that the cable conductors do not protrude from the terminal block CAUTION After checking the specifications of individual signal lines see p 24 connect the cable to the I O signal terminal block The cable inserted into the cable clamp should be a multi core cable as those recommended below If two or more cables are inserted into the clamp the cable clamp does not conform to the specified pr...

Страница 23: ...thed length of the cable and insert it all the way into the terminal so that the conductors will not become loose 3 Tighten the screw with a screwdriver 4 Pull the cable lightly to make sure that it is securely connected Unsheathed length of the cable 6 mm 6 Procedure for connecting the cable to the terminal block ...

Страница 24: ...witching command in the setting mode 14 DIN2 Digital input 2 5 DIN3 Digital input 3 15 DIN4 Digital input 4 6 Digital I O terminal DIN5 Digital input 5 P Q selection patterns 0 to 15 can be changed depending on the combination of input signals 16 DO1 Digital output 1 7 DO2 Digital output 2 17 OCOM Digital output common 8 AL_A Contact output a 18 AL_B Contact output b 9 Digital contact output termi...

Страница 25: ...ital input 4 6 ICOM5 Digital input 5 P Q selection Nos 0 to 15 can be selected depending on the combination of digital input status For P Q selection setting see p 37 Note While the unit is stopped by digital input the panel shows Note Set the time between unit stop and unit start at 0 5 seconds or more Combination of digital inputs for P Q selection P Q selection No Digital input 2 Digital input ...

Страница 26: ...A or higher capacity Power cannot be supplied from this controller to external equipment Terminals for input signals are available for contact relay and non contact transistor output The current flowing through each input circuit is 5 mA typical To configure a circuit with a contact be careful about the minimum current of the contact ...

Страница 27: ...ly Power cannot be supplied from this controller to external equipment This controller s output circuit serves as negative common Not capable for positive common The maximum output current of an output circuit is 30 mA resistance load If you attempt to drive load higher than the allowable current the circuit may be damaged Pay attention to the maximum allowable current To drive induction load take...

Страница 28: ... Pay attention to the maximum allowable current The minimum allowable load of the contact output is 10 mVDC 10 A However it is an approximate lower limit that enables the contact to be opened closed under minute load This value varies depending on switching frequency and environmental conditions We recommend you to check the minimum allowable load in actual conditions To drive induction load take ...

Страница 29: ...eck loop all pipes except for the actuator and execute flushing operation for approx two hours while running hydraulic oil through the filter To conduct flushing operation loop all pipes and run the oil through a filter Before flushing operation check all pipe connections for looseness and oil leak After completion of the flushing operation check the return filter indicator If the filter is clogge...

Страница 30: ...tions Description on individual modes Normal mode Displays an actual pressure value or alarm code Monitor mode Displays a pressure switch set value pressure set value flow rate set value actual flow rate and actual rpm Setting mode Used to set or change a parameter such as pressure and flow rate Alarm mode Alarm records can be checked Shift between individual modes Key switch operations for shift ...

Страница 31: ...er 1 n07 Reverse rpm at power OFF Displays a motor reverse rpm due to counter flow from the load when the unit power supply is turned OFF This parameter is used to estimate the machine load volume n08 Regenerative load integration ratio Displays the load integration ratio of the current regenerative braking resistance n10 Motor thermistor temperature Displays the temperature detected by the thermi...

Страница 32: ...dure Key operation 3 digit LED Remarks Power ON Startup Run Actual pressure display Shift to monitor mode Parameter No selection Press the key three times Blinking Monitor display Flow rate theoretical value 83 0 L min Return to actual pressure display mode To monitor other parameter return to the actual pressure display mode once and then select a desired item ...

Страница 33: ...al value the product of theoretical displacement volume by rpm It is slightly different from the actual flow rate 2 For the pressure flow rate setting parameters P13 through P28 the following settings are not allowed a If PH is set lower than PL PL automatically becomes equal to PH b PL cannot be set higher than PH c If qL is set lower than qH qH automatically becomes equal to qL d qH cannot be se...

Страница 34: ...o seconds After two seconds Parameter No selection or P Q selection 1 Set value display Displays pressure setting of high pressure pump for P Q selection 1 P Q selection Press three times PH 1 qH 1 PL 1 qL 1 Ut 1 and dt 1 are alternately displayed in this order Displays flow rate setting of low pressure pump for P Q selection 1 Changing set value or Writing set value Displays acceleration time set...

Страница 35: ...er ON Actual pressure display Setting mode Keep pressing two keys simultaneously for at least two seconds After two seconds Parameter No selection or P Q selection 1 Set value display Displays pressure setting of high pressure pump for P Q selection 1 P Q selection Press two times PH 1 qH 1 PL 1 qL 1 Ut 1 and dt 1 are alternately displayed in this order Displays flow rate setting of low pressure p...

Страница 36: ...mal pressure response FF DH P06 Deceleration load command ratio 30 20to100 Limits the torque command ratio if the command changes by more than 1 2 of the maximum flow rate when a change is made in the PQ selection 0 No output 1 Warning output P07 Warning output level setting 0 2 Alarm equivalent output Specify a warning output level 0 Individual output 1 Integrated output 2 Pressure switch functio...

Страница 37: ...P29 High Low switching response time 0 30 0 05to1 00 sec Used to adjust the minimum response time for switching the solenoid valve when the pump operation is unstable because the operating point is close to the high pressure low pressure switching point solenoid valve switching point P30 Single mode switching rpm dead zone 400 0to999 min 1 Used to adjust the dead zone of the solenoid valve switchi...

Страница 38: ...cify operation of the high pressure small capacity pump only Normally the P05 P10 and P11 settings need not to be changed However if a special circuit condition large load volume etc is expected these settings must be changed This hydraulic unit allows 16 patterns from PQ selection numbers 0 to 15 to be set when using a single pattern only however select PQ selection 0 The pressure and flow rate c...

Страница 39: ...r P08 1 Integrated alarm output P08 2 Expansion of pressure switch function 時間 P39 Digital output selection Digital output selection is available by changing parameter P18 and P39 as shown below P08 setting P07 setting P39 setting Digital output 1 Digital output 2 Contact output 0 Completion output 1 Motor operation output 0 2 High pressure pump operation output Alarm output 0 Completion output 1 ...

Страница 40: ... Displays the latest alarm After two seconds Selecting alarm No Press once Displays an alarm before the latest one Displays alarm condition Alarm code and power ON count are alternately displayed at a second interval Return to actual pressure display mode Alarm code display list The hydraulic unit incorporates alarm detecting functions that are classified as follows Panel display unit operation an...

Страница 41: ...al rise E41 Radiator fin thermistor cable break E42 Fin temperature abnormal rise E43 Drying operation error E64 CPU runaway watchdog E91 EEPROM data error 1 E93 2 EEPROM data error 2 E94 Motor temperature abnormal warning L44 Fin temperature abnormal warning L45 3 Power supply voltage drop warning L50 Pressure deviation abnormal warning L60 4 Pressure switch activation Note 1 L63 During activatio...

Страница 42: ...t output 60 seconds at 110 The motor output is larger than the normal output If the event is repeated contact DAIKIN Magnetic pole detection error E18 Faulty detection of the initial position of the motor If the event is repeated contact DAIKIN Encoder cable break E20 Alarm outputted as a result of a break in the encoder Parts should be replaced contact DAIKIN Motor cable break E21 Alarm outputted...

Страница 43: ...or Carry out servicing Fin temperature abnormal warning L45 Alarm outputted when the fin thermistor temperature exceeds the threshold 78 C The event can be caused as a result of a decrease in the heat radiation and cooling performance of the controller Carry out servicing Power supply voltage drop warning L50 Alarm outputted when the power supply voltage falls below 180 V Check the power supply vo...

Страница 44: ...aily Occasionally Make sure that the AC fan is rotating Clogging of the core Semiannually Visually check the core for clogging If the AC fan rotation is stopped or the core is clogged 1 the oil cooler cooling capacity remarkably deteriorates This causes the hydraulic oil or the unit to become hot resulting in burns Also this accelerates deterioration of the hydraulic oil causing the unit service l...

Страница 45: ...the indicator shows filter clog replace the filter element Replace the filter element according to the maintenance procedure on p 51 1 The type of the return filter is MAR10 10P S manufactured by Masuda Mfg The type of the filter element is AR10 010P DANGER 1 Do not access or touch rotating parts 2 If you touch internal components of the controller observe the following procedure to prevent electr...

Страница 46: ... two pieces in the full cover and remove the full cover The full cover has been fastened to the unit body with the claws at six places in total two at the front of the unit one on each side and two at the top of the unit Lift the cover vertically from the unit 2 Open the controller small cover and remove the fan connector and the fan ground cable 3 Cut the binding strap that ties the fan harness 4...

Страница 47: ...ooler 1 Remove the cross recessed hexagon head bolts M5 L12 4 pieces and separate the shroud from the core 2 Remove the cross recessed head machine screws M4 L70 2 pieces and separate the AC fan and finger guard from the shroud Oil cooler Full cover hook at six places Hose bands Cross recessed hexagon head bolt M5 x L15 2 pieces Finger guard AC fan Shroud Core Cross recessed head machine screw ...

Страница 48: ...periphery and the casing as well as the blades and the casing by using a cloth CAUTION 1 Prohibition of steam air blow Never attempt to blow steam or air onto the fan motor Steam air blow causes foreign bodies to be blown into the motor 5 Reassembling the oil cooler After cleaning is completed reassemble the oil cooler After reassembling is completed conduct the test run procedure described on p 2...

Страница 49: ...t Blow steam or air onto the AC fan bracket to eliminate dust or contamination accumulated on adhering to the bracket 4 Cleaning the AC fan Clean the clearance between the blade periphery and the casing as well as the fan blades and the casing by using a cloth CAUTION 1 Prohibition of steam air blow Never attempt to blow steam or air onto the fan motor Steam air blow causes foreign bodies to be bl...

Страница 50: ...N m from the cleaning door cover and remove the cover from the cleaning door When the Super Unit uses the 160 L tank there are 14 nuts for the cleaning door 2 You can see the suction strainer Loosen the strainer and remove it Hexagon nut Width across flats 41 mm 2 Cleaning procedure Blow air onto the filter to blow off dust accumulated on adhering to the filter Remove dust from inside of the strai...

Страница 51: ...ket head bolts 1 that fasten the cover 3 and pull up the cover Then the element 5 can be removed 2 Pull out the split pin 10 from the element loosen the element tightening nut 9 and remove the parts 6 to 8 3 Replace the element with a new one and re mount it by following the above procedure in reverse 4 Tighten the hexagon socket head bolts 1 securely in the diagonal order 1 Hexagon socket head bo...

Страница 52: ...e transient period when the circuit is blocked due to stop of the master machine hydraulic actuator However the safety valve set pressure will be lowered due to long term repeated operations and contaminants in the hydraulic oil If the safety valve is activated even with normal conditions safety valve adjustment is required Judgment criteria The hydraulic oil temperature rising time is shorter tha...

Страница 53: ... unit power supply and select the setting mode through panel key operation Then set a desired pressure 4 Select n05 rpm display in the monitor mode through panel key operation to show the current rpm 5 Adjust the pressure adjusting screw length in the longitudinal direction and find an activation starting point as shown on the right 6 Turn the pressure adjusting screw clockwise by 1 8 turn from th...

Страница 54: ...o adjust the safety valve follow the procedure below First set the safety valve by following the above steps 1 to 5 so that the pressure setting is 7 7 MPa corresponding to one turn of the pressure adjusting screw lower than a target pressure Then tighten the adjusting screw by turning it clockwise by one turn and conduct the above step 7 Pressure adjusting screw length Reference Pressure adjustin...

Страница 55: ...lay 3 sec max 0 2 sec average Charging Magnetic pole detection Actual pressure display Normal control Actual pressure display Actual pressure display H Stop command L Operation command H Normal H Normal pressure condition The output may be unstable depending on the relationship between the pressure switch setting and delay time L Activated L Abnormal Pressure switch setting Power supply 200V Start...

Страница 56: ... Mode Display Normal control Actual pressure display Controlled in warning status When Level 0 is selected an actual pressure value is displayed Level 0 H Normal Level 1 H Normal Level 2 H Normal H Normal pressure condition Temperature error threshold level 10 sec L Abnormal L Abnormal 0 5 sec 0 5 sec L Alarm code H Actual pressure display Alternately displayed at 1 second interval Alarm Warning P...

Страница 57: ...ing procedure for each mode b Setting mode on p 39 Note For the purpose of explanation the above 1 7 Alarm classification 4 chart shows the case where the pressure switch is activated without a dead zone Actually however the pressure switch has a dead zone of approx 0 5 MPa Note Set the time interval after a stop signal at 0 5 seconds or longer Pressure switch Relay output Start stop signal Mode D...

Страница 58: ...lay 3 sec max 0 2 sec average Charging Magnetic pole detection Normal control Actual pressure display Actual pressure display Actual pressure display H Stop command L Operation command H Normal The output may be unstable depending on the relationship between the pressure switch setting and delay time L Abnormal Pressure switch setting Power supply 200V Start stop signal Alarm Warning Relay output ...

Страница 59: ...ning Relay output Pressure Mode Display L Abnormal Charging 3 sec max Motor stop due to alarm activation L Alarm code H Setting No Alternately displayed at 1 second interval P07 Warning output level setting Alarm Warning Relay output Thermistor temperature Mode Display Normal control Actual pressure display Controlled in warning status When Level 0 is selected an actual pressure value is displayed...

Страница 60: ... For the setting procedure and setting range see Operating procedure for each mode b Setting mode on p 39 Note For the purpose of explanation the above 2 7 Alarm classification 4 chart shows the case where the pressure switch is activated without a dead zone Actually however the pressure switch has a dead zone of approx 0 5 MPa Note Set the time interval after a stop signal at 0 5 seconds or longe...

Страница 61: ...anged to Hi Actual pressure P Q 0 input Complete signal output P Q 1 input P Q 2 input P Q 3 input Pressure Command rpm Command Actual rpm P Q selection Start stop command input P Q selection 1 P Q selection P Q selection 5 1 Start by a start stop signal Speed control state 2 Change of a P Q selection number Deceleration 3 Change of an operation state Feed to pressure holding 4 Change of a P Q sel...

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