Operation Manual: SUT06D40L16-20 SUT10D40L16-20 SUT06D60L21-20 SUT10D60L21-20
Operation Manual: SUT06D40L16-20 SUT10D40L16-20 SUT06D60L21-20 SUT10D60L21-20
Operation Manual: SUT06D40L16-20 SUT10D40L16-20 SUT06D60L21-20 SUT10D60L21-20
[Super Unit]
SUT06D40L16-20
SUT10D40L16-20
SUT06D60L21-20
SUT10D60L21-20
Operation Manual
<Safety Precautions>
Before using this product
Give consideration to make users thoroughly understand the contents of this operation manual.
Please incorporate the contents of this operation manual in operation manuals for your machine using this product.
To ensure proper operation of this unit, be sure to read this operation manual and all other attached documents
carefully, to have a thorough understanding of the equipment, safety information and all other precautions before
installation, operation and maintenance/inspection of this unit.
Be sure to keep this operation manual, attached documents and delivery specifications in place, so that you can read
them whenever required.
For detailed explanation of the unit, all figures and photographs included in this manual show the unit without covers
or safety shields. To operate this unit, be sure to mount the covers and shields in the specified manner, and observe
the operating procedures described in this manual.
The contents of this operation manual are subject to change appropriately for product improvement, specification
change or easier operations.
The latest version of this manual is available through DAIKIN Oil Hydraulics Division Internet Service
(http:// www.dhcnet.daikin.co.jp:8100/).
This operation manual should be used as a reference that provides safety instructions for DAIKIN 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.
Safety precautions
♦ General precautions
DANGER
Transportation, installation, piping, wiring, operations, maintenance and inspections must be conducted by qualified
personnel.
During the above work, wear protective gear required for safe work (work clothes, safety band, helmet, safety shoes,
gloves and so on).
Do not use this unit under conditions other than those specified in the catalog or delivery specifications.
CAUTION
Be sure to conduct daily inspections (described in this manual or attached documents).
Do not apply external force to this unit. (Do not step on, or pound on this unit.) Otherwise, you may suffer from
injury, or the unit may be damaged.
<Escape Clauses>
DAIKIN shall not be responsible for any damage attributable to a fire, earthquake, third party’s action and other
accidents, as well as customer’s intention, misuse or use under abnormal conditions.
DAIKIN shall not be responsible for any damage incidental to use of this product or impossibility to use this product
(loss of business profit, discontinuation of business).
DAIKIN shall not be responsible for any accident or damage attributable to 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 human body, such an application must be considered depending on the case.
This unit has been manufactured under strict quality control. However, when it is used for important equipment, the
equipment must be provided with a safety device to prevent malfunction of this unit from resulting in serious
accident or damage.
Contents
[1. Introduction] 5
[12. Maintenance] 40
[1. Introduction]
Thank you for selecting IPM Motor Drive Hydraulic Unit <Super Unit>.
Using the oil hydraulic technology and energy-saving IPM motor drive system that DAIKIN originally developed, the
IPM Motor Drive Hydraulic Unit <Super Unit> provides overwhelmingly excellent energy conservation performance
and advanced functions.
Before using the SUT Series <Super Unit>, please read this manual thoroughly, and handle and maintain this unit
properly, so that this unit can retain excellent performance for a long period.
The components of this unit may be modified for the purpose of quality/performance improvement or other reasons. In
such a case, some parts of this product may be different from those described in this manual.
Discharge
Flow control
valve
Large and small capacity pumps join
qL
Drive joining/dividing flow
solenoid operated valve
Pressure and flow rate setting
Relief valve of low avalable 4 patterns
pressure side Pressure
sensor PL
IPM motor
(2) Multi-stage speed control/Multi-stage pressure control, and shockless control functions
The Super Unit enables multi-stage pressure control/flow rate control by selecting 4 patterns of P-Q characteristics
that have been registered in the controller from the master machine (via a contact input).
The Super Unit enables shockless control by setting/adjusting the rising/falling time at changes of the P-Q
characteristics.
The functions that have been controlled with valves in a conventional system can be controlled with pumps.
Therefore, when this system is used for high-speed/low-speed switching (for a press etc.) and multi-stage pressure
control applications, the system configuration can be simplified, and costs can be reduced.
Flow controlled
valve
Elimination of the flow
controlled valve
Generalized solenoid
Special shock-less operated valve
solenoid operated Standardization of the
valve solenoid operated valve
Elimination of the
proportional valve Joining/dividing
diverter valve
M M
Driver Controller
Time (second)
MFG. No
(i) (j) (k)
** ** - **-*****
SUT**D40L16 SUT**D60L21
60.3
40.2
Fl ow流量[L/min]
Fl ow流量[L/min]
(23.7) (32.0)
rate
rate
15.2 20.4
(8.7)
(7.7)
0 (3.2) 7.0 (7.9) 15.7 0 (3.0) 7.0 (8.3) 20.6
圧力[MPa]
Pressure 圧力[MPa]
Pressure
* The above charts show the typical characteristics at an oil temperature of 40°C.
* Above PQ characteristics show the usable range by actual flow rate.
It is preset to be Max. discharge flow rate when delivered.The maximum flow rate is a theoretical value, not a
guaranteed value.
Please refer to the specification sheet (drawing) for other specifications.
Pressure and flow rate can be set higher than the above adjusting ranges. However, the hydraulic unit must be
operated at pressure and flow rate within the above adjusting ranges.
This hydraulic unit incorporates a high-pressure safety valve. With SUT**D40L16, the maximum pressure of the
safety valve has been adjusted at “+2.0 MPa”. With SUT**D60L21, the maximum operating pressure has been
adjusted at “+1.0 MPa”.
Even when the safety valve is used with a low-pressure setting, specific adjustment is not required. However, if it
is necessary to minimize surge pressure during actuator operation, adjust the pressure setting, according to
“High-pressure Safety Valve Adjusting Procedure” described in the Attachment.
(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) Dedicated mineral hydraulic oil / Wear-resistant hydraulic oil
(For recommended brands, see DAIKIN “Hydraulic Equipment General Catalog (HK196)”.)
Viscosity grade: ISO VG 32 to 68 Viscosity range: 15 to 400 mm2/s
Pollution degree: NAS Class 9 or lower level
Tank oil temperature 0 to 60°C (Recommended operating temperature range: 15 to 50°C) (Note 4)
Operating ambient temperature 0 to 35°C
Storing ambient temperature –20 to 60°C
Humidity 80% RH or less (No condensation)
Height above the sea level 1,000 m or less
Installation place Indoor (Be sure to fasten the unit with bolts.)
Others Be sure to mount a 3-pole circuit breaker and earth leakage breaker.
Make sure that the electric wiring conforms to European Norm EN60204-1.
If you frequently turn ON/OFF the power supply for this unit, the controller service life will
be remarkably deteriorated. To start/stop the hydraulic unit by turning ON/OFF the power
supply repeatedly at intervals of 8 minutes or less, use the control stop function of this unit.
Be sure to connect the ground terminal.
(Note 3)
This unit can use only mineral hydraulic oil. (Water-containing or synthetic oil such as water-glycol cannot be
used.)
(Note 4)
When the tank oil temperature exceeds the recommended operating temperature range, pressure pulsation may
be increased, or the discharge rate may be decreased. However, such phenomena do not indicate abnormality.
(2) This hydraulic unit switches over combined and single operations of the dual pumps with the solenoid valve, in
order to provide excellent energy-saving performance. If an operation point of your machine is close to the
switching point of this solenoid valve, the switching operation may become unstable. In this case, change the flow
rate setting (qH) or pressure setting (PL) so that it is lower than the switching point.
Also, the switching operation can be stabilized by adjusting the width of the dead zone provided near the switching
point. (Refer to [P16] and [P17] on page 35.)
(3) In this hydraulic unit, the motor pump unit is equipped with vibration suppressing rubber to prevent vibration of
the motor pump unit from being conveyed to the whole unit. For this purpose, the discharge pipe provides a large
degree of freedom. Therefore, when connecting the discharge pipe, be careful that the discharge pipe will not
touch the cover even if the pipe shakes with 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.
(4) This hydraulic unit is equipped with an AC fan to cool down the hydraulic oil, controller and motor. To ensure air
intake and exhaust, do not place an obstacle within 10 cm from the end surfaces of the unit.
(5) Frequently turning ON/OFF the power supply causes the controller service life to be remarkably shortened. If you
start and 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.
(6) This hydraulic unit incorporates a check valve that provides an orifice in the discharge line. If high response is
required for machine pressure release or other purpose, the machine must be provided with an additional pressure
release circuit.
If the load volume is large, you may hear a fluid flow sound from this orifice when the unit is stopped. However,
this phenomenon does not indicate abnormality.
(7) This hydraulic unit uses an IPM motor, which generates counter-electromotive force during changeover
(regenerative operation). If the motor is frequently turned ON/OFF in the operating condition (with a large load
volume, and resulting in large reaction force of load) that easily generate counter-electromotive force, it causes
regenerative overload, resulting in unit stop.
(8) This hydraulic unit is equipped with a safety valve.This safety valve has been set to a specified pressure before
shipment. However, the set pressure of the safety valve may decrease while the machine is repeatedly used for a
long period, or due to contaminants in the hydraulic oil.
If this unit is continuously used with the safety valve activated, it may output an alarm due to a temperature rise
and so on. In this case, re-adjust the pressure setting of the high-pressure safety valve, according to “High-Pressure
Safety Valve Adjusting Procedure” described in the Attachment.
(9) Continuous operations with maximum pressure is only allowable when operating flow rate is 8.0L/min or below
for SUT**D40L16, and 6.5L/min or below for SUT**D60L21.
Return port
(Rc3/4)
Option port
(Rc3/8)
Discharge port
(Rc3/4)
Tank
Valve block
Oil cooler
Hydraulic pump
Stop valve
Transport nameplate
Motor
Above the
oil surface
Hose
(Low pressure) (High pressure)
Components
Piping
This hydraulic unit is equipped with a return filter, and also a return port (submerged in oil), a drain port (above the oil
surface) and a discharge port. Connect pipes as required. Each piping port has been covered with a taper plug (vinyl
cap) before shipment.
In this hydraulic unit, the motor pump unit is equipped with vibration suppressing rubber to prevent vibration of the
motor pump unit from being conveyed to the whole unit. For this purpose, the discharge pipe provides a large degree of
freedom. Therefore, when connecting the discharge pipe, be careful that the discharge pipe will not touch the cover
even if the pipe shakes with 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) Tighten each pipe connection by winding seal tape.
Option port
Return port
Return filter Drain port (Rc1/2)
(Rc1) Return port
(Rc3/4) (Rc1)
Return port
(Rc3/4)
Discharge port
Option port
(Rc3/4)
(Rc3/8)
CAUTION
This hydraulic unit incorporates a check valve. If an additional inline check valve is mounted to the discharge port,
resonance occurs, which may have bad influence on the master machine. Therefore, do not use an inline check
valve.
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 (in the table below), 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 places.
During transportation using lifting slings, never come close to the unit. If the unit falls or turns over, you may suffer
from injury.
CAUTION
Avoid transporting the hydraulic unit with hydraulic oil contained in the tank.
(This may cause oil leak, or malfunction due to air intrusion.)
During transportation, hold the hydraulic unit securely so that it will not be moved by vibration or external force.
Air
Exhaust
intake
10 cm or more
10 cm or more 10 cm or more
WARNING
If the hydraulic unit is used in a place without an air intake/exhaust space, or a place stuffed with hot air, the oil
cooler/AC fan heat exchanging function will deteriorate, causing 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 temperature protection function is activated to stop operation.
(When the motor or controller becomes extremely hot, the warning signal and alarm signal will be output.)
If the hydraulic unit is continuously used at a high temperature, the hydraulic equipment (pump, valves, etc.) will
have defects or shortened service life, as well as the electric components described above.
Using the hydraulic unit at a high temperature accelerates deterioration of the hydraulic oil, resulting in shortened
service life.
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 install the unit on a level plane.
Oil level
gauge
Stop valve
Stop valve is opened. Be sure to open it before use.
(Lever is horizontal: Open, Lever is vertical: Closed)
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 initial operation of the machine, oil will be supplied into the hydraulic circuit of the machine. Be careful
about a decrease in oil level in the tank.
[4] The oil level in the tank may largely fluctuate depending on the machine hydraulic circuit. This may result in oil
leak from the tank, or decrease in oil level.
Electric wiring
To conduct electric wiring, remove the full cover and the controller.
To remove the full cover, loosen the cross-recessed truss head machine screws (at 2 places), and pull the full cover
upward so as to release the hooks at the top and bottom of the full cover from the hook slots of the tank. Then, pull
the cover forward to remove it.
Controller cover
Cross-recessed truss head machine screws
Loosen these screws when removing the full cover. Hexagon socket head bolts for fastening the controller
You need not remove these screws. Loosen these screws when removing the full cover.
You need not remove these screws.
<Unit front view> < When the full cover is removed >
Hooks of full cover (at 2 places on the top)
Loosen the hexagon socket head bolts that fasten the controller (at 2 places).
Pull the controller straight upward, and move it from the front of the unit to the right, until the controller fin almost
touches the end of the solenoid valve block.
(This procedure applies to SUT06D60L21 and SUT10D60L21 only.)
CAUTION
[1] Before connecting the cable, you must remove the controller fastening bolts. Be careful not to drop the controller.
[2] The controller has harnesses to which cables are already connected. Be careful not to disconnect other harnesses.
DANGER
In order to protect the electric circuit against short-circuiting and over-current and prevent electric shocks, the
hydraulic unit main power supply must be equipped with a safety device (no-fuse breaker, earth leakage breaker, etc.)
conforming to European Norm EN60947-2.
(For capacity of each model, see the table below.)
The ground terminal is connected to the motor frame. Ensure Class D (former Class 3) or higher grounding
condition.
(Connect the ground terminal directly without using a breaker.)
Be sure to complete installation of the hydraulic unit before wiring.
Before wiring work, 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 specified power supply voltage to the hydraulic unit.
[Rated current and breaker setting for the models without code symbol “-F” (DCL: Not provided)]
♦ Wiring procedure
To connect the main power supply and I/O signal cables, remove the cover of the controller.
<Remove the controller cover by loosening the cross recessed head machine screws (six M5 screws, Tightening
torque: 0.9 N·m).>
Shielded cable
ground terminal
AC fan harness
DANGER
[1] To access inside of the controller, follow the procedure described below.
i) Turn OFF the hydraulic unit main power supply.
(Turn OFF the power supply circuit breaker.)
To prevent erroneous operation during wiring work, post an “Operation Prohibited (During Work)” sign on the
power supply circuit breaker.
ii) Remove the controller cover after elapse of at least five minutes.
The controller uses a large-capacitance capacitor. If you connect cables with the capacitor charged, you may get
electric shock. Before removing the controller cover, be sure to leave the controller for at least five minutes to
discharge electricity from the capacitor.
[2] Before turning ON the power supply to start operation, mount all controller covers.
Tightening cap
Power supply terminal block Ground terminal Power supply terminal block
Wiring hole
<When the unit controller small cover is removed> <Enlarged view of power supply terminal block>
DANGER
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 conductors.
Be careful that the cable conductors do not protrude from the terminal block.
CAUTION
For connection of the power supply cable, attach a crimp terminal to the tip of the cable.
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 protection rating
because of a gap between the cables and the cable clamp.
When connecting the cable, be careful not to drop a screw into the housing.
80 mm
[1] Unsheathe the cable by approx. 80 mm.
[2] Remove the inner sheath so that the core wires are
exposed by 8 to 10 mm.
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.
Shielded cable
connection terminal
<When the unit controller cover is removed> <Enlarged view of I/O signal terminal block>
DANGER
Do not connect the I/O signal cable to the power supply terminal block.
When unsheathing the cable, be careful not to damage the conductors.
Be careful that the cable conductors do not protrude from the terminal block.
CAUTION
After checking the specifications of individual signal lines (see page 23), 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 protection rating
because of a gap between the cables and the cable clamp.
Terminate the shielded cable securely, and connect it to the shielded cable connection terminal.
7 Digital I/O Digital input 0 signal switching parameter in the setting mode,
terminal the operation at signal input can be changed.
8 Digital input 1 PQ0 P-Q selections (0 to 3) can be changed
9 Digital input 2 PQ1 depending on combination of the input signals.
10 Digital output 0
11 Digital output 1
See the table below.
12 Digital/contact Digital output common
With the default setting, individual alarm output
13 output terminal Contract output a
is selected.
14 Contract output b
15 Contract output common
16
These terminals are not open to users. Do not use
17 No connection
these terminals.
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
<Enlarged view of I/O signal terminal block> <When the unit controller cover is removed>
♦ Digital input
These terminals are used for sequence input signals that control the unit operations from external equipment.
Connect these terminals as required, with reference to the table below.
Terminal No.
(Symbol of
Signal name Remarks
switchboard
wiring diagram)
6
Digital input common Both positive and negative signals are acceptable.
(COM)
7 Used for start/stop control. With the start/stop signal switching parameter (Setting
Digital input 0
(DIN0) mode: [P11]), you can change the operation at signal input. (See pages 34 and 35.)
8
Digital input 1 PQ0 P-Q selection Nos. 0 to 3 can be selected depending on the combination of digital
(DIN1) input status.
9
Digital input 2 PQ1 (For P-Q selection setting, see pages 34 and 35.)
(DIN2)
Note) While the unit is stopped by digital input, the panel shows “STP”.
Note) The time interval to restart the unit after the unit stop command should be at least 0.5 sec.
3 ON ON
2.2 kΩ
8
4.7 kΩ
2.2 kΩ
9
5 mA
CAUTION
For the external power supply, use a power supply with 24 VDC ± 1V, 0.5 A or higher capacity.
Power cannot be supplied from this controller to external equipment.
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.
External power
supply
24VDC
Load
10 + −
K
MAX 30 mA
11 Load
K
12
CAUTION
As the external power supply, prepare a 24 VDC ± 1V, 0.5 A power supply. Power cannot be supplied from this
controller to external equipment.
This controller’s output circuit serves as negative 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 surge preventive measures.
Terminal No.
(Symbol of switchboard Signal name Remarks
wiring diagram)
13
Contact output a Normally, connected with the common terminal.
(ALMa)
14
Contact output b Connected with the common terminal when signal output.
(ALMb)
15
Contact output common Negative common
(COM)
CAUTION
The contact output switching capacity is 30 VDC/0.5 A (resistance load). If you attempt to drive load higher than the
allowable current, the contact may be damaged. Pay attention to the maximum allowable current.
The minimum allowable load of the contact output is 10 mVDC/10 µA. 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 surge preventive measures.
After connecting the cables, re-mount the controller to the original position, and fasten it with hexagon socket head
bolts.
Re-mount the controller cover and the full cover securely to the original positions.
NOTE) This hydraulic unit takes a warm-up time of approx. three seconds until it
starts operation after power-ON.
(The pressure rising time varies depending on the pipe volume.)
Furthermore, the hydraulic unit takes a time to increase the circuit pressure
above the set pressure of the pressure switch. During this period, the
♦ Flushing
pressure switch signal may be output depending on the pipe condition
(pipe volume). In such a case, set up the master machine so that it dose not
receive the alarm output.
After completion of the start check, loop all pipes (except for the actuator), and
execute flushing operation for approx. two hours while running hydraulic oil
through the filter.
♦ Oil replacement 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
return filter is clogged, replace the filter element, and fully drain the hydraulic oil
from the tank via the oil drain port.
Fill new hydraulic oil through the oil filling port (air breather) to the specified
level.
♦ Air vent
(Use new clean hydraulic oil with pollution degree of NAS Class 9 or lower
level.)
Evacuate air from the hydraulic circuit completely. If air is not completely
evacuated, the following phenomena may occur.
[1] Abnormal operation of cylinder actuator
[2] Abnormal sound of pump and valve
Note: The return filter and element are subjected to modification. When you order a
filter element for replacement, check the type of the return filter mounted to your
unit.
DANGER
When evacuating air, high-pressure and high-temperature oil may spout out. Pay attention to oil splash.
Outline of functions
The operation panel is comprised of the 3-digit LED , mode key , setting keys and ENT
key . Normally, the panel shows an actual pressure value. It can be switched between the monitor display mode
3-digit LED
key
(MODE key)
key
(ENT key)
keys
(Setting keys)
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.
Power-ON
Note1) With the factory setting, “MPa” is the standard unit. When it is changed to the PSI unit, attach a label to
indicate the PSI display mode.
However, if the PSI unit is used in Japan, you will be punished under the Measuring and Weighing Law.
The indication label should be prepared by the user.
Note 2) For details on the alarm codes, refer to description on the alarm display mode.
You can check the current power-ON count by pressing the key when an alarm code is displayed.
Monitor display
Discharge rate
(theoretical value)
41.0 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.
b) Setting mode
The setting mode allows you to set or change a parameter such as pressure and flow rate on the operation panel.
For the parameters that can be specified or changed in the setting mode and their adjusting ranges, see the list of
setting ranges on pages 34 and 35.
For the initial values and adjusting ranges of non-standard models or custom-made models, see the delivery
specifications on separate sheets.
NOTE:
[1] The above flow rate set value is a theoretical value (the product of theoretical displacement volume by
rpm). It is slightly different from the actual flow rate.
[2] Note that you cannot specify the following conditions with the pressure/flow rate settings ([P00] to [P03]):
a) If [PH*] is set to a value equal to, or lower than [PL*], the [PL*] setting will be automatically changed
to a value equal to [PH*].
b) [PL*] cannot be set higher than [PH*].
c) If [qL*] is set to a value equal to, or lower than [qH*], the [qH*] setting will be automatically changed
to a value equal to [qL*].
d) [qH*] cannot be set higher than [qL*].
Herein, [PH*] is a pressure setting of the high-pressure pump, and [qH*] is a setting of small flow rate.
[PL*] is a pressure setting of the low-pressure pump, and [qL*] is a setting of large flow rate.
Example) If you change [PH0] to “5.5 MPa” with [PL0] set at “6.0 MPa”, the [PL0] setting will be
automatically changed to “5.5 MPa”.
If you do not change the P-Q selection No., select “P00” without changing the item No., and set “0” for P-Q
selection.
Operating procedure
Key operation 3-digit LED Remarks
Power-ON
CAUTION: Since the flow rate setting is indicated in steps of “theoretical displacement volume of the pump ×
100 min−1”, the set value is not an integer. The follow rate is indicated by rounding down the
second decimal place after calculation.
If you do not change the P-Q selection No., select “P00” without changing the item No., and set “0” for P-Q
selection.
Setting mode
Press and hold two keys After two seconds
simultaneously for two
seconds or more.
Parameter No. selection or
P-Q selection 1
Displays a pressure
setting of the
↓↑ high-pressure pump for
P-Q selection 1
P-Q selection Press twice.
“PH1”, “qH1”, “PL1” and Displays a pressure
“qL1” are alternately setting of the
displayed in this order. ↓↑ low-pressure pump for
P-Q selection 1.
Changing set value or
Setting range
Pressure
Pressure
c) Alarm mode
The alarm mode allows you to check alarm conditions listed below by selecting any item between A00 and A09.
Alarm mode
Press and hold two After two seconds
keys simultaneously
for two seconds or After two seconds
more. (Displays the latest alarm)
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
♦ Panel display, unit operation and external output signal at occurrence of trouble
Unit status Error condition Panel display Unit operation External output signal
Normal operation [1] Alarm No. display
Alarm No. and erroneous Operation stop
Power-ON
[2] parameter No. are alternately
(during initialization)
displayed. See the table on the next
Warning No. and actual page.
[3]
Normal operation pressure value are alternately Operation
[4]
displayed. continued
Normal operation [5] Warning No. display
During activation of an alarm of Classification [1], the system records the alarm, and holds the alarm code on the display.
During activation of an alarm of Classification [1], the pressure switch does not work. The system retains the status
immediately before activation of the alarm.
When alarm output combination setting [P08] is “1” (integrated alarm output is selected), the alarm signal is output even
if the warning/pressure switch is activated.
Note 1 The pressure switch activation alarm code (“L63” of Classification [5]) is displayed only with the a) or b)
setting below:
a) When the pressure switch display hold setting (Setting mode [P08]) is “1” or “2.
b) When the pressure switch setting [P12] is enabled (When any number other than “0” is entered)
When the pressure switch display hold setting [P08] is “1” or “2”, the display hold status cannot be reset until
the key is pressed.
When the pressure switch display hold setting [P08] is “2”, the alarm is stored in the alarm record if the
pressure falls below the value of the pressure switch setting [P12].
* For the timing chart, see “Power-ON and External I/O Signal Timing Chart” in the Attachment.
The power device self-protecting function is Turn OFF the power supply once, and then turn it ON
Output device error E10
activated. again.
Detection of instantaneous overcurrent in the current Turn OFF the power supply once, and then turn it ON
Instantaneous overcurrent E11
control unit again.
The motor rotation speed exceeded the allowable Make sure that there is no problem in the hydraulic
Overspeed E12
speed. (Including reverse rotation) circuit.
Check the regenerative load integration ratio [n08] in
The alarm is output when regenerative overload
Regenerative brake overload E14 the monitor mode, and reduce the load condition in the
occurs due to regenerative current of the motor.
process with an increased integration ratio.
The main circuit voltage has dropped below 190 VDC
Undervoltage E15 Check the power supply voltage.
(134 VAC).
Overvoltage E16 The main circuit voltage has exceeded 400 VDC. Check the power supply voltage.
[12. Maintenance]
To keep the motor pump performance in good conditions for a long period, conduct periodic maintenance on the
following items. If there is a problem, repair or replace defective parts.
Standard inspection cycles are listed below. However, these cycles considerably vary depending on the operating
conditions and environment.
Periodic inspection
Item Inspection cycle Method
Oil tank
Oil level check Daily, Occasionally Make sure that the float of the oil level gauge is between the red and
yellow lines. Check the hydraulic oil for whitish muddiness and air
bubbles.
Oil temperature check Daily, Occasionally Make sure that the oil temperature is 60°C or less.
(Normally, use the oil at 15 to 50°C.)
Oil color check Semiannually Deterioration of hydraulic oil can be checked by color. If the
hydraulic oil turns brownish (ASTM L4 level: bright yellow),
replace it.
Return filter Daily, Occasionally Monitor the indicator to check the filter for clogging.
If the filter is clogged, replace the filter element.
Oil cooler
AC fan rotation Daily, Occasionally Make sure that the AC fan is rotating.
Clogging of the core Daily, Occasionally Visually check the core for clogging.
Pressure display
Operation check Daily, Occasionally Check if the indicated value changes according to load condition
changes.
Pressure display check Daily, Occasionally Make sure that the pressure display for D.H. conforms to the preset
value.
Sound and vibration Daily, Occasionally Check for abnormal sound and vibration.
Electric wiring Semiannually [1] Check the cable sheathing for cracks or fracture.
[2] Measure the insulation resistance, and check for a decrease in
insulation resistance.
[3] Make sure that the ground cable is securely connected.
Screws and pipes Daily, Occasionally Check screws and pipes for looseness and oil leak.
Cleaning of oil cooler Yearly Disassemble and clean the oil cooler and the core according to
and core “Maintenance Procedure” on pages 42−46.
Oil filling port Yearly Disassemble and clean the oil filling port (air breather) according to
(Air breather) “Maintenance Procedure” on page 47.
Suction strainer Yearly Disassemble and clean the suction strainer according to
“Maintenance Procedure” on page 47.
DANGER
[1] Do not access or touch rotating parts.
[2] If you touch internal components of the controller, observe the following procedure to prevent electric shock.
i) Turn OFF the hydraulic unit main power supply.
(Turn OFF the power supply circuit breaker.)
To prevent erroneous operation during work, post an “Operation Prohibited (During Work)” sign on the power
supply circuit breaker.
ii) Remove the controller cover after elapse of at least five minutes.
The controller uses a large-capacitance capacitor. If you work with the capacitor charged, you may get electric
shock. Before removing the controller cover, be sure to leave the controller for at least five minutes to discharge
electricity from the capacitor.
[3] Before turning ON the power supply to start operation, mount all covers to the controller.
[4] When touching inside of the noise filter box, observe the following procedure in order to prevent an electric shock:
i) Turn OFF the main power supply for the hydraulic unit.
(Turn OFF the power supply circuit breaker for the power supply circuit.)
Put a sign to indicate “DO NOT OPERATE (DURING WORK)” on the power supply circuit breaker, to prevent
erroneous operation during work.
ii) After elapse of at least 5 minutes, remove the cover of the noise filter box.
A large-capacitance capacitor is provided in the noise filter box. If you access the noise filter box with the
capacitor being charged with electricity, you may get an electric shock. Be sure to leave the unit for 5 minutes or
longer (to discharge electricity from the capacitor) before removing the noise filter box cover.
[5] To operate the unit, re-mount all covers to the noise filter box before turning ON the power supply.
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.
Hose bands
Core
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.
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.
Cross-recessed
head machine screw
Relay box
Finger guard
Cross-recessed
head machine
screw AC fan bracket
AC fan
Shroud
Finger guard
Core
Cross-recessed head
machine screw
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.
2. Cleaning procedure
Blow air onto the filter to blow off dust accumulated on/adhering to the
filter.
Remove dust from inside of the strainer cylinder.
WARNING
During air blow, wear protective goggles to prevent accumulated substances or dust from touching your eyes.
2. Cleaning procedure
Blow air onto the filter to blow off dust
accumulated on/adhering to the filter.
Remove dust from inside of the strainer
cylinder.
WARNING
During air blow, wear protective goggles to prevent accumulated substances or dust from touching your eyes.
When the detector indicates that the filter is clogged (the indicator ring is raised to hide the green part of the
indication column completely), replace the filter element according to the procedure below.
1. Loosen the hexagon socket head bolts [1] that fasten the cover [3], and pull the cover upward. Now, you can
remove the element [5] together with the cover.
2. To remove the element, pull out the snap pin [10], 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 according to the above procedure in reverse.
4. Tighten the hexagon socket head bolts [1] in a crisscross order thoroughly.
[4] Packing
[5] Element
[6] Packing
DANGER
In order to protect the electric circuit against short-circuit and over-current, and to prevent electric shocks, provide a
safety device (no-fuse breaker, earth leakage breaker, etc.) conforming to European Norm EN60947-2 for the main
power supply of the hydraulic unit. (For capacity of each model, see the table below.)
For connection of the ground terminal, ensure Class D (former Class 3) or higher grounding condition.
(Connect the ground terminal directly, without using a breaker.)
Before wiring, be sure to complete installation of the hydraulic unit.
Before wiring, be sure to turn OFF the main power supply breaker, and make sure that the power is interrupted.
Do not connect the power supply cable to the I/O signal terminals.
Do not apply an excessive power supply voltage higher than the power supply voltage rating of the hydraulic unit.
CAUTION
The hydraulic unit incorporates an overcurrent protecting function. Therefore, no thermal relay is required for
protection again overcurrent. If a thermal relay is used, it may malfunction with influence of the inverter switching
operation.
[Rated current and breaker setting for the models with code symbol “-F” (DCL: provided)]
Power supply voltage and frequency
Model Breaker setting
3φ 200 V 50 Hz 3φ 200 V 60 Hz 3φ 220 V 60 Hz
SUT06D40L16/SUT10D40L16 13.0 A 12.8 A 11.6 A 30 A
SUT06D60L21/SUT10D60L21 16.8 A 16.4 A 15.2 A 30 A
[1] Connect the ground cable to the ground terminal (PE) on the
power supply terminal block circuit board.
(2) After connecting the cable, re-mount the noise filter box cover
securely to the original position. (M4 cross-recessed head
machine screw, Tightening torque: 1.0 N·m)
DANGER
Use an AC power supply conforming to the power supply rating of this product.
Use a power supply cable suitable for the power supply capacity. (See the table below.)
Do not connect the power supply cable (L1, L2 and L3) to the ground terminal on the power supply terminal block.
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 conductors.
Be careful that the cable conductors do not protrude from the terminal block.
CAUTION
For connection of the power supply cable, attach a crimp terminal to the tip of the cable.
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 meet the specified protection rating,
because there is a clearance between the cables and the cable clamp.
Recommended crimp
Model Cable size Recommended cable Recommended cable clamp
terminal
RBV-2-4 Manufactured by OHM
SUT06D40L16 2.5 mm2 or more CE362 2.5 mm2 × 4 cores
(Manufactured by ELECTRIC
SUT10D40L16 (AWG14 or larger size) (Manufactured by KURAMO)
NICHIFU) OA-W2216
RBV-5.5-4 Manufactured by OHM
SUT06D60L21 4.0 mm2 or more CE362 5.5 mm2 × 4 cores
(Manufactured by ELECTRIC
SUT10D60L21 (AWG10 or larger size) (Manufactured by KURAMO)
NICHIFU) OA-W2219
<I/O signal wiring diagram> <When the noise filter box cover is removed>
DANGER
For the I/O signal cable, use a shielded cabtyre cable equivalent to AWG22 (0.3 sq) or larger size.
Terminate the shielded cable securely. Ground one end of the shielded cable singly.
Do not connect the I/O signal cable to the power supply terminal block.
When unsheathing the cable, be careful not to damage the conductors.
Be careful that the cable conductors do not protrude from the terminal block.
CAUTION
During normal operation, the ALMa terminal of the alarm output signal is connected with the COM terminal, as
shown in the wiring diagram.
If special measures are required to prevent loosening or corrosion of the end of the conductors, use the crimp terminal
with a dedicated insulation sleeve, as listed below. (For handling procedure, refer to the catalog issued by the
manufacturer (WAGO).)
For AWG22, 0.3 sq: 216-322 (Light green)
For AWG20, 0.5 sq: 216-221 (White)
Crimping tool: 206-204 (BIO CRIMP)
Type of terminal block: 255-410 [1] Push the lever with a screwdriver.
(manufactured by WAGO) [2] Check the unsheathed length of the cable, and insert it into the terminal so
レバー
Lever
that the conductors will not become loose. In this step, be careful that the
cable sheath is not caught in the terminal.
[3] Remove the screwdriver from the lever.
[4] Pull the cable lightly to make sure that it is securely connected.
Symbol of
Type Function of terminal Remarks
wiring diagram
COM2 Digital input common Negative common
Used for start/stop control. With the start/stop
DIN0 Digital I/O Digital input 0 signal switching parameter in the setting mode, the
terminal operation at signal input can be changed.
DIN1 Digital input 1 PQ0 P-Q selections (0 to 3) can be changed depending
DIN2 Digital input 2 PQ1 on combination of the input signals.
DOUT0 Digital output 0
DOUT1 Digital output
See the table below.
COM1 Digital/contact Digital output common
With the default setting, individual alarm output is
ALMa output terminal Contract output a
selected.
ALMb Contract output b
COM Contract output common
♦ Digital input
These terminals are used for sequence input signals that control the unit operations from external equipment.
Connect these terminals as required, with reference to the table below.
Symbol of
Signal name Remarks
wiring diagram
Negative common (To use COM2 as a positive common terminal, refer to
COM2 Digital input common
“External I/O Signal Input Common Terminal” described in the Attachment.
Used for start/stop control. With the start/stop signal switching parameter (Setting
DIN0 Digital input 0
mode: [P11]), you can change the operation at signal input. (See pages 34 and 35.)
P-Q selection Nos. 0 to 3 can be selected depending on the combination of
DIN1 Digital input 1
digital input status.
DIN2 Digital input 2 (For P-Q selection setting, see pages 34 and 35.)
Note) While the unit is stopped by digital input, the panel shows “STP”.
Note) The time interval to restart the unit after the unit stop command should be at least 0.5 sec.
3 ON ON
2.2 kΩ
DIN1
4.7 kΩ
2.2 kΩ
DIN2
5 mA
CAUTION
For the external power supply, use a power supply with 24 VDC ± 1V, 0.5 A or higher capacity.
Power cannot be supplied from this controller to external equipment.
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.
External power
supply
24 VDC
Load
DOUT0 + −
K
MAX 30 mA
DOUT1 Load
K
COM2
CAUTION
As the external power supply, prepare a 24 VDC ± 1V, 0.5 A power supply. Power cannot be supplied from this
controller to external equipment.
This controller’s output circuit serves as negative 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 surge preventive measures.
CAUTION
The contact output switching capacity is 30 VDC/0.5 A (resistance load). If you attempt to drive load higher than the
allowable current, the contact may be damaged. Pay attention to the maximum allowable current.
The minimum allowable load of the contact output is 10 mVDC/10 µA. 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 surge preventive measures.
However, in a case corresponding to any of the following three conditions, re-adjust the setting of the high-pressure
safety valve, by referring to <High-pressure Safety Valve Adjusting Procedure> described on the next page.
Lock nut
ロックナット
<Detailed安全弁部詳細図
view of safety valve> Lock nut fastening slot
High-pressure safety valve
[3] Turn ON the hydraulic unit power supply, and select the setting adjusting window
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. Activation starting point
[5] Adjust the pressure adjusting screw length in the longitudinal
direction, and find an activation starting point as shown on the
Current rpm
right.
[6] Turn the pressure adjusting screw clockwise by 1/4 turn from
the activation starting point to tighten the adjusting screw (when
SUT06D40L16 or SUT10D40L16 is used), or by 1/8 turn
(when SUT06D60L21 or SUT10 D60L21 is used).
[7] Tighten the lock nut. This completes the safety valve adjusting procedure. Pressure adjusting screw length
(When tightening the lock nut, be careful not to allow the adjusting screw to turn.)
Caution: Use caution when you set the safety valve pressure higher than 20 MPa.
(If the safety valve pressure setting is too high, the pump may be damaged by surge pressure.)
As the setting procedure, you should set the safety valve pressure at “a target pressure −7.7 MPa
(corresponding to one turn of the adjusting screw), and then perform the above setting steps (1) to (5).
After that, turn the pressure adjusting screw clockwise by one turn to tighten it, and perform the above
step (7).
(MPa) 圧力調整ネジ長さ(目安)
Pressure adjusting screw length (Reference)
21.0
19.5
18.0
16.5
PC設定圧力(MPa)
PC set pressure
15.0
13.5
12.0
10.5
9.0
7.5
6.0
4.5
3.0
1.5
13.5 14.0 14.5 15.0 15.5 16.0 16.5
圧力調整ネジ長さ(mm)
Pressure adjusting screw length (mm)
Display Actual pressure display Actual pressure display Actual pressure display
Display Actual pressure display Actual pressure display Actual pressure display
Magnetic pole
Mode Charging Standby for operation detection Normal control
Warning H: No warning
Pressure switch H: Normal pressure condition * Holding the status immediately before alarm activation
Pressure
3 sec. max.
Pressure
Alarm H: No alarm
Temperature error
threshold level
10 sec.
Thermistor
temperature
Alarm H: No alarm
Actual pressure
Display Actual pressure display display L: Alarm code H: Actual pressure display Actual pressure display
* Alternately displayed at 1 second interval.
H: Stop command
Start/stop signal L: Operation command
Alarm H: No alarm
Warning H: No warning
The above chart shows the case where “P08” (Pressure switch display hold setting) is [1] or [2].
When “P08” is [0], an actual pressure value is displayed.
When the stop command is activated by the start/stop signal, the pressure switch is in the normal condition.
The “P12” and “P13” settings (above [1] and [2]) can be changed in the setting mode.
For the setting procedure and setting range, see “Operating procedure for each mode: b) Setting mode” on page 31.
Note) For the purpose of explanation, the above “1-8 Alarm classification [5]” 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) To activate the stop signal, provide a time interval of 0.5 sec. or longer.
Display Actual pressure display Actual pressure display Actual pressure display
Display Actual pressure display Actual pressure display Actual pressure display
Magnetic pole
Mode Charging Standby for operation detection Normal control
Pressure
3 sec. max.
Pressure
Temperature error
threshold level
10 sec.
Thermistor
temperature
H: Stop command
Start/stop signal L: Operation command
[Note]
The above chart shows the case where “P08” (Pressure switch display hold setting) is [1] or [2].
When “P08” is [0], an actual pressure value is displayed.
When the stop command is activated by the start/stop signal, the pressure switch is in the normal condition.
The “P12” and “P13” settings (above [1] and [2]) can be changed in the setting mode.
For the setting procedure and setting range, see “Operating procedure for each mode: b) Setting mode” on page 31.
Note) For the purpose of explanation, the above “2-8 Alarm classification [5]” 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) To activate the stop signal, provide a time interval of 0.5 sec. or longer.
DIN0 2.2 kΩ
4.7 kΩ
DIN1 2.2 kΩ
4.7 kΩ
DIN2 2.2 kΩ
5 mA
JP851
<Cutting out the jumper from the noise filter box terminal block circuit board>
(1) Identify the jumper position (JP851).
(2) Cut one end of the jumper, and raise the cut end.
(3) While holding the raised end of the jumper with long-nose pliers, cut another end of the jumper.
Note) If you cut another end of the jumper without holding the cut end, the jumper may spring and touch your eye, or the
jumper may touch conductors, resulting in short-circuit.