Daikin ECORCH 40 Series User manual

H y b r i d H y d r a u l i c S y s t e m
Design #40 Series
EHU1404 | EHU2504
EHU2507 | EHU3007

Table of Contents
CHAPTER 1 0BSAFETY INSTRUCTIONS ........................................................................ EN-3
1.1 12BFor Safe Operation .................................................................................... EN-3
1.2 13BGeneral Precautions ................................................................................. EN-4
1.3 14BDisclaimers ................................................................................................ EN-4
1.4 15BRestrictions on Users................................................................................ EN-5
1.5 16BRestrictions on Applications .................................................................... EN-5
1.6 17BPrecaution.................................................................................................. EN-5
1.6.1 56BInstallation and wiring ............................................................................................... EN-6
1.6.2 57BOperation ................................................................................................................... EN-8
1.6.3 58BMaintenance inspections .......................................................................................... EN-8
1.6.4 59BDisposal...................................................................................................................... EN-9
1.6.5 60BWarning plates ........................................................................................................... EN-9
CHAPTER 2 1BCHECKS UPON RECEIVING THE PRODUCT ........................................... EN-10
2.1 18BCheck on the Contents of the Packaging .............................................. EN-10
2.2 19BCheck on the Model ................................................................................ EN-10
CHAPTER 3 2BTRANSPORTATION/INSTALLATION ........................................................ EN-11
3.1 20BTransportation ......................................................................................... EN-11
3.1.1 61BTransportation in the packaged state .................................................................... EN-11
3.1.2 62BTransportation of the product ................................................................................. EN-11
3.2 21BInstallation ............................................................................................... EN-12
3.2.1 63BSecure the space for air intake/exhaust ................................................................ EN-12
3.3 22BSecuring the Hydraulic Unit .................................................................... EN-13
CHAPTER 4 3BHYDRAULIC PIPING ............................................................................ EN-14
4.1 23BPiping ....................................................................................................... EN-14
4.2 24BFilling with Hydraulic Oil ......................................................................... EN-15
CHAPTER 5 4BElectric wiring .................................................................................. EN-16
5.1 25BProcedure for Mounting Exterior Covers ............................................... EN-18
5.2 26BOverall Wiring Diagram ........................................................................... EN-20
5.3 27BInstallation of the Breaker ...................................................................... EN-21
5.4 28BConnection of the Main Power Supply................................................... EN-21
5.5 29BConnection of Input/Output Signal Cables ............................................ EN-23
5.5.1 64BDigital input .............................................................................................................. EN-25
5.5.2 65BDigital output ............................................................................................................ EN-26
5.5.3 66BContact output ......................................................................................................... EN-27
CHAPTER 6 5BPRODUCT SPECIFICATIONS AND CONDITIONS OF USE .......................... EN-28
6.1 30BProduct Specifications ............................................................................ EN-28
6.2 31BConditions of Use .................................................................................... EN-30
6.3 32BPQ Representative Characteristic Diagram ........................................... EN-31
6.4 33BExternal Dimensions ............................................................................... EN-32
6.5 34BHydraulic Circuit...................................................................................... EN-33

CHAPTER 7 6BCOMPONENT PARTS AND PART NAMES ............................................... EN-34
CHAPTER 8 7BPROCEDURE FOR STARTING UP .......................................................... EN-35
CHAPTER 9 8BTRIAL RUNNING ................................................................................. EN-36
CHAPTER 10 9BPANEL OPERATIONS ........................................................................ EN-37
10.1 35BNames and Main Functions of Each Part of the Operation Panel ....... EN-37
10.2 36BFunctions of the Operation Panel ........................................................... EN-38
10.2.1 67BFunction overview.................................................................................................... EN-38
10.2.2 68BSwitching among modes ......................................................................................... EN-38
10.3 37BRegular Mode .......................................................................................... EN-39
10.4 38BMonitor Mode .......................................................................................... EN-39
10.4.1 69BList of display items in the monitor mode ............................................................. EN-39
10.4.2 70BMonitor mode operations ........................................................................................ EN-41
10.5 39BSetting Mode ........................................................................................... EN-42
10.5.1 71BSetting mode operations ......................................................................................... EN-42
10.6 40BAlarm Mode Display ................................................................................ EN-44
10.6.1 72BAlarm mode operations ........................................................................................... EN-44
CHAPTER 11 10BMAINTENANCE ............................................................................. EN-46
11.1 41BDisplay of Alarms .................................................................................... EN-46
11.2 42BAlarm Causes and Corrective Actions ................................................... EN-47
11.3 43BWarning Causes and Corrective Actions ............................................... EN-50
11.4 44BPeriodic Maintenance ............................................................................. EN-51
11.5 45BCleaning/Replacement Work .................................................................. EN-52
11.6 46BOil Cooler Maintenance Instructions ..................................................... EN-53
11.6.1 73BRemoving the oil cooler .......................................................................................... EN-54
11.6.2 74BDisassembling the oil cooler .................................................................................. EN-54
11.6.3 75BCleaning the core .................................................................................................... EN-55
11.6.4 76BCleaning the DC fan ................................................................................................ EN-55
11.6.5 77BReassembly .............................................................................................................. EN-55
11.7 47BOil Filler Port cum Air Breather Maintenance Instructions ................... EN-56
11.7.1 78BRemoval/fitting ......................................................................................................... EN-56
11.7.2 79BCleaning ................................................................................................................... EN-56
11.8 48BSuction Strainer Maintenance Instructions ........................................... EN-56
11.8.1 80BRemoval method ...................................................................................................... EN-56
11.8.2 81BCleaning ................................................................................................................... EN-57
11.8.3 82BReassembly .............................................................................................................. EN-57
11.9 49BSafety Valve Adjustment Instructions .................................................... EN-57
11.10 50BFixed Throttle ( 0.8) Mounting Instructions .......................................... EN-59
11.11 51BMinimum Rotational Speed Adjustment Instructions............................ EN-60
CHAPTER 12 11BAPPENDIX .................................................................................... EN-61
12.1 52BTiming Chart at Powering Up .................................................................. EN-61
12.2 53BParameter List ......................................................................................... EN-61
12.3 54BAbout the European Directive on 400 V Specifications ........................ EN-65
12.4 55BABOUT Hybrid-Win (MAINTENANCE/CONTROL FUNCTIONS) ........... EN-66

CHAPTER 1 0BSAFETY INSTRUCTIONS
1.1 12BFor Safe Operation
DANGER
Improper handling without regard to this indication will cause an
imminently
hazardous condition that may result in death or serious injury.
WARNING
Improper handling without regard to this indication will cause a potentially
hazardous condition that may result in death or serious injury.
CAUTION
Improper handling
without regard to this indication will cause a potentially
hazardous condition that may result in moderate or slight injury, or property
damage.
NOTICE
Improper handling without regard to this indication will damage or shorten
the life of equipment.
Ev
instructions given in this manual include important information regardless of their categories. Be sure to observe all of
them.
In addition to the above, the following icons are also used.
Indicates the reference destination for related information.

1.2 13BGeneral Precautions
DANGER
Ensure that transportation, installation, piping, wiring, running,
operation, maintenance and inspection work are carried out
by people with the required expertise.
When working, wear the safety gear required for safe work
(working clothes, helmet, safety shoes, gloves, etc.).
Do not use this product outside the specifications stated in
the catalog, the delivery specifications and elsewhere.
CAUTION
Be sure to carry out daily inspections (as described in this manual or the accompanying documents).
Do not apply any external force to this product, for example by climbing on it or striking it. Otherwise,
there is a risk of injury and breakage.
1.3 14BDisclaimers
DAIKIN shall not be responsible for any damage attributable to fire, earthquake, a third
DAIKIN shall not be responsible for any consequential damages (loss of business profits, business
interruption) attributable to the use of this product, or the inability to use it.
Daikin shall not be responsible for any accident or damage attributable to negligence in observing the
instructions given in the instruction manual or delivery specifications.
DAIKIN shall not be responsible for any damage attributable to malfunction, etc., resulting from the
combination with connected equipment.
Daikin shall not be responsible for any injury or accident incurred as a result of equipment operation or
maintenance work performed by persons who do not meet the 1.4
Restrictions on Users

1.4 15BRestrictions on Users
DANGER
Please restrict the personnel responsible for operating or maintaining equipment to those who have
received the necessary training on the handling of the product in advance, fully understand how to
the customer. Electrical maintenance in particular must be restricted to those who have certain
qualifications prescribed by law (e.g. licensed electrical engineers).
Be sure to stipulate the above qualification conditions in the company regulations.
1.5 16BRestrictions on Applications
DANGER
Do not use this product for special applications where human lives are at stake, for life-support
equipment for example, or its associated systems, or for special applications including mobile
structures that carry people, or for medical uses and nuclear power uses.
This product has been manufactured under strict quality control, but when it is used with equipment
where its failure, for example, can be anticipated to result in a serious accident or loss, install safety
devices in the machinery.
1.6 17BPrecaution
Regarding the hydraulic connections to this hydraulic unit, use hoses to prevent transmission of the
vibration of the motor pump to the machine.
This hydraulic unit is equipped with a fan to cool the hydraulic oil, controller and motor. To assure the air
intake and exhaust for the fan, do not place any obstruction within 10 cm from the unit. In addition, install
the unit at a location with good ventilation so that hot air does not remain.
Turning the power ON/OFF frequently significantly shortens the life of the controller. Run and stop this
hydraulic unit by using start/stop digital inputs. Leave an interval of at least 5 minutes between stopping
and running of the unit by turning the power ON/OFF. When stopping and running of the unit with start/stop
signals, leave an interval of at least 0.5 seconds between the stop command and restarting.

This hydraulic unit incorporates a safety valve, and its factory default pressure is set to the maximum
operating pressure of the hydraulic unit + 0.5 MPa. Adjust the set pressure of the safety valve according to
the application. The same applies when the surge pressure upon operation of actuators has to be kept to a
minimum.
49B
Note also that the set pressure of the safety valve may drop due to repeated protracted operation of
the machine or contamination in the hydraulic oil. If the product is used continuously with the safety
valve actuated, an alarm may occur due to temperature rise for example. In this case too, carry out
readjustment.
If the operating pressure is changed, the rotation speed also changes.
11.11 51BMinimum Rotational Speed Adjustment Instructions
Restrict continuous use at the maximum pressure to 5 L/min or less. The factory default setting is the
maximum flow rate.
The pressure and flow rate can be set beyond the adjustment ranges stated above, but be sure to use the
product within the operating pressure range and operating flow rate range stated above.
Refer to the specification documents (External dimension sheet) for other specifications.
1.6.1 56B
DANGER
The wiring work must be done by a qualified electrical engineer. Otherwise, there is
a risk of electric shock or fire.
Personnel doing wiring work must wear gloves and long sleeves and implement
safety measures to avoid injuries such as grazes.
Personnel doing wiring work must wear gloves and long sleeves and implement
safety measures to prevent electric shocks and fire due to static electricity.
Complete the installation before starting the wiring work. Otherwise, there is a risk of
electric shock and fire.
Check that the input power supply is OFF before starting the wiring work.
Otherwise, there is a risk of electric shock.
When carrying out wiring work again after the power has been ON, check that the
motor is stopped, and wait at least 5 minutes after powering OFF before starting
the work. Otherwise, there is a risk of electric shock.
Use an EN60947-2-compliant no-fuse breaker and earth leakage circuit breaker
(with overcurrent protection). Otherwise, there is a risk of electric shock and fire.

DANGER
Ground the grounding terminals in accordance with the law in the country
concerned. Otherwise, there is a risk of electric shock and fire. Make a direct
connection without going through a circuit breaker.
Make sure that no conductive foreign objects such as screws or metal scraps, or
combustible foreign matter such as wood debris or oil, get inside the controller.
Otherwise, there is a risk of electric shock, fire, and accidents.
Never use the product in a location where water will get onto it, in a corrosive
atmosphere, or an atmosphere containing inflammable gas, or near flammable
materials. Otherwise, there is a risk of electric shock and fire.
Do not damage harnesses, apply strong forces to them, rest heavy objects on
them, trap them or bend them excessively. Otherwise, there is a risk of electric
shock and breakage.
To move this product, use the eye bolts. Hoisting it by the pump piping, for
example, will pose a danger of the product falling or overturning.
Do not install or run this product while it is damaged or has missing parts.
Otherwise, there is a risk of accidents.
CAU
TION
Strictly follow the requirements for the installation environment. Otherwise, there is a risk of fire and
accidents.
Install it at a location that can bear its weight. Otherwise, there is a risk of accidents.
Do not expose terminals or other parts to static electricity. Otherwise, there is a risk of failures.
Check that the input power supply voltage is within the rated voltage range. Otherwise, there is a risk of
fire and accidents.
Check terminal pinouts and terminal codes, and make error-free connections.
Carry out withstand voltage tests at DC2 kV or lower. Applying voltages higher than this may damage
this product.
Do not perform Megger testing on control circuits. Otherwise, there is a risk of damage.
Take measures to ensure that sensors and devices in the vicinity do not malfunction due to
electromagnetic noise. Otherwise, there is a risk of accidents.
Do not subject this product to strong impacts. Otherwise, there is a risk of accidents.
Do not climb onto the product, or rest any heavy object on it. Otherwise, there is a risk of electric shock,
accidents and breakage.
humidity ranges. Otherwise, there is a risk of failures and shortening of service life.

1.6.2 57B
DANGER
While the product is powered up, do not change the wiring, or connect/disconnect
terminals, etc. Otherwise, there is a risk of electric shock, accidents and damage.
Do not turn on and shut off the power frequently. Otherwise, there is a risk of failures.
CAUTION
Set the pressure and flow rate such that they do not exceed the permissible range for
the machine. Otherwise, there is a risk of accidents.
Before running the product, set parameters appropriate for the machine. Otherwise,
there is a risk of injury, and failures of the machine.
Before running the product, ensure that you will be able to effect an emergency stop at
any time. Otherwise, there is a risk of injury, and failures of the machine.
When a power outage occurs, do not approach the machine since it is possible that it
will suddenly resume motion after the power is restored. Otherwise, there is a risk of
injury. It is advisable to set the start/stop signals to positive logic for starts to ensure
safe restarting.
While the product is powered up, and for some time after shutting the power off, the
heat-radiating fins and electronic devices will be hot, so do not touch them. Otherwise,
there is a risk of burns.
1.6.3 58B
DANGER
Maintenance inspections must be performed by an appropriately qualified technician.
Otherwise, there is a risk of electric shock and injury.
Check that the input power supply is OFF before starting the work. Otherwise, there is
a risk of electric shock.
Check that the motor is stopped, and wait at least 5 minutes after powering OFF
before starting the work. Otherwise, there is a risk of electric shock.
While the product is powered up, do not change the wiring, or connect/disconnect
terminals, etc. Otherwise, there is a risk of electric shock, accidents and damage.
Do not disassemble this product. Otherwise, there is a risk of electric shock and injury.

CAUTION
Wear protective glasses and gloves for this work.
Do not touch the controller board directly. Otherwise, it could be damaged by static
electricity.
Carry out withstand voltage tests at DC2 kV or lower. Applying voltages higher than
this may damage this product.
Do not perform Megger testing on control circuits. This could damage the product.
1.6.4 59B
CAUTION
When disposing of this product, entrust it to a specialist contractor as general industrial waste.
1.6.5 60B
WARNING
The warning plates are very important, so do not damage or remove them.
If a warning plate becomes difficult to read through peeling or losses, contact Daikin
immediately.
This is a warning plate that indicates
a high voltage hazard.
This is a caution plate for high
temperatures.

CHAPTER 2
1BCHECKS UPON RECEIVING THE PRODUCT
2.1 18BCheck on the Contents of the Packaging
CAUTION
Check that the product is the right way up, then unpack it. Otherwise, there is a danger of falling and
breakage.
When the product has been unpacked, check that the following items are present.
Hydraulic unit body 1 piece
Instruction Manual 1 copy
2.2 19BCheck on the Model
CAUTION
Check that the model designations indicated on the product nameplates of the motor pump and
controller match the ordered product. Using a product that is incorrect will result in breakage.
Check, with the product nameplates, that the actual item matches the ordered product.
This is the model code of the product.
Check that it matches the ordered product.

CHAPTER 3 2BTRANSPORTATION/INSTALLATION
3.1 20BTransportation
3.1.1 61B
To transport the product in the packaged state, lift by using the handgrip openings in the cardboard, and
transport it on a dolly, for example.
The weight in the packaged state is indicated on the label affixed to the side face.
WARNING
Ensure that transportation work is carried out by people with the required expertise.
Transport the product with material handling equipment appropriate for the packaged
state. Otherwise, there is a danger of falling or toppling over.
This is a heavy item and should therefore not be lifted by one person alone.
Otherwise, there is a danger of it falling or toppling over.
3.1.2 62B
When transporting the product, hoist it by using the holes provided for hooks at two locations. Using other
locations will lead to a risk of falling/toppling over. Check the mass of the hydraulic unit, and make sure that
the hoisting load is within the rated load of the hoisting equipment.
WARNING
Check the mass of the hydraulic unit in the table above, and ensure that the hoisting
load is within the rated load of the hoisting equipment.
Hoisting holes
- Product Masses (Excluding Hydraulic Oil)
Product Model Mass [kg]
EHU1404
26
EHU2504
EHU2507
29
EHU3007

NOTICE
Do not move the product while there is oil in the tank (this could cause malfunctions due to oil leakage
or inclusion of air).
3.2 21BInstallation
3.2.1 63B
Install the unit at a well ventilated location where heat will not build up, and secure a surrounding space of
10 cm from each of the four end faces of the unit. Also take care that the temperature of the intake air
complies with the stipulated ambient temperature (40 C max.).
WARNING
If the intake air/exhaust spaces described above are not secured, the heat exchange
function of the oil cooler/DC fan will deteriorate, and the oil temperature and
temperature of the hydraulic devices will become abnormally high, posing a risk of
fire. Be sure to secure the space for air intake /exhaust.
Do not touch hot parts. It can cause burns.
Provide sufficient maintenance space so that working postures will not be
uncomfortable.
At least 10 cmAt least 10 cm
Air intake
Air intake
Exhaust
Air intake
At least 10 cm
At least 10 cm

NOTICE
If the intake air/exhaust spaces described above are not secured, the motor and controller will reach
high temperatures and the lives of the devices will be significantly shortened. Be sure to secure the
space for air intake /exhaust.
If the intake air/exhaust spaces described above are not secured, the motor and controller will reach
high temperatures, temperature protection will be actuated and the product will stop running.
Continuing to use the product while it is at a high temperature will result in trouble affecting, and shorten
the lives of, the electrical components as described previously, but also hydraulic devices such as
pumps and valves. It will also promote deterioration of the hydraulic oil, shortening the service life of the
oil.
3.3 22BSecuring the Hydraulic Unit
Secure the hydraulic unit on a level platform, or a floor, that will not be affected by the vibration of the main
machine (M10 bolts at 4 locations). For details on the mounting method and position, refer to the Delivery
Specification (outline drawing).
WARNING
If the hydraulic unit is not secured, it may topple over or move as a result of reactions to the hydraulic
pressure in the piping and so on, imposing a hazard. Be sure to secure it with bolts, etc.
NOTICE
Installing the product on a sloping surface may cause oil leakage and inclusion of air in the oil, leading
to abnormal noises and shortening of equipment life. Be sure to install it on a level surface.
4- 13 holes ( positions)
4- 10 holes ( positions)
Oil filling / drain port

CHAPTER 4 3BHYDRAULIC PIPING
4.1 23BPiping
Be sure to connect piping at the following ports. Details on the piping positions can be found in the outside
view drawing. Use hoses for the piping work, and fasten them with sealing tape.
<Piping Specifications>
Piping Port Piping Size Recommended Hose
Withstand Pressure At Shipment
P Rc 3/8 10.5 MPa
Plastic plug
DR1 Rp 1 1.5 MPa
DR2
T1
T2
Rp 1/2
Rp 1/2
Rp 1/2
1.5 MPa
DANGER
When connecting
Regarding the method for securing the hoses, fix them as recommended by the hose manufacturer.
When doing the piping work, make the piping strong enough for the pressures to be used.
DR2 Drain port Rp1/2 Above the oil level
P Discharge port Rc3/8
DR1 Drain port Rp1 Above the oil level
T1 Return port Rp1/2
T2 Return port Rp1/2

CAUTION
Use hoses for the piping to this product.
Connect the hoses without any twisting.
In cases where excessive strain is likely to occur due to the weight of the hose, support the hose.
4.2 24BFilling with Hydraulic Oil
Remove the cap of the filler port cum air breather by turning it counterclockwise, then pour clean
hydraulic oil (within NAS class 10) into the tank. The volume of oil should be that sufficient to bring the
float to between the red line and yellow line.
6.1 Product Specifications
CAUTION
6.1 Product Specifications
Running the product while the tank is not filled with oil will cause seizure and/or wear of the pump,
leading to breakage. Be sure to check the oil level.
During the initial operation of the machine, oil is supplied to the hydraulic circuits at the machine side
and the oil in the tank may decrease. Add oil to bring the height of the oil level to within the stipulated
range.
Depending on the volumetric capacity of the hydraulic circuits at the machine side, the fluctuations in oil
level in the tank may become large, and oil may overflow from the tank or the oil level may drop. Adjust
while watching the oil level gauge to achieve the optimum oil level.
Oil level gauge
Oil filler port cum air breather

CHAPTER 5 4BElectric wiring
In order to run this product, the main power supply has to be connected. Also connect input/output signal
cables as necessary.
Connect the main power supply and input/output signal cables after removing the exterior cover. To
remove this cover, unscrew the four M4 cross recessed screws. After completing the wiring work, mount
the exterior cover before use.
The recommended tightening torque is 1.0 N m.
When wiring the main power supply and input/output signal cables, pass the cables through the
specified cable ports.
Fit a no-fuse breaker conforming to European standard EN60947-2 to the source power supply of the
hydraulic unit in order to protect the electrical circuits against short circuits, overcurrents, etc., and to
prevent electric shock.
Use a power supply connection device that has a switch specification where the distance between
contacts is at least 3 mm for all three poles when the switch is OFF.
Controller cover mounting screws
Control/communication
cable port,
16 hole
Power supply cable port,
23 hole
The screw cannot be removed
from the cover.
Do not forcibly remove them.

DANGER
The wiring work must be done by a qualified electrical engineer. Otherwise, there is a
risk of electric shock or fire.
Personnel doing wiring work must wear gloves and long sleeves and implement safety
measures to avoid injuries such as grazes.
Personnel doing wiring work must wear gloves and long sleeves and implement safety
measures to prevent electric shocks and fire due to static electricity.
Fit a safety device in the form of a no-fuse breaker conforming to European standard
EN60947-2 to the source power supply of this product in order to protect the electrical
circuits against short circuits, overcurrents, etc., and to prevent electric shock.
Be sure to ground ground terminals in accordance with the law in the country
concerned. Make a direct connection without going through a circuit breaker.
Turn the breaker at the source power supply side OFF and wait at least 5 minutes
before starting the wiring work. Otherwise, there is a risk of electric shock.
Do not apply any excessive power supply voltage, beyond the power supply
specifications of this product. This will damage the controller.
Perform the wiring so as not to cause short circuit or ground faults between terminals
and electric wires. Otherwise, there is a risk of electric shock and fire.
When stripping electric wires, take care not to damage the conductors.
For wiring, use multi-conductor cables and cable clamps, and do the work so as to
satisfy protection class IP54 or better.

5.1 25BProcedure for Mounting Exterior Covers
After connecting the main power supply and input/output signal cables, the exterior cover needs to be
mounted. Mount it by following the procedure below.
1. Engage the corners of the controller and corners of the cover together.
2. Close the cover.
3. Holding the grips at the left and right of the cover, engage the cover with the bottom of the
controller.
Exterior cover Controller box
Engage the parts encircled in red.
Grips

4. Press in the vicinity of the two screws at the bottom of the exterior cover to position it.
When pressing the vicinity of the screws, confirm that a clicking sound is heard as the projections
on the exterior cover go into the mating parts on the interior cover.
Check that the 7-segment display is located in the center of the display window in the operating
section.
5. Tighten the two screws in the lower part of the cover, then tighten the two screws at the top.
Vicinity of screws
Exterior cover
(back face)
Interior cover
Projection Mating part
Display window
Position check with the display window
Operating section sheet