SMC HRG 001-A, HRG 002-A, HRG 005-A Thermo cooler Operation Manual

Operation Manual

Air-refrigerated Thermo cooler

HRG001-A

HRG002-A

HRG005-A

HRX-OM-H043

1 st

edition：Dec. 2003

Rev. D ：Nov. 2008

SMC Corporation

Save This Manual Carefully for Use at Any Time

© 2003 SMC CORPORATION All Rights Reserved

To the Customers

Thank you for purchasing our THERMO COOLER HRG Series (hereinafter called “This unit”).

For safety and efficiency, be sure to read and understand this manual thoroughly before performing operation of this unit. z All warnings and precautions defined in this manual shall be observed. z This manual provides instructions for the installation and operation of this unit. Only those who have understanding of the operating procedure or have knowledge of the installation and operation of this unit are qualified to work with this unit. z The contents of this manual and related documents shall be neither regarded as a provision of the contract nor utilized to correct or modify the existing agreements, commitments and relations. z Copying, duplicating or transferring any part of or whole contents of this manual without SMC

Corporation’s permission is strictly prohibited. z The Service Manual is supplied to provide additional information and troubleshooting of this unit. Only those who have full understanding of this unit are allowed to perform maintenance and repair of the unit with the use of the Service Manual.

Note: The contents of this manual are subject to change without notice.

Address : 4-14-1 Sotokanda, Chiyoda-ku, Tokyo 101-0021, Japan

TEL : +81 3 5207 8249 FAX : +81 3 5298 5362

URL : http://www.smcworld.com

HRX-OM-H043

Table of Contents


1.

Safety Instructions ...................................................................... 1-1

1.1

B

EFORE

U

SING THIS

U

NIT

..............................................................................................1-1

1.2

D

ANGER

, W

ARNING AND

C

AUTION

.................................................................................1-2

1.2.1

Level of risk ......................................................................................................................... 1-2

1.2.2

Definitions of “Serious injury” and “Minor injury” ................................................................. 1-2

1.2.3

Symbols............................................................................................................................... 1-3

1.3

H

AZARD

W

ARNING

L

ABEL

.............................................................................................1-4

1.3.1

Classification of risks........................................................................................................... 1-4

1.3.2

Type of hazard warning labels ............................................................................................ 1-5

1.3.3

Location of hazard warning label ........................................................................................ 1-6

1.4

M

ODEL LABEL

...............................................................................................................1-6

1.5

D

ISPOSITION OF WASTE

.................................................................................................1-7

1.5.1

Recovery of refrigerant and compressor oil ........................................................................ 1-7

1.5.2

Disposal of unit.................................................................................................................... 1-7

2.

Descriptions of Components...................................................... 2-1

2.1

A

PPEARANCE OF UNIT

...................................................................................................2-1

2.1.1

HRG001-A / HRG002-A ...................................................................................................... 2-1

2.1.2

HRG005-A........................................................................................................................... 2-1

2.2

D

ESCRIPTIONS AND FUNCTIONS OF COMPONENTS

...........................................................2-2

2.2.1

HRG001-A / HRG002-A ...................................................................................................... 2-2

2.2.2

HRG005-A........................................................................................................................... 2-3

2.2.3

Control panel ....................................................................................................................... 2-4

3.

Transport and Installation........................................................... 3-1

3.1

T

RANSPORT

..................................................................................................................3-1

3.2

I

NSTALLATION

................................................................................................................3-3

3.2.1

Installation Conditions ......................................................................................................... 3-3

3.2.2

Installation ........................................................................................................................... 3-4

3.2.3

Electrical wiring ................................................................................................................... 3-4

3.2.4

Piping................................................................................................................................... 3-7

3.2.5

Supply of circulating fluid..................................................................................................... 3-8

3.2.6

Reinstallation of unit ............................................................................................................ 3-9

4.

Startup and Shutdown ................................................................ 4-1

4.1

P

RE

-

CHECK

...................................................................................................................4-1

4.1.1

Installation condition............................................................................................................ 4-1

4.1.2

Connection of cable............................................................................................................. 4-1

4.1.3

Piping for circulating fluid .................................................................................................... 4-1

HRG001-A HRG002-A HRG005-A

1 st

edition :Dec. 2003

Table of Contents-1

HRX-OM-H043


4.1.4

Level indicator（for level in the tank） ................................................................................ 4-1

4.2

P

REPARATION FOR STARTUP

.......................................................................................... 4-2

4.2.1

Power supply ....................................................................................................................... 4-2

4.2.2

Setting of circulating fluid temperature ................................................................................ 4-2

4.2.3

Additional water supply........................................................................................................ 4-3

4.3

U

NIT

S

TARTUP AND

S

HUTDOWN

..................................................................................... 4-4

4.3.1

Starting the unit.................................................................................................................... 4-4

4.3.2

Stopping the unit .................................................................................................................. 4-4

4.4

C

HECK AT STARTUP

....................................................................................................... 4-5

5.

Error Message and Troubleshooting ......................................... 5-1

5.1

E

RROR

M

ESSAGE

.......................................................................................................... 5-1

5.2

T

ROUBLESHOOTING

....................................................................................................... 5-2

6.

Unit Maintenance......................................................................... 6-1

6.1

C

ONTROL OF WATER QUALITY

........................................................................................ 6-1

6.2

I

NSPECTION AND CLEANING

........................................................................................... 6-2

6.2.1

Daily inspection.................................................................................................................... 6-3

6.2.2

Monthly inspection ............................................................................................................... 6-4

6.2.3

Biannual inspection.............................................................................................................. 6-5

6.3

S

TORAGE

...................................................................................................................... 6-6

6.4

C

ONSUMABLES

............................................................................................................. 6-6

7.

Documents ................................................................................... 7-1

7.1

S

PECIFICATIONS LIST

..................................................................................................... 7-1

7.2

O

UTLINE DIMENSIONS

.................................................................................................... 7-2

7.2.1

HRG001-A and HRG002-A.................................................................................................. 7-2

7.2.2

HRG005-A ........................................................................................................................... 7-2

7.3

E

LECTRIC CIRCUIT DIAGRAM

.......................................................................................... 7-3

7.3.1

HRG001-A and HRG002-A.................................................................................................. 7-3

7.3.2

HRG005-A ........................................................................................................................... 7-4

7.4

F

LOW CHART

................................................................................................................. 7-5

7.4.1

HRG001-A and HRG002-A.................................................................................................. 7-5

7.4.2

HRG005-A ........................................................................................................................... 7-5


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edition : Dec. 2003

Table of Contents-2

HRX-OM-H043

1 Safety Instructions

1. Safety Instructions

Be sure to read and understand all the important precautions in this manual before operating the unit.

1.1 Before Using this Unit

z

This chapter describes the safety-related items that users should be aware of upon handling this unit. z

This unit operates under high voltage and contains components that cause a rise in temperature and rotate. All personnel are required to read and understand the safety-related items in this manual before working with this unit. z

This manual is not for comprehensive safety and hygiene education. Such a manual should be provided by a safety training manager. z

All personnel who work on or around this unit are to have proper training and education on dangers specific to this unit and safety measures against potential hazards. z

A safety manager is responsible for observing safety standards. Operators and service technicians have individual responsibilies for their safety during operation of this unit in his/her daily work. z

Operators must individually take account of safety and assure a proper working area and working environment. z

The relevant personnel must receive proper safety education before working on this unit to prevent dangers. Never conduct work training without giving proper consideration to safety. z

Save this manual at a designated place for reference when necessary.


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1.1 Before Using this Unit

1-1

HRX-OM-H043


1.2 Danger, Warning and Caution

1.2.1 Level of risk

This unit is designed with the safety of workers and the prevention of system damage. This manual classifies the risks into the following three categories according to the level of the hazard: Danger, Warning, and Caution. Read the statements carefully and thoroughly understand them before operating this unit.

DANGER, WARNING and CAUTION signs are in order according to severity

(DANGER > WARNING > CAUTION). See below for the details.

"DANGER" denotes that there is an imminent hazard which will cause serious personal injury or death during operation.

"WARNING" denotes that there is a hazard which may cause serious personal injury or death during operation.

"CAUTION" denotes that there is a hazard which may cause minor personal injury during operation.

"CAUTION" without an exclamation symbol denotes that there is a hazard which may cause damage or failure of this system, facility, or devices.

1.2.2 Definitions of “Serious injury” and “Minor injury”

“Serious injury”

This term describes injuries such as loss of eyesight, wound, burns, frostbite, electric shock, fracture, and toxication that leaves aftereffects which may require prolonged treatment and hospitalization.

“Minor injury”

This term describes injuries that do not require prolonged treatment or hospitalization (injuries other than “serious injuries” described above).

1.2 Danger, Warning and Caution

1-2


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HRX-OM-H043


1.2.3 Symbols

This manual provides the following symbols in addition to “Danger”, “Warning”, and “Caution” to present the warning details in easy-to-understand manner.

Symbol of electrical hazard

This symbol warns you of possible risk of electrical shock.

Symbol of heat hazard

This symbol warns you of potential burns.

Symbol of rotating shaft hazard

Symbol of “Don’ts”

This symbol warns you of possible risk caused by a rotating object.

This symbol denotes the items that must not be attempted.

Symbol of “Dos”

This symbol denotes the “obligation” items which you must follow in operation of this unit.


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1.2 Danger, Warning and Caution

1-3

HRX-OM-H043


1.3 Hazard Warning Label

The hazard warning labels indicate where potential hazards are present during unit operation and maintenance.

The hazard warning labels are in appropriate sizes and colors. They contain symbols in addition to the descriptions of warnings.

1.3.1 Classification of risks

High voltage hazards

The unit is operated at high voltage and may cause an electrical shock. The attached label contains the symbol .

Do not operate the unit without cover panel mounted.

The unit contains the power supply carrying high voltage inside that is isolated with the cover panel. Unit operation without the cover panel allows the high votage to apply outside and cause injuries.

Only trained personnel are allowed to work around the power supply.

High temperature hazards

The unit reaches high temperature during operation and may cause burns when an operator comes in contact. The attached label contains the symbol .

This symbol indicates the presence of a section where temperature reaches high and the operator sustains burns when coming in contact. Even after the power is turned off, residual heat may still cause burns. The work must not be started until the section drops to sufficiently low temperature.

Rotating object hazards

The unit includes several parts that rotate during operation and may cause the operator to get the finger caught in these parts.

The attached label contains the symbol .

The unit includes several parts which rotate during operation, and the operator who comes in contact may get injured. Even if that part seems to stop rotating, avoid touching it because the condition may be temporary and the rotation may restart.

1.3 Hazard Warning Label

1-4


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HRX-OM-H043


1.3.2 Type of hazard warning labels

Do not remove or deface the warning labels.

Read the contents of the hazard warning labels with care to keep them in mind.

Warning label on the front panel

Fig. 1-1 Warning label on the front panel

Warning label for high voltage

Fig. 1-2 Warning label for high voltage


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1.3 Hazard Warning Label

1-5

HRX-OM-H043


1.3.3 Location of hazard warning label

z Recognize where the hazard warning labels are attached. z The user is not allowed to reposition the labels. If the label is replaced due

to being peeled off or worn out, keep the previous position.

Warning label for high voltage

Front

Warning label on the front panel

1.4 Model label

Fig. 1-3 Location of hazard warning label

Check the model no. described on the label.

Front

Fig. 1-4 Location of model label

1.4 Model label

1-6


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HRX-OM-H043


1.5 Disposition of waste

1.5.1 Recovery of refrigerant and compressor oil

The unit belongs to Class 1 in the “Fluorocarbon Recovery and Destruction Law” and uses freon type refrigerant (HFC) and compressor oil. When these fluids need to be recovered, read the instructions below and ensure thorough understanding of them. If you have any questions, contact the local distributor or SMC’s sales branch.

Only service personnel or qualified personnel are allowed to open the cover panel of the unit.

Do not mix the compressor oil with domestic waste for disposition.

Also, incineration is permitted only at an authorized incinerator.

Comply with municipal ordinances or regulations to dispose of waste.

The release of refrigerant to atmosphere is banned by law. If the refrigerant needs to be removed for repair of the unit, recover it with specific equipment and request a specialized waste disposal agency for disposal of the recovered refrigerant. A person must have proper license to perform refrigerant recovery.

Only personnel with sufficient knowledge and experiences with the unit and associated equipment are allowed to recover refrigerant and compressor oil. The person must have proper license to perform refrigerant recovery.

Remarks

The type and amount of used freon can be found on the label.

1.5.2 Disposal of unit

If the unit needs to be discarded, be sure to follow local laws and regulations on disposing of industrial waste.


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1.5 Disposition of waste

1-7

HRX-OM-H043


1.5 Disposition of waste

1-8


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HRX-OM-H043

2 Descriptions of Components

2. Descriptions of Components

2.1 Appearance of unit

2.1.1 HRG001-A / HRG002-A

Front

Left

Top

Back

Right

Fig. 2-1 Appearance of unit（HRG001-A / HRG002-A）

2.1.2 HRG005-A

Left

Front

Top

Back

Right

Fig. 2-2 Appearance of unit（HRG005-A）


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2.1 Appearance of unit

2-1

HRX-OM-H043


2.2 Descriptions and functions of components

2.2.1 HRG001-A / HRG002-A

Tank lid

Power cable access

（Cable Grip）

Signal cable access

（Cable Grip）

Electrical unit

Top

Control panel

Level indicator

Circulating fluid

OUT Rc1/2

Bypass valve

Circulating fluid

RETURN Rc1/2

Port for overflow Rc1/2

Air vent OUT

Left

Air vent IN

Front

Right

4-

φ

13

（For anchor bolt）

Air vent OUT

Tank drain port Rc1/2

（plugged）

Fig. 2-3 Piping connection port（HRG001-A / HRG002-A）

2.2 Descriptions and functions of components

2-2


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HRX-OM-H043


2.2.2 HRG005-A

Eye bolt M12

Left

Air vent IN

Electrical unit

Top

Front

Tank lid

Power cable access

（Cable Grip）

Control panel

4-

φ

13

（for anchor bolt）

Right

Fig. 2-4 Piping connection port（HRG005-A）

Level indicator

Signal cable entry

（Cable Grip）

Circulating fluid

RETURN Rc1/2

Circulating fluid

OUT Rc1/2

Bypass valve

Air vent OUT

Port for overflow Rc1/2

Tank drain port Rc1/2

（plugged）


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2-3

HRX-OM-H043


No.

1

5

6

7

8

9

10

[ALARM] LED

[ON] switch

[OFF] switch

[MODE] key

[DOWN] key

[UP] key

Name

Digital display, PV / SV

2 [POWER] LED

The control panel is common to all models.

Fig. 2-5 Control panel

Table 2-1 Control panel

Function

PV Indicates actual temperature of a circulating fluid

SV Indicates set temperature of a circulating fluid

Lights up when the power is supplied.

Lights up when the [ON] switch is pressed.

Lights up when an alarm arises.

This is used to run the unit.

This is used to stop the unit.

This is used to switch the screens between PV and SV.

This is used to decrease set temperature.

This is used to increase set temperature.


2-4


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3. Transport and Installation

HRX-OM-H043

3 Transport and Installation

The unit must be handled in correct manner.

Exercise caution to assure personnel safety during the installation, operation, maintenance, and inspection of the unit.

Only personnel with sufficient knowledge and experiences with the unit and system are allowed to transport, install and conduct maintenance possibly exposed to dangerous situations.

3.1 Transport

The unit is heavy and poses potential danger at transportation. To prevent damage to the unit, be sure to follow the instructions below when transporting the unit.

If the forklift is used for transporting, ensure that the fork is inserted in a place as specified in Fig. 3-1 “Fork insertion position and unit lifting ”.

If eyebolts are used for lifting, ensure the unit is held at four points.

Keep each eyebolt at an angle from 45 to 60 degrees with repect to the postion of the center of gravity when lifting the unit.

Never set the unit on its side.

The refrigerant oil will drain into refrigerant piping from the compressor, reducing its amount in the compressor. It results in a compressor failure.

Drain the residual fluid from piping as much as possible to prevent spill.

If the forklift is used for transporting the unit, be sure to prevent the fork from contacting the cover panel or pipe connection ports.


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3.1 Transport

3-1

HRX-OM-H043


HRG001-A/HRG002-A

Fork insertion position

HRG005-A


Lifting position



Approx. 60deg.



Approx. 60deg.

Fig. 3-1 Fork insertion position and unit lifting



3.1 Transport

3-2


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HRX-OM-H043


3.2 Installation

Do not install the unit in a place possibly exposed to flammable gas.

Ignition may occur if leaked gas is collected around the system.

This unit is NOT designed for outside use. The unit exposed to moisture may develop a short circuit which can result in an electrical shock, fire and failure in the unit.

Install the unit on a flat and level floor which can support the weight of the unit. Take measure to prevent the unit from tipping over. Improper setup may cause water leakage from the unit and personal injury.

Keep ambient temperature of the unit between 5 and 40

°C. Unit

operation at below 5

°C may lead to failure in the compressor.

Operation at above 40

°C will reduce effectiveness of the condenser

and trigger the safety device which brings the unit to a stop.

Do not use or store the unit in the following environments. Potential unit malfunction and damage may occur if disregarded. z

Environment that is exposed to water vapor, salt water or oil mist z

Environment that is exposed to dust or powdery materials z

Environment that is exposed to corrosive gas, flammable gas or solvent z

Environment that is exposed to direct sun light or radiant heat z

Environment where ambient temperature is out of the specified range between 5

°C to 40°C z

Environment that is subjected to abrupt changes in temprature z

Environment that is subjected to strong electromagnetic noise（incl. strong electrical field, strong magnetic field, or surge voltage） z

Environment that generates static electricity, or condition in which static electricity discharges to the unit z

Environment that generates strong high frequencies z

Environment at high altitudes of over 1000m z

Condition which allows strong vibrations and impacts to transmit to the unit z

Condition with external force or load to deform the unit z

Condition with an insufficient maintenance space as required z

Condition with an insufficient maintenance space as required


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3.2 Installation

3-3

HRX-OM-H043


3.2.2 Installation

z

Keep the unit away from vibration. Install the unit on a flat and stable surface. z

Refer to “7.2 Outline dimensions” for the dimensions of the unit. z Do not modify the electrical wiring. Incorrect wiring can cause an electrical

shock and fire. Failure to do so will void any warranty.

z The set value of the safety device must not be changed. Changing the set

value can cause system failure and fire.

z Only qualified personnel are allowed to install wiring. z Be sure to disconnect the power for safety. Wiring installation with the unit

energized is strictly prohibitted.

z Use the specified cables. Properly apply strain relief to prevent an external

force from being exerted on the terminals. Poor or loose connection can cause electrical shock, heat spots, or fire.

z Supply the power to the unit from a reliable power source (without surge or

sag voltage).

z Be sure to use a GFCI breaker to prevent an electrical shock and burnt

compressor motor. The breaker with adequate capacity of current leakage and load should be selected in accordance with “7.1 Specification list”.

z Ensure that the power supply meets the specification of the unit. z Always establish a ground for safety. z Do not connect the ground to a water line, gas pipe or lighting conductor. z Do not branch off the wiring to make multiple circuits. Potential hot spots or

fire may occur if disregarded.

Power supply cable and GFCI breaker

Select a cable for power supply and GFCI breaker corresponding to the model no. provided in the following table.

Power supply cable

Table 3-1 Cable for power supply and current leakage

Item HRG001-A HRG002-A

Size 4-core

Round compressive terminal size

HRG005-A

3.5－4S 5.5－4S

Signal cable

Fork terminal size

Capacity of GFCI breaker

※

1.25Y－3

5A 10A 20A

※Use the breaker with current sensitivity of 30mA at minimum.


3-4


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HRX-OM-H043


How to conduct wiring

1.

Undo the screws (6 pcs.) and take off the front panel.

Screw

Front panel

Front

Screw

Fig. 3-2 Removal of front panel

2.

Connect the power supply cable and signal cable as shown in the figure.

Power supply cable

Front

Signal cable

Signal cable entry

Front

Power supply cable entry

Fig. 3-3 Electrical wiring (HRG001-A / HRG002-A)

Power supply cable

Signal cable entry

Power supply cable entry

Fig. 3-4 Electrical wiring (HRG005-A)

Signal cable


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3-5

HRX-OM-H043


Electrical wiring diagram z Prepare cables for the power supply and signal lines separately . z Maintain polarities (+, -) of DC24V when connecting the signal cable for transmitting

start/stop command (remote operation).

z Refer to “7.3 Electrical circuit diagram” for the electrical circuit of the unit.

•

HRG001-A / HRG002-A

Power supply input

User’s preparation

ELB/Current leakage breaker

Power supply cable

Thermo cooler

Electrical circuit

FG（Frame ground）

Remote operation signal input

DC +24V input

Error detected stop signal output, relay contact

（normally open, closed for error）

Operation signal output, relay contact

（normally close, opened for error）

Signal cable

Remote operation input circuit

Error detected stop signal output circuit

Operation signal output circuit

I/O board

Fig. 3-5 Installation (electrical wiring)

•

HRG005-A

Power supply input

User’s preparation

ELB/Current leakage breaker

Power supply cable

Power supply box

Electrical circuit

Remote operation signal input

DC +24V input

FG（Frame ground）

Remote operation input circuit

Signal cable

Error detected stop signal output, relay contact

（normally open, closed for error）

Operation signal output, relay contact

（normally close, opened for error）

Error detected stop signal output circuit

Operation signal output circuit

I/O board

Fig. 3-6 Installation (electrical wiring)


3-6


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HRX-OM-H043


3.2.4 Piping

z Install piping properly. Improper installation may cause leaks. z Keep facility water pressure below 0.5MPa. z Make sure the locations of IN and OUT ports for circulating fluid supply.

The reverse connection inhibits proper operation of the unit.

z Make sure no entry of dust and foreign materials into the water circuit

during piping installation.

z Hold the piping connected port with a pipe wrench when tightening the

pipe. Excessive force will damage the port and cause leaks if disregarded.

Pipe diameter

The pipe diameters are common to all models.

Table 3-2 Pipe diameter

Pipe

Recirculating fluid OUT

Recirculating fluid return

Port for overflow

Port for drain in tank

Diameter

Rc1/2

Rc1/2

Rc1/2

Rc1/2

How to install piping

1.

Hold the piping connected port with a specific wrench and tighten the pipe.

Connected port

29.4N・m or less

Fig. 3-7 Tightening of pipe

Remarks

Install a valve at the drain port to facilitate the draining of the circulating fluid from the tank. (The valve needs to be prepared separately.)


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3-7

HRX-OM-H043


Recommended piping installation

Circulating fluid OUT

Circulating fluid return

Tank drain port

Port for overflow

Drain pit

Load device

Fig. 3-8 Recommended piping installation

No. Name Size

1 Valve

3

4

5

Relieving valve

Pressure gauge

Flow meter

Rc1/2

Rc1/2

Rc1/2, set from 0 to 0.5 MPa

0 to 1.0 MPa

0 to 50 L/min

3.2.5 Supply of circulating fluid

１．

Open the tank lid and supply the circulating fluid until the fluid reaches the range specified on the level indicator.

Opening for level check

Keep the fluid level in the tank between “HIGH” and “LOW”. If the fluid is out of the range, the circulating fluid may overflow that results in a ground falut.

HIGH

HIGH

LOW

Opening for level check

Level range

Level range

HRG001-A & HRG002-A

Fig. 3-9 Level indicator

LOW

HRG005-A


3-8


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HRX-OM-H043


3.2.6 Reinstallation of unit

If the unit is relocated, only personnel with knowledge of the unit and associated equipment are allowed to perform unit reinstallation.

Precautions described below must always be followed.

When the unit is transferred to and reinstalled in a different place after operation at the original place (including trial run), perform transporting and installation of the unit according to the procedures described below and in

Chapter 3.

Disconnection of power supply cable

Be sure to cut off the power supply when disconnecting the power supply cable. z Only qualified personnel are allowed to install wiring. z Be sure to cut off the power supply for safety. Wiring with the unit

energized is strictly prohibitted.


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3-9

HRX-OM-H043



3-10


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HRX-OM-H043

4 Startup and Shutdown

4. Startup and Shutdown

Personnel with adequate knowledge and experiences of this product and peripheral devices shall be in charge of starting up and shutting down the unit.

4.1 Pre-check

Check the following items before starting up the unit. z

Make sure the unit is installed horizontally. z

Do not put any heavy object on the unit or apply excess force by piping.

4.1.2 Connection of cable

Check that the power cable, ground and I/O signal cables are correctly connected.

4.1.3 Piping for circulating fluid

Check the I/O piping of the circulating fluid is installed correctly.

Check the fluid level is within the specified range.


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4.1 Pre-check

4-1

HRX-OM-H043


4.2 Preparation for startup

Supply the power.

The following conditions are observed on the control panel upon power-ON. z

The [POWER] LED lights up. z

The digital display PV lights up and displays temperature of the circulating fluid. z

The [ALARM] LED lights up and goes out in 5 sec.

［POWER］LED

［ALARM］LED

Fig. 4-1 Power supply

4.2.2 Setting of circulating fluid temperature

Digital display PV

Press the [UP] and [DOWN] keys to set a desired temperature in the digital display SV.

Digital display SV

［DOWN］key

Fig. 4-2 Setting of circulating fluid temperature z

Note: Circulating fluid setting temp.range is 5 to 35°C.

［UP］key

4.2 Preparation for startup

4-2


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HRX-OM-H043


[TS] switch (pump manual operation switch): HRG005-A only

HRG005-A has the [TS] switch (pump manual operation switch) to purge air from the circulating fluid circuit at initial startup. Remove the front panel, and purge air according to the procedures given below.

[TS] switch

Front

Fig. 4-3 ［TS］switch（ポンプ単独運転 switch）

1.

Press the [TS] switch for several seconds, monitoring the fluid level gauge.

Air is purged from the pipe, and the fluid level is lowered.

2.

Supply the circulating fluid again according to section 3.2.5.

If leakage occurs due to faulty piping including an opened fitting of eternal piping, stop manual operation of the pump and fix the leak.


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4.2 Preparation for startup

4-3

HRX-OM-H043


4.3 Unit Startup and Shutdown

4.3.1 Starting the unit

1.

Press the [ON] switch on the control panel.

The unit starts operating and regulates the circulating fluid temperature.

The [RUN] LED and [PUMP] LED on the control panel come on.

［RUN］LED

［PUMP］LED

［ON］switch

Fig. 4-4 Starting the unit

4.3.2 Stopping the unit

1.

Press the [OFF] switch on the control panel.

The unit stops.

The [RUN] LED and [PUMP] LED on the control panel go out.

［RUN］LED

［PUMP］LED

［OFF］switch

Fig. 4-5 Stopping the unit

4.3 Unit Startup and Shutdown

4-4


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HRX-OM-H043


4.4 Check at startup

Check the following items at startup of the unit.

When any abnormality is found, press the [OFF] switch immediately to stop the unit and turn the power breaker off.

z

No leak from circulating fluid piping z

No circulating fluid flowing out of the tank drain port z

Circulating fluid pressure within the specified range

Bypass valve

Normally, the bypass valve is fully opened. If the unit is started up with the valve fully closed, water supply may reach abnormal high pressure depending on external piping conditions. Be sure to keep the bypass valve fully opened for initial startup of the unit installed.

Adjust the bypass valve to obtain required pressure and flow rate by checking on the external pressure gauge and flow meter that can be prepared by customer or mounted on external piping.

Bypass valve

Right Right

Fig. 4-5 Bypass valve (HRG001-A / HRG002-A) Fig. 4-6 Bypass valve (HRG005-A)


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4.4 Check at startup

4-5

HRX-OM-H043


4.4 Check at startup

4-6


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HRX-OM-H043

5 Error Message and Troubleshooting

5. Error Message and Troubleshooting

5.1 Error Message

This product stops when an error is detected.

Table 5-1 shows the LED conditions (ON/OFF) and signal output in the event of the error.

［POWER］LED

［RUN］LED

［ALARM］LED

Fig. 5-1 Control panel

Alarm

Setting range

Table 5-1 Error message

LED

(●: Off, ○: On)

Unit status

POWER RUN ALARM

Operation signal output

Power error

Start-up failure

－

Reverse of pump and compressor

－

Tank water level drop

Lower limit of water level in the tank

Pump overload

－

Compressor overload

High temp. of supplied water

Excess temp. rise in fan motor*

* Only HRG005-A

－

－

Stopped

● ● ●

Stopped Green○

● Red

Stopped Green○

● Red

Stopped Green○

● Red

Stopped Green○

● Red

Stopped Green○

● Red

Min.40°C Stopped Green○

● Red

Min.40°C Stopped

Green○

● Red

Open contact

Open contact

Open contact

Open contact

Open contact

Open contact

Open contact

Open contact

Error stop signal output

Closed contact

Open contact

Open contact

Open contact

Open contact

Open contact

Open contact

Open contact


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5.1 Error Message

5-1

HRX-OM-H043

5 Error Message and Troubleshooting

5.2 Troubleshooting

Table 5-2 Troubleshooting

Alarm

Power error

Startup failure

Reverse of pump and compressor

Tank water level drop

Pump overload

Compressor overload

High temp. of circulating fluid

Temp. rise in fan motor*

Unit status Cause Remedies

The [POWER]

LED is not turned on.

Power is not supplied.

A breaker is tripped.

Low voltage

Failure in the [POWER] LED

The [RUN]

LED remains off even with

One of the three-phase power is interrupted. A voltage sag occurred. the press of

Failure in the [RUN] LED the [ON] switch Failure in the [ON] switch

Reverse phase relay triggered.

Level switch contact is opened.

Pump thermal overload switch has been tripped.

Compressor thermal overload switch has been tripped.

The contact of temperature controller EV1 is opened.

The contact of the thermostat for fan motor is open.

Incorrect phase sequence of power wiring

Supply the power.

Fix a short or ground fault.

Supply a rated voltage.

Ask for service.

Normal according to product spec.

Supply three-phase power.

Inadequate water in the tank

(natural evaporation)

Power voltage sag

Abnormal rise in circullating fluid pressure

Abnormal failure of pump

Power voltage sag

Abnormal heat dissipation capability of condensor.

Improper rated cooling capability

Ask for service.

Ask for service.


Rewire the power cable for two of three phases. Wiring should be performed by a qualified person.


Circulating water is low in amount.

Supply the circulating water.


Boost up the capacity of power breaker. Wiring should be performed by a qualified person.

Adjust the opening of the manual relief valve. Ask for service.

Change the pump.

Ask for service.


Boost up the capacity of power breaker. Wiring should be performed by a qualified person.


Improve ambient conditions to provide ventilation and exhaust heat. Failed condensing fan


Reduce a heating value output from user’s unit.

Refrigerant leak

Abnormal failure in the compressor

Failure in the electromagnetic switch

Rise in ambient temperature


Ask for service to get the refrigerant gas charged and the compressor and electromagnetic switch replaced.

Improve ambient conditions. Avoid installing it at a place exposed to direct sunlight or radiant heat.



Refrigerant leak

Failure in the refrigerant solenoid valve

Failure in the compressor

Other abnormalities in the refrigeration circuit

Failure in the temperature controller

Rise in ambient temperature


Failure in the fan motor

Ask for service to get the refrigerant gas charged and the compressor and electromagnetic switch replaced.

Improve ambient conditions. Avoid installing it at a place exposed to direct sunlight or radiant heat.


Replace the fan motor.

Ask for service.

*Only apply to model HRG005-A

How to reset

Manual reset

Auto reset

Auto reset

Auto reset

Manual reset

Manual reset

Auto reset

Auto reset

5.2 Troubleshooting

5-2


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HRX-OM-H043

6 Unit Maintenance

6. Unit Maintenance

6.1 Control of water quality

Standard

Reference

The circulating fluid used in this unit is fresh water (tap water). This unit may be damaged when unpermitted fluids are used. Potential fluid leak may occur if disregarded, which results in electric shock and ground fault.

ONLY use fresh water (tap water) which satisfies water quality standards as shown in the table below.

Table 6-1 Water quality standards for fresh water (tap water)

Cooling water system/ Circulating

Substances fluid

pH (25°C)

Electrical conductivity (25°C) (µs/cm)

Chloride ion (mgCl-/L)

Sulfuric acid ion (mgSO

4

2-

/L)

Acid consumption (pH4.8) (mgCaCO

3

/L)

Total hardness (mgCaCO

3

/L)

Calcium hardness (mgCaCO

3

/L)

Ion silica (mgSiO

2

/L)

Iron (mgFe/L)

Copper (mgCu/L)

Sulfide ion (mgS

2-

Ammonium ion (mgNH

4

+

/L)

Residual chlorine (mgCl/L)

6.8 to 8.0

1 to 400

50 and below

50 and below

50 and below

70 and below

50 and below

30 and below

1.0 and below

1.0 and below

1.0 and below

0.3 and below

Free carbon dioxide (mgCO

2

/L) 4.0 and below

*Excerpt from the Refrigeration and Air Conditioning Equipment Water Quality

Guideline JRA-GL-02-1994

If the periodic inspection finds a nonconforming substance in the facility water, wash the tank and the cirulating circuit, and replace the water in the tank. Water will evaporate, and impurities will build up.

Even if no abnormal event occurs, it is recommended to replace the water in the tank once every three months. Refer to section "6.2

Inspection and Cleaning" for the periodic inspection.


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6.1 Control of water quality

6-1

HRX-OM-H043


6.2 Inspection and cleaning

Do not operate the switches, etc. with wet hands and do not touch any electrical components such as a power supply plug. It may cause an electric shock if disregarded.

Keep this unit from water.

Do not wash the unit with water. It may cause an electric shock and fire if disregarded.

Do not touch the fin directly during cleaning of the condenser. It may cause personal injury if disregarded.

Cut off the power supply of the unit before performing cleaning, maintenance and inspection. It may cause an electric shock, injury or burn if disregarded.

Always mount the panel back onto the unit after removing the panel for inspection or cleaning. Failure to close or re-attach the panel may cause personal injury or electric shock during unit operation.

6.2 Inspection and cleaning

6-2


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HRX-OM-H043


Check the items listed below before, during, and after operation of this unit.

If any abnormal event is detected, stop operation and turn off the main breaker. Be sure to lock out and tag out the unit before asking for service. z

The circulating fluid should fall within the specified level. When it is out of the range, replenish or drain excess circulating fluid to maintain a proper level. (Be sure to stop the unit before replenishing the circulating fluid.) z

The characters and numbers on the liquid crystal display of the control display panel should be clear. z

There should be no leak from circulating fluid piping. z

Water supply pressure of the circulating fluid should be within the specified range.

(Discharge pressure of the circulating fluid should be lower than the proof pressure of user’s unit.) z

There should be no abnormal sound or abnormal vibration from this unit. z

There should be no foul smell or smoke from this unit.


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6-3

HRX-OM-H043


Cleaning of the filter for the air-cooled condenser (optional accessory)

Attach a filter screen when operating this unit in a place that the fin of the air-cooled condenser becomes dirty and clogged. The filter screen is an optional accessory.

z

Remove the filter and eliminate dirt with a vaccum cleaner. z

Detach the filter and wash it with detergent if it is dirty. Place it back when it is dried.

Brush z

Vacuum cleaner

Wash it with water and apply gentle brush motion.

Fig. 6-1 Cleaning of the filter for the air-cooled condenser. (Optional accessory)

Inspection of the tank

Check the following items. Replenish or replace fresh water (tap water), or clean it when an abnormal event is found. z

Foreign materials adhere to the inner wall of the tank. z

Slime is found on the inner wall of the tank. z

Foreign materials float on the surface of fulid in the tank. z

There is scale deposited in the tank. z

It has a foul odor. z

The water has been discolored.


6-4


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HRX-OM-H043


Cleaning of the air-cooled condenser

with dust.

The safety device may get activated to stop the operation when the fin is clogged

z

Clean the fin with a soft brush or an air gun with caution not to damage the fin.

Cleaning of the condenser with a brush Cleaning of the condenser with an air gun

Fig. 6-2 Cleaning of air-cooled condenser

Check for leak from the pump mechanical sealing

Remove the panel and check for leak from the pump mechanical sealing.

When a leak is found, it is necessary to replace the mechanical sealing.

Contact the local distributor or SMC’s sales branch.

I m p o r t a n t

z Leak from the mechanical sealing

Leakage from the mechanical sealing occurs in structure. Although JIS defines leakage for 3cc/hr or less (reference value), 0.3cc/hr or more is our leakage standard suggested for the replacement of the mechanical sealing.

A recommended replacement cycle of the mechanical sealing is 6000 to 8000 hours a year

(usually).


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6-5

HRX-OM-H043


6.3 Storage

Follow the procedures below for long-term storage of the unit.

1.

Turn off the main power breaker.

2.

Fully open the drain valve and drain the water from the tank.

3.

Remove the drain plug of the circulating pump and drain the water from the pump.

4.

Cover the unit with a plastic sheet for storage after draining is completed.

6.4 Consumables

Replace the following parts in response to the level of wearing out at inspection.

Part number

HRG-S0003

Table 6-2 Biannual inspection

Part

Pump mechanical sealing

Qty. Remarks

1 set For HRG005

* It is not required for HRG001 and HRG002.

6.3 Storage

6-6


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HRX-OM-H043

7 Documents

7. Documents

7.1 Specifications list

t ）

Item

Installation/

Op. Environment

Operating fluid

Rated ambient humid

.

range

Table 7-1 Specifications list

HRG001-A HRG002-A

32°C

45-75%RH（No condensation）

HRG005-A

Circulating fluid/fresh water (tap water)

Rated capacity of tank

Power sup. voltage

Recommended leak breaker capacity

Breaker sensitivity current

Start/stop instruction signal

(Remote op. signal)

Rated temp. & accuracy of circulating fluid

Rated cooling capacity

10L

3-phase AC200/200－220V（50/60 Hz）

5A 10A

30mA

20L

20A

Remote operation starts at DC24V and 8 mA are applied and stops at DC0V.

20±1.0°C and 0.5°C（Temp. setting range 5-35°C）

4.5/4.8 kW（50/60 Hz）

Pumping capacity

Op. signal

Emergency.

Stop signal

Emergency stop

Others

Outside panel

Relay contact (Contact cap. AC250V, 1A, resistance load. Contact closes during operation, and contact opens during stop and during power shutdown.)

Relay contact (Contact cap. AC250V, 1A, resistance load. Contact closes while alarm light remains OFF and during power shutdown, and contact opens while alarm light remains ON.)

Unit stop function for low tank level (with tank level switch)

Pump reverse rotation detection (with phase relay)

Pump/compressor reverse rotation detection

(with phase relay)

Unit stop function for pump/compressor overload (with over current relay)

Unit stop function for abnormal fan motor temperature rise

(Temp. fuse is built into fan motor)

Unit stop function for abnormal fan motor temperature rise

(Thermostat is built in fan motor.)

Unit stop function for abnormal circulating fluid temperature rise (Set temp. of the temp. controller: 40°C)

Protection against excessive temp. increase of compressor（OLP）, Protection against pressure increase of circulating fluid （With manual valve), Leak protection （With drain pan）

SGCC（Munsell 10Y8/0.5 Urban white）

Control panel SGCC（DIC183 Blue）

Base SECC（Paint Munsell 10Y6/0.5 Urban gray）

Wetted part

SUS (connections such as inlet and outlet), BC

(hose fitting, tube fitting), PVC (piping hose for internal water feeding), PPE (pump casing, impeller), PE (tank)

SUS (pump impeller, connections such as Inlet and outlet), BC (pump casing, hose fitting), PVC (piping hose for internal water feeding), PE (tank)

Internal piping for refrigerant

Operating refrigerant

C1220T

HFC－407C

Accessories

No accessories Eye bolt M12×4 pcs.

(Please prepare a power supply, signal cable and connection terminal under your responsibility.)

Approx. 117kg


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7.1 Specifications list

7-1

HRX-OM-H043

7 Documents

7.2 Outline dimensions

7.2.1 HRG001-A and HRG002-A

500

Top view

300 250

Left side Front view

Right side

Fig. 7-1 Outline dimensions (HRG001-A / HRG002-A)

7.2.2 HRG005-A

328

Left side

595

Top view

536

Front view

Fig. 7-2 Outline dimensions (HRG005-A)

Right side

7.2 Outline dimensions

7-2


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HRX-OM-H043

7 Documents

7.3 Electric circuit diagram

7.3.1 HRG001-A and HRG002-A

Fig. 7-3 Electric circuit diagram (HRG001-A / HRG002-A)


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7.3 Electric circuit diagram

7-3

HRX-OM-H043

7 Documents

7.3.2 HRG005-A

Fig. 7-4 Electric circuit diagram (HRG005-A)

7.3 Electric circuit diagram

7-4


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HRX-OM-H043

7 Documents

7.4 Flow chart

7.4.1 HRG001-A and HRG002-A

PS

R

Over flow port

Draft

CD

FM Draft

SV

CRV

R

TI

Circulating fluid feeding port

RV

Circulating fluid return port

Tank drain port

Recirculating fluid flow

Refrigerant flow

Fig. 7-5 Flow chart (HRG001-A and HRG002-A)

7.4.2 HRG005-A

Draft

CD

ＰＳ１

FM

SV

R

R

R

Draft

TI

RV

Over flow port

Circulating fluid feeding port

Circulating fluid

return port

Tank drain port

Circulating fluid flow

Refrigerant flow

Fig. 7-6 Flow chart (HRG005-A)

Sym bol

Name

CM Compressor

PS Pressure switch for fan

A Accumulator

CRV

Capacity regulating valve

T Tank

PM Pump

Sym bol

Name

CM Compressor

PS1 Pressure switch for fan

EV Evaporator（Cooler）

A Accumulator

PS2 Low pressure switch

T Tank

PM Pump


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7.4 Flow chart

7-5

SMC HRG 001-A, HRG 002-A, HRG 005-A Thermo cooler Operation Manual

Assistant Bot

Operation Manual

Air-refrigerated Thermo cooler

To the Customers

Table of Contents

Table of Contents-1

Table of Contents-2

1. Safety Instructions

1.1 Before Using this Unit

1-1

1.2 Danger, Warning and Caution

1-2

1-3

1.3 Hazard Warning Label

1-4

1-5

1.4 Model label

1-6

1.5 Disposition of waste

1-7

1-8

2. Descriptions of Components

2.1 Appearance of unit

2-1

2.2 Descriptions and functions of components

2-2

2-3

2-4

3. Transport and Installation

3.1 Transport

3-1

3-2

3.2 Installation

°C. Unit

°C may lead to failure in the compressor.

°C will reduce effectiveness of the condenser

3-3

3-4

Undo the screws (6 pcs.) and take off the front panel.

Connect the power supply cable and signal cable as shown in the figure.

3-5

3-6

Hold the piping connected port with a specific wrench and tighten the pipe.

3-7

Open the tank lid and supply the circulating fluid until the fluid reaches the range specified on the level indicator.

3-8

3-9

3-10

4. Startup and Shutdown

4.1 Pre-check

4-1

4.2 Preparation for startup

Supply the power.

4-2

Press the [TS] switch for several seconds, monitoring the fluid level gauge.

Supply the circulating fluid again according to section 3.2.5.

4-3

4.3 Unit Startup and Shutdown

Press the [ON] switch on the control panel.

Press the [OFF] switch on the control panel.

4-4

4.4 Check at startup

4-5

4-6

5. Error Message and Troubleshooting

5.1 Error Message

5-1

5.2 Troubleshooting

5-2

6. Unit Maintenance

6.1 Control of water quality

6-1

6.2 Inspection and cleaning

6-2

6-3

6-4

6-5

6.3 Storage

6.4 Consumables

HRS012-W-20-