1. - SMC Pneumatics
Contents
1. Tank lid In Power cable access Cable Grip Eye bolt M12 tp Mos Level indicator Electrical TOP Control panel Z A unit E E 7 Signal cable entry OO OO OUUU OD j LIDL BEBE 000000000000 0900 Cable Grip Circulating fluid RETURN Rc1 2 Pp EM LO 7 Circulating fluid a OUT Rc1 2 j O 777 Bypass valve AC O Air vent OUT DO evi E Port for overflow Rc1 2 SEEMS Tank drain port Rc1 2 Left Front 4 613 plugged for anchor bolt Fig 2 4 Piping connection port HRG005 A HRG001 A HRG002 A HRG005 A 2 2 Descriptions and functions of components 1 edition Dec 2003 2 3 HRX OM H043 2 Descriptions of Components 2 2 3 Control panel The control panel is common to all models POWER RUN ALARM O y j A O ON Tor O OFF MODE an UP FUNC N OM ATO Fig 2 5 Control panel Table 2 1 Control panel i Indicates actual temperature of a circulating fluid Pta CSP Ea Indicates set temperat2. i Op a H 3 X J N gt 500 Top view i ei H o UJ ll m ni 300 250 Left side Front view LU i sala yp A i Right side Fig 7 1 Outline dimensions HRG001 A HRG002 A 7 2 2 HRGO005 A i 9 i e j x td i 595 Top view O Q I H pe INR E LLL BD DDR 10000 DUUE S m O I LO Jb Y 328 536 Left side Front view Fig 7 2 Outline dimensions HRG005 A 7 2 Outline dimensions 1 2
3. TITTI INU LJ 2i gt Right side HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 HRX OM H043 7 Documents cal idu 405ues dua SET 2 1349 CUL ZSW Tul VE TSV IWON LOGUAR t diagram HRG001 A and HRG002 A IC CIFCUI 7 3 Electr 7 3 1 SS dt indu hs uanod 49 043002 duaj QU eo eo My t D m ca 1 0 Tal O CTER Se DE COE bel
4. d L B J EE EF n TRITT LUUD UE E B nnn A A DORAMA as Right Right Fig 4 5 Bypass valve HRG001 A HRG002 A Fig 4 6 Bypass valve HRG005 A HRG001 A HRG002 A HRG005 A 4 4 Check at startup 1 edition Dec 2003 4 5 HRX OM H043 4 Startup and Shutdown 4 4 Check at startup HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 4 6 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 MODE DOWN UP FUNC PTE Pp ALARM LED Fig 5 1 Control panel Table 5 1 Error message Operation Setting 0 Off O On as ha POWER RUN ALARM output Open Closed Powerenor _ Stopped MINE 1 SOS a Reverse of pump andy o Open Sped areno Red comact contac Lower limit of Ob n nen Tank water level drop water level in Stopped GreenO Red O p p contact contact MEN tank Open Open Pump overload Stopped Greeno Stopped GrenO Open Open High temp of Losi Open Excess temp rise in 3 Open Open Only HRG005 A HRG001 A HRG002 A HRG005 A 5 1 Error Message 1 edition Dec 2003 5 1 HRX OM H043 5 Error Message and Troubleshooting 5 2 Troubleshooting Table 5 2 Troubleshooting How to Alarm Unitstatus Cause Remedies LA The
5. TT SS E gt ER X cd A EN KS Fork insertion Fork insertion position position Fig 3 1 Fork insertion position and unit lifting 3 1 Transport HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 3 2 HRX OM H043 3 Transport and Installation 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 3 2 1 Installation Conditions Do not use or store the unit in the following environments Potential unit malfunction and damage may occur if disregarded Environment that is exposed to water vapor salt water or oil mist Environment that is exposed to dust or powdery materials Environment that is exposed to corrosive gas flammable gas or solvent o o o
6. 7 3 Electric circuit diagram HRG001 A HRG002 A t diagram IC CIFCUI Fig 7 3 Electr HRG001 A HRG002 A HRG005 A 1 edition 7 3 Dec 2003 XUDWI JJOO O g1UNIA m ea lt T Jd inding indu Si 8 clll L A ON o 281 0 H andino ou6 9501 440 1nus ddns HRG005 A t diagram IC CIFCUI Fig 7 4 Electr Dec 2003 HRG001 A HRG002 A HRG005 A 1 edition HRG005 A 0 08 HRX OM H043 7 Documents 7 3 2 7 3 Electric circuit diagram 7 4 HRX OM H043 7 Documents 7 4 Flow chart
7. with dust O 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 B 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 Important 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 HRG001 A HRG002 A HRG005 A 6 2 Inspection and cleaning 1 edition Dec 2003 6 5 HRX OM H043 6 Unit Maintenance 6 3 Storage Follow the procedures below for long term storage of the unit 1 2 3 4 Turn off the main power breaker Fully open the drain valve and drain the water from the tank Remove the drain plug of the circulating pump and drain the water from the pump 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 Table 6
8. 7 4 1 HRG001 A and HRG002 A TA PS Over flow port Sit R J D TO bol Name 99 Compressor Air cooled condenser PS Pressure switch for fan FM Fan Motor D Refrigerant dryer Evaporator Cooler Draft R Capillary tube Capacity regulating valve Circulating fluid Solenoid valve LOR LS Level switch __ Tank drain port T Level indicator Co Pump 2 Recirculating fluid flow Regulating valve Circulating fluid feeding port n3110 uoneJeBujeu Refrigerant flow Fig 7 5 Flow chart HRG001 A and HRG002 A 7 4 2 HRG005 A n Over flow port Sym riot CI D Refrigerantaryer R Capillary tube E etc E E N PM X RV Circulating fluid LI Level indicator return port PM E PM Pump Temperature switch Tank drain port Regulating valve Circulating fluid flow Draft n3110 uoneJeBujeu INOJ 099 191eM Refrigerant flow Fig 7 6 Flow chart HRG005 A HRG001 A HRG002 A HRG005 A 7 4 Flow chart 1 edition Dec 2003 7 5
9. Environment that is exposed to direct sun light or radiant heat Q Environment where ambient temperature is out of the specified range between 5 C to 40 C Q Environment that is subjected to abrupt changes in temprature o Environment that is subjected to strong electromagnetic noise incl strong electrical field strong magnetic field or surge voltage Q Environment that generates static electricity or condition in which static electricity discharges to the unit Q Environment that generates strong high frequencies Q Environment at high altitudes of over 1000m Condition which allows strong vibrations and impacts to transmit to the unit Q Condition with external force or load to deform the unit Q Condition with an insufficient maintenance space as required Condition with an insufficient maintenance space as required HRG001 A HRG002 A HRG005 A 3 2 Installation 1 edition Dec 2003 3 3 HRX OM H043 3 Transport and Installation 3 2 2 Installation Keep the unit away from vibration Install the unit on a flat and stable surface Refer to 7 2 Outline dimensions for the dimensions of the unit 3 2 3 Electrical wiring e Do not modify the electrical wiring Incorrect wiring can cause an electrical shock and fire Failure to do so will void any warranty e The set value of the safety device must not be changed Changing the set value can cause system failure and fire e Only qualified personnel are allowed
10. 2 2 2 1 piger IR GOO LIE 2 2 222 A eee ee ee ee eee 2 3 2293 COMMON BANE Mover Ix T 2 4 3 Transport and Installation 3 1 3 1 TRANSPOR iet PLE a a aaa 3 1 3 2 INSTALLATION isla 3 3 3 2 1 Installation COMIN OMS sii idad 3 3 3 2 2 INSTa lato erstes surcos icons iso 3 4 3 2 3 ElCCMICA WIN oo 3 4 3 2 4 AA SCE et M ere ee 3 7 3 25 Supply of circulating flUid ccccccoooccnnncccnnncccoonnncnnnnccnonnonnncnononononnnnnnnnnnnnnonnnnnncnnnnnnnnnns 3 8 320 Belnstalallon OP Unai Dd 3 9 4 Startup and Shutdown 0ccooccccoccccnnnccnnnncnnnncnnnncnnnnnnnnnrnnanennnncnnanenas 4 1 4 1 PRE CHECK aia os 4 1 4 1 1 Installation CONCISA AAA A AS 4 1 41 2 Gonnecliomof Cables ted tb oto od ob a 4 1 4 1 3 PPNO TOP CIRC UIATING Ml c 4 1 HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 Table of Contents 1 HRX OM H043 Table of Contents 4 1 4 Levelindicator for level in the tank _ nana nana nennen 4 1 42 PREPARATION FOR STARTUP ista 4 2 4 2 1 POW i i SUPPI Voen a dd 4 2 4 2 2 Setting of circulating fluid temperature ooconnnccnnncccccconnnccnnnncnnnnnnnnnnnnnnnnonnnnncnnnnnnnnnonanennnns 4 2 4 2 9 Additional Water SHbbly ai ei 4 3 4 3 UNIT STARTUP AND SHUTDOWN e eene nennen nn serene irene iii 4 4 4 3 1 EA Pe sedes ue eso ae codo ed oet esas boo osos nas eui eba o a 4 4 43 22 OPPN We uniche EU
11. POWER Power is not supplied Supply the power reset Power error LED is not A breaker is tripped Fix a short or ground fault turned on Supply a rated voltage Failure in the POWER LED One of the three phase power is N ian i to product spec LED remains interrupted A voltage sag a te e off even with occurred Supply three phase power Auto the press of Failure in the RUN LED Ask for service ISS the ON switch Failure in the ON switch Normal according to product spec Auto vani e sequence of Rewire the power cable for two of reset pais E p 9 three phases Wiring should be P performed by a qualified person Tank water Level switch Inadequate water in the tank RM SARO si product ar Auto level drop contact IS natural evaporation Irculating water Is low In amount reset opened Supply the circulating water Normal according to product spec Boost up the capacity of power Pump thermal breaker Wiring should be Pump overload performed by a qualified person Manual overload switch has Abnormal rise in circullating fluid Adjust the opening of the manual reset been tripped pressure relief valve Ask for service Change the pump Normal according to product spec Power voltage sag Boost up the capacity of power breaker Wiring should be performed by a qualified Normal according to product spec COIDESGHOE Abnormal heat dissipation Improve ambient conditions to a capability of condensor provide ven
12. 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 4 1 1 Installation condition Make sure the unit is installed horizontally 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 l 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 4 1 4 Level indicator for level in the tank Check the fluid level is within the specified range 1 edition Dec 2003 4 1 HRX OM H043 4 Startup and Shutdown 4 2 Preparation for startup 4 2 1 Power supply Supply the power The following conditions are observed on the control panel upon power ON The POWER LED lights up O The digital display PV lights up and displays temperature of the circulating fluid O The ALARM LED lights up and goes out in 5 sec GM THERMO CO HH MEE X ULL MODE DOWN UP FUNC o V y Digital display PV Fig 4 1 Power supply 4 2 2 Setting of circulating fluid temperature Press the UP and DOWN keys to set a desired temperature in the digital display SV iF mr j SV o B 8 Digital display SV POWER RUN PUMP ALARM ON OFF Fig 4 2 S
13. 2 Biannual inspection HRG S0003 Pump mechanical sealing For HRG005 6 3 Storage 6 6 It is not required for HRG001 and HRG002 HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 HRX OM H043 7 Documents 7 Documents 7 1 Specifications list Table 7 1 Specifications list 7 HRG001 A HRG002 A HRG005 A Installation _ rien m A A Spee vronment humid 45 75 RH No condensation range Operating fluid i Circulating fluid fresh water tap water Rated capacity of tank 10L 20L Power sup voltage 3 phase AC200 200 220V 50 60 Hz E Breaker sensitivity current 30mA Start stop instruction signal Remote operation starts at DC24V and 8 mA are applied and stops at DCOV Remote op signal Rated temp amp accuracy of circulating fluid Rated cooling capacity 0 9 1 1 KW 50 60 Hz 9 2 3 kW 50 60 Hz 4 5 4 8 kW 50 60 Hz Pumping capacity 29 37 Limin Head 10 m 33 42 L min Head 10 m Relay contact Contact cap AC250V 1A resistance load Contact closes during operation and contact Op signal opens during stop and during power shutdown Emergency Relay contact Contact cap AC250V 1A resistance load Contact closes while alarm light remains OFF Stop signal _ 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 Emergency st
14. 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 SNC THERMO COOL TT ATI PUMP LED vl 8 8 8 SV f MODE DOWN UP FUNC HH E E I n OFF Ei 2 OFF switch Fig 4 5 Stopping the unit 4 3 Unit Startup and Shutdown HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 4 4 HRX OM H043 4 Startup and Shutdown 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 O No leak from circulating fluid piping O No circulating fluid flowing out of the tank drain port O Circulating fluid pressure within the specified range B 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 7 O
15. C4 prezzo Error detected stop signal output circuit normally open closed for error 0 75 NED TB2 3 Operation signal output relay contact 6 ve f TB2 4 Operation signal output circuit normally close opened for error LU Y O board Fig 3 5 Installation electrical wiring e HRG005 A User s preparation Power supply box ELB Current leakage breaker 5 5 45 Power supply input bn IS R Power supply R4 Ac2001200 220v d D HOS B cable Sj 5 E Electrical circuit 50 60Hz SIM WI ae ED T FG Frame ground Remote operation signal input ode A 24 TB1 TEN e E dia 25 181 25 v Remote operation input circuit pr Signal cable Error detected stop signal output relay contact 3 28 gna ca 284 TB2 1 normally open closed for error 3729 5 29 1782 2 Error detected stop signal output circuit Operation signal output relay contact mms 0 75 30 TB2 3 PE cot normally close opened for error 317 TB2 4 Operation signal output circuit TTT VO board Fig 3 6 Installation electrical wiring 3 2 Installation 3 6 HRGOO1 A HRGOO2 A HRGOO5 A 1 edition Dec 2003 HRX OM H043 3 Transport and Installation 3 2 4 Piping e Install piping properly Improper installation may cause leaks o Keep facility water pressure below 0 5MPa e Make sure the locations of IN and OUT ports for circulating fluid supply The reverse connection inhibits proper operation of the unit e Make sur
16. ER 4 4 44 GHECKATSTARTUDP iiossuisstusxat iu vatvacaterseudswtuseudawontes 4 5 5 Error Message and Troubleshooting 5 1 51 ERROR MESSAGE maa in dron P eDesds a ne ai 5 1 bi2 TROUBLESHOOTING esie cuan aa 5 2 6 Unmt Maintenarite oco nos veio d a ecd is 6 1 6 1 CONTROL OF WATER QUALITY noria 6 1 6 2 INSPECTION AND CLEANING siii is 6 2 6 2 1 Bla AAA NA In ON 6 3 6 2 2 MOM N DOC O cca 6 4 623 Bla niUualiAnspeclioniissanazzan cacao tacere 6 5 SA MED x reli CIE ODE 6 6 6 4 CONSUMABLES nia daa 6 6 7 Bele METRE OO oT 7 1 Tal SPECIFICATIONS LIST 5 ioo oos coe Es Ent xx aas ia 7 1 Tie OUTLINE DIMENSIONS uc 7 2 7 2 1 FAGOOTH As and EIRGIDOS SA al ia ia 7 2 E A III II RC eS 7 2 7 3 ELECTRIC CIRCUIT DIAGRAM nba a 7 3 7 3 1 HRG001 A and HRGOO2A occoccccnccccncnconcnoncncnncnnnncnnnnnnonanonnnnnnnnnnnnnnonrnonnnnonnnnonancnnnncnncnanananans 7 3 132 TRAGOS ut us deal ai 7 4 FO FLOWCNAR Tasio 7 5 7 4 1 HRGOOT A and GOO 22 A dida id e ea ia 7 5 lAa MEE ILICE ERO E mc 7 5 HRG001 A HRG002 A HRG005 A 1 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 HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 This chapter describes the safety related items that users should be aware of upon handling
17. HRX OM H043 1 edition Dec 2003 Rev D Nov 2008 Air refrigerated Thermo cooler HRG001 A HRG002 A HRG005 A O GSMC 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 e All warnings and precautions defined in this manual shall be observed e 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 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 e Copying duplicating or transferring any part of or whole contents of this manual without SMC Corporation s permission is strictly prohibited e The Service Manual is supplied to provide additional information and troubleshooting of this unit Only t
18. ccess Cable Grip sla Top Control panel Circulating fluid IL OUT Rc1 2 Bern M Bypass valve Circulating fluid RETURN Rc1 2 5 E e eds Port for overflow Rc1 2 NOOO r J CT de Air vent OUT Tank drain port Rc1 2 c E jt JC C C j 1 JC 4 Ga att so TE LP 2 HBRTIIIT plugged E n ij al as Front N Right Air vent OUT Air vent IN 4 13 For anchor bolt Fig 2 3 Piping connection port HRG001 A HRG002 A 2 2 Descriptions and functions of components HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 2 2 HRX OM H043 2 Descriptions of Components 2 2 2 HRGO005 A
19. d Installation B How to conduct wiring 1 Undo the screws 6 pcs and take off the front panel Front panel JA Fig 3 2 Removal of front panel 2 Connect the power supply cable and signal cable as shown in the figure Signal cable Power supply cable Signal cable entry Power supply cable entry Fig 3 3 Electrical wiring HRG001 A HRG002 A Signal cable Power supply cable Signal cable entry Power supply cable entry Fig 3 4 Electrical wiring HRG005 A HRG001 A HRG002 A HRG005 A 3 2 Installation 1 edition Dec 2003 3 5 HRX OM H043 3 Transport and Installation B Electrical wiring diagram o Prepare cables for the power supply and signal lines separately e Maintain polarities of DC24V when connecting the signal cable for transmitting start stop command remote operation o Refer to 7 3 Electrical circuit diagram for the electrical circuit of the unit HRG001 A HRG002 A User s preparation ELB Current leakage breaker 3 5 45 Thermo cooler Power supply input Somo A Power supply R o O AC200 200 220V 4 S70 AO cope 4 a E Electrical circuit 50 60Hz dd dI VW E 3 5 CE O T FG Frame ground 1 25Y 3 pace Remote operation signal input gem NE 1 1B 1 1 P cla 2 TB1 21 y Remote operation input circuit DC 24V input CE ch DC OV input mmi xignal cabie ris E TEASE Error detected stop signal output relay contact A y
20. d 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 Opening for level check Opening for level check CEA HIGH Level range Level range LOW EA LOW HRG001 A_ amp HRG002 A HRG005 A Fig 3 9 Level indicator 3 2 Installation HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 3 8 HRX OM H043 3 Transport and Installation 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 B Disconnection of power supply cable Be sure to cut off the power supply when disconnecting the power supply cable e Only qualified personnel are allowed to install wiring Be sure to cut off the power supply for safety Wiring with the unit energized is strictly prohibitted HRG001 A HRG002 A HRG005 A 3 2 Installation 1 edition Dec 2003 3 9 HRX OM H043 3 Transport and Installation 3 2 Installation HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 3 10 HRX OM H043 4 Startup and Shutdown 4 Startup
21. disposing of industrial waste HRG001 A HRG002 A HRG005 A 1 5 Disposition of waste 1 edition Dec 2003 1 7 HRX OM H043 1 Safety Instructions 1 5 Disposition of waste HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 1 8 HRX OM H043 2 Descriptions of Components 2 Descriptions of Components 2 1 Appearance of unit 2 1 1 HRG001 A HRG002 A y Top Left Back Front Fig 2 1 Appearance of unit HRG001 A HRG002 A 2 1 2 HRG005 A Left D Front MEE Fig 2 2 Appearance of unit HRG005 A HRG001 A HRG002 A HRG005 A 2 1 Appearance of unit 1 edition Dec 2003 2 1 HRX OM H043 2 Descriptions of Components 2 2 Descriptions and functions of components 2 2 1 HRG001 A HRG002 A nest Tank lid Power cable access E Cable Grip Level indicator Signal cable a
22. e no entry of dust and foreign materials into the water circuit during piping installation e Hold the piping connected port with a pipe wrench when tightening the pipe Excessive force will damage the port and cause leaks if disregarded B Pipe diameter The pipe diameters are common to all models Table 3 2 Pipe diameter Pipe Diameter Recirculating fluid OUT Rc1 2 Recirculating fluid return Rc1 2 Port for overflow Hc1 2 Port for drain in tank Hc1 2 B How to install piping 1 Hold the piping connected port with a specific wrench and tighten the pipe N 29 4N mor 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 HRG001 A HRG002 A HRG005 A 3 2 Installation 1 edition Dec 2003 3 HRX OM H043 3 Transport and Installation B Recommended piping installation 4 Os 1 Circulating fluid OUT bad bad ym pad AI Circulating fluid return 2 4 Tank drain port Pp Port for overflow Fig 3 8 Recommended piping installation No Name Size A __ ade Y shaped strainer Hc1 2 317 Relieving valve ReT 2 set trom 015 05 MPa 0 to 50 L min 3 2 5 Supply of circulating fluid 7 Open the tank lid and supply the circulating fluid until the fluid reaches the range specified on the level indicator Keep the flui
23. etting of circulating fluid temperature O Note Circulating fluid setting temp range is 5 to 35 C UP key 4 2 Preparation for startup HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 4 2 HRX OM H043 4 Startup and Shutdown 4 2 3 Additional water supply B TS switch pump manual operation switch HRG005 A only HRGO005 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 a LZ bey JA q ue n w hi rd Fm SA Si Mi pr TS 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 HRG001 A HRG002 A HRG005 A 4 2 Preparation for startup 1 edition Dec 2003 4 3 HRX OM H043 4 Startup and Shutdown 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 GZ SNC PUMP LED MODE DOWN UP FUNC oo ON WY ON switch Fig 4 4 Starting the unit
24. he 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 HRG001 A HRG002 A HRG005 A 3 1 Transport 1 edition Dec 2003 3 1 HRX OM H043 3 Transport and Installation HRG001 A HRG002 A Fork insertion position qe I Fork insertion ree i position PA of 74 0 y MN EAM MB LY jt Y Mali I J Je e II UG Su e Ps Fork insertion Fork insertion position position N Lifting position HRG005 A Approx 60deg om Approx 60deg Fork insertion position Fork insertion pen 2 E h d EN SE ZA eh zd xg RSS la fu gt xd Pd d m O Y T Sn I q Juan Y d OQ Dor 1 di Ll DL 4 O gt S gt
25. he 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 fluid nda lares 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 HRG001 A HRG002 A HRG005 A 6 1 Control of water quality 1 edition Dec 2003 6 1 HRX OM H043 6 Unit Maintenance 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 co
26. hose who have full understanding of this unit are allowed to perform maintenance and repair of the unit with the use of the Service Manual SMC Corporation 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 Table of Contents 1 Safely INSTITUCION S cnc 1 1 1 1 BEFORE USING THIS UNIT Sua 1 1 1 2 DANGER WARNING AND CAUTION occoccoccocconconconconconconconcnnronnnnannnnnacnn RR RAS RR nna ran nnmnnn 1 2 1 2 1 AB AAA O 1 2 1 2 2 Definitions of Serious injury and Minor INjury i 1 2 ERA MO Sd ee 1 3 1 3 HAZARD WARNING LABEL 102120 serra rear iena arene iaia ire rnnnnanarancannaannana 1 4 1 3 1 GlasSsiliGatlompor TIS Suri eee AAA 1 4 1 3 2 Type of hazard warning labels i 1 5 133 Locatuon ofhazard Wwaming Iabel i on E alla liete 1 6 1 4 MODECLABE MIC P EEEO 1 6 1 5 DISPOSITION OF WASTE sisse aues elo epa Era CoEo Rn ERES ia 1 7 1 5 1 Recovery of refrigerant and compressor Oll i 1 7 1 92 DisposaLlof nib oia iE ea ope dit Lasa 1 7 2 Descriptions of Components eee seere ree 2 1 2 1 APPEARANCE OF UNIT zo cesse nO EO FR DKU bos 2 1 2 1 1 mimic E PIR GOO2 A ME mE 2 1 MP ARAU A o loe 2 1 2 2 DESCRIPTIONS AND FUNCTIONS OF COMPONENTS cocccconconcononconcanonnancancnnnnroncancnanarancananana 2
27. mad on or is operating There is risk of the electric shock the burn and the laceration by rotalion motor ele 4 Turn off the power soppiy when the alarm will be genereied 1 FAMN EE ORME ES MEE 2 EE XREIBIN ERSUSTCESL es A MENO AAA A Eyt BE UE BE 00t ADAM BET 4 REHHGAEREIGZELL E NEMESZICHBOSMSL Fivorocarbon Collection and Destruction Law in Japan 70 B RES E E This product uses Fluorocarbon HFC as a retrigarant 1 It is strictly forbidden to emit Fluorocarbon lo the atmosphere 2 pt pi this product F luerocarbon must be collected in an 3 The kind Si Fineco D oe rU Gent bi product is printed on the mame label Warning label for high COMBINE LT 70 8 HFC MONTAR voltage 1 4T JE 1 2028 amp 5U AA AHTO cEHNULGORCUNT AL 2 COMATARTI MANO FOLROERAeETT 37030 Rave it CHARICE AAT eT Warning label on the front panel Fig 1 3 Location of hazard warning label 1 4 Model label Check the model no described on the label a ZZSMC THERMO COOLER E io MAKER SMC CORPORATION 4 14 1 Solokanda Chiyoda ku Tokyo 101 0021 Japan SERIAL NO Front NE POWER CAPACITY AJ I 9 qi REFRIGERANT D 4 C mil WEIGHT ju A i MADE IN JAPAN ad TIL LT Uni DL ba Wa lt I Su ed x 3 7 LA id Fig 1 4 Location of model label 1 4 Model label HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 1 6 HRX OM H043 1 Safety Instruc
28. n Read the statements carefully and thoroughly understand them before operating this unit DANGER WARNING and CAUTION signs are in order according to severity DANGER gt WARNING gt CAUTION See below for the details A DANGER 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 B 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 B 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 HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 HRX OM H043 1 Safety Instructions 1 23 Symbols This manual provides the following symbols in addition to Danger Warning and Caution to present the warning details in easy to under
29. ndenser It may cause personal injury if disregarded Cut off the power supply of the unit before performing cleaning maintenance and inspection lt 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 HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 6 2 HRX OM H043 6 Unit Maintenance 6 2 1 Daily inspection HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 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 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 The characters and numbers on the liquid crystal display of the control display panel should be clear There should be no leak from circulating fluid piping O 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 O There should be no abnormal
30. of the electric shock the burn and the laceration by rotation motor etc 4 Turn off the power supply when the alarm will be generated 1 EARRA A SL MOC Se 2 RE FALE SPREDT ESL 3 MESITA ML TL EMI ERIC A WATE BR AS DEWAOFFAADERMHVET 4 REI Li ERA CHE ESL Fluorocarbon Collection and Destruction Law in Japan FOV EMR EA GH This product uses Fluorocarbon HFC as a refrigerant 1 It is strictly forbidden to emit Fluorocarbon to the atmosphere 2 When disposing this product Fluorocarbon must be collected in an appropriate manner 3 The kind of Fluorocarbon and the amount used in this product is printed on the name label COMMITISBRCUT 707 HFC DMEDNTUEJ 170 GWEA YTKAPIRHYHTICHIEEUSNTWET 2 COMERTE ARAN 2n 2 olil 55 5 cd 37n 8O0UR RUSSES EEHRERIRSI SORE S CU ES Fig 1 1 Warning label on the front panel B Warning label for high voltage Fig 1 2 Warning label for high voltage HRG001 A HRG002 A HRG005 A 1 3 Hazard Warning Label 1 edition Dec 2003 1 5 HRX OM H043 1 Safety Instructions 1 3 3 Location of hazard warning label e Recognize where the hazard warning labels are attached e 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 1 Read manual before operation 2 Se up by qualification preson s piping and elecrical work 3 Doni remove the extermalprame while power supply leew been tu
31. op Unit stop function for abnormal fan motor Unit stop function for abnormal fan motor temperature rise temperature rise Temp fuse is built into fan motor Queuudinbe 104 uonounj eAnoaloJg Protection against excessive temp increase of compressor OLP Protection against pressure increase PES of circulating fluid With manual valve Leak protection With drain pan Outside panel 2 SGCC Munsell 10Y8 0 5 Urban white Control panel 00000000 SGCC DIC183 Blue 00 Base A SECC Paint Munsell 10Y6 0 5 Urban gray 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 MOSS for internal water feeding PE tank Wetted part eouejsqng peuere N Internal piping for i C1220T refrigerant 1 111111 1222 6 Operating refrigerant HFC 407C l No accessories Eye bolt M12 x 4 pcs Accessories Please prepare a Powe supply signal cable and connection terminal under your responsibility Approx 65kg Approx 70kg i Approx 117kg HRG001 A HRG002 A HRG005 A 7 1 Specifications list 1 edition Dec 2003 7 1 HRX OM H043 7 Documents 7 2 Outline dimensions 7 2 1 HRG001 A and HRG002 A
32. ring operation and may cause burns when an operator comes in contact The attached label contains the symbol A 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 B 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 A 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 HRG001 A HRG002 A HRG005 A Me 1 edition Dec 2003 HRX OM H043 1 Safety Instructions 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 1 Read manual before operation A 2 Setitup by qualification preson s piping and electrical work 3 Dont remove the externalprane while power supply hasu been turned on or is operating There is risk
33. sound or abnormal vibration from this unit O There should be no foul smell or smoke from this unit 6 2 Inspection and cleaning 6 3 HRX OM H043 6 Unit Maintenance 6 2 2 Monthly inspection B 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 O Remove the filter and eliminate dirt with a vaccum cleaner O Detach the filter and wash it with detergent if it is dirty Place it back when it is dried 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 B Inspection of the tank Check the following items Replenish or replace fresh water tap water or clean it when an abnormal event is found O Foreign materials adhere to the inner wall of the tank Slime is found on the inner wall of the tank O Foreign materials float on the surface of fulid in the tank O There is scale deposited in the tank O li has a foul odor O The water has been discolored 6 2 Inspection and cleaning HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 6 4 HRX OM H043 6 Unit Maintenance 6 2 3 Biannual inspection B Cleaning of the air cooled condenser The safety device may get activated to stop the operation when the fin is clogged
34. stand manner B Symbol of electrical hazard This symbol warns you of possible risk of electrical shock B Symbol of heat hazard y This symbol warns you of potential burns B Symbol of rotating shaft hazard This symbol warns you of possible risk caused by a rotating object B Symbol of Don ts This symbol denotes the items that must not be attempted B Symbol of Dos This symbol denotes the obligation items which you must follow in operation of this unit HRG001 A HRG002 A HRG005 A 1 2 Danger Warning and Caution 1 edition Dec 2003 1 3 HRX OM H043 1 Safety Instructions 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 B High voltage hazards The unit is operated at high voltage and may cause an electrical shock The attached label contains the symbol DM 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 B High temperature hazards The unit reaches high temperature du
35. this unit 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 O This manual is not for comprehensive safety and hygiene education Such a manual should be provided by a safety training manager O 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 O 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 O Operators must individually take account of safety and assure a proper working area and working environment O 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 Save this manual at a designated place for reference when necessary 1 1 Before Using this Unit 1 1 HRX OM H043 1 Safety Instructions 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 Cautio
36. tilation and exhaust Compressor heat Failed condensing fan Manual overload da Normal according to product spec reset LE tipps d Improper rated cooling capability Reduce a heating value output from user s unit Ask for service to get the opu A refrigerant gas charged and the SII m compressor and electromagnetic switch Rise in ambient temperature Improve ambient conditions Avoid installing it at a place exposed to direct sunlight or radiant heat Normal according to product spec Improper rated cooling capabilit Reduce a heating value output The contact of dud doct from user s unit Seung i Auto circulating controller EV1 E SS Failure in the refrigerant solenoid reset Failure in the compressor refrigerant gas charged and the The RUN Startup failure Rever f oe Reverse phase relay triggered Power voltage sag Other abnormalities in the compressor and electromagnetic controller Rise in ambient temperature Improve ambient conditions Avoid The contact of installing it at a place exposed to Temp rise in i direct sunlight or radiant heat Auto fan motor Improper rated cooling capability Reduce a heating value output reset open from user s unit Replace the fan motor Only apply to model HRG005 A 5 2 Troubleshooting HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 5 2 HRX OM H043 6 Unit Maintenance 6 Unit Maintenance 6 1 Control of water quality T
37. tions 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
38. to install wiring Be sure to disconnect the power for safety Wiring installation with the unit energized is strictly prohibitted 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 Supply the power to the unit from a reliable power source without surge or sag voltage 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 Ensure that the power supply meets the specification of the unit Always establish a ground for safety Do not connect the ground to a water line gas pipe or lighting conductor Do not branch off the wiring to make multiple circuits Potential hot spots or fire may occur if disregarded B 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 Table 3 1 Cable for power supply and current leakage itm HRGOOf A HRG002 A HRG005 A Power Signal Size 6 core 0 75 mm cable Fork terminal size 125Y 39 Capacity of GFCI breaker BA 7 Use the breaker with current sensitivity of 30mA at minimum 3 2 Installation HRGOO1 A HRGOO2 A HRGOO5 A 1 edition Dec 2003 3 4 HRX OM H043 3 Transport an
39. ure of a circulating fluid POWER LED Lights up when the power is supplied 6 ONjswitth This is used to run the unit 8 MODE key This is used to switch the screens between PV and SV 9 DOWN key This is used to decrease set temperature 2 2 Descriptions and functions of components HRG001 A HRG002 A HRG005 A 1 edition Dec 2003 2 4 HRX OM H043 3 Transport and Installation 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 t
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