SMC Networks HRGC001-A Series Operation Manual Download | Manualshive

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HRX-OM-L014

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st

edition: Jun. 2007

Operation Manual

Refrigerant Type Thermo-cooler

HRGC001-A

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HRGC001-W

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HRGC002-A

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HRGC002-W

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HRGC005-A

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HRGC005-W

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SMC Corporation

Keep this manual available whenever necessary.

© 2007 SMC CORPORATION All Rights Reserved

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Summary of Contents for HRGC001-A Series

Page 1: ...ion Jun 2007 Operation Manual Refrigerant Type Thermo cooler HRGC001 A HRGC001 W HRGC002 A HRGC002 W HRGC005 A HRGC005 W SMC Corporation Keep this manual available whenever necessary 2007 SMC CORPORATION All Rights Reserved ...

Page 2: ...on of the unit Only the person who understands basic operation of the unit through this manual or who performs installation and operation of or has basic knowledge about industrial machines is allowed to work on the unit This manual attached to the unit and its contents will not be a part of contract and accompany modification or change of existing agreement commitment or relation It is strictly p...

Page 3: ... 1 6 Emergency Measures 8 1 7 Disposal of waste 9 1 7 1 Recovery of refrigerant and compressor oil 9 1 7 2 Discarding the unit 9 1 8 Material Safety Data Sheet MSDS 9 Chapter 2 Name and Function of Parts 1 2 1 HRGC001 A HRGC002 A HRGC001 W and HRGC002 W 1 2 2 HRGC005 A and HRGC005 W 2 Chapter 3 Transport and Setting Up 1 3 1 Transport 1 3 2 Installation 3 3 2 1 Environment 3 3 2 2 Location 4 3 2 3...

Page 4: ...ating Fluid 7 Chapter 5 Operation 8 5 1 Operation panel 8 Chapter 6 Error Display and Remedy 1 6 1 Error Display 1 6 2 Remedy for Error 3 6 3 How to Reset Alarm 4 6 3 1 Reset by using RESET button 4 6 3 2 Reset of pump overload AL02 and compressor overload AL03 5 6 4 Other Errors 7 Chapter 7 Control Inspection and Cleaning 1 7 1 Control of Recirculating Fluid Quality 1 7 2 Inspection and Cleaning ...

Page 5: ...st edition Jun 2007 8 3 Electric Circuit Diagram 4 8 3 1 HRGC001 A HRGC002 A HRGC001 W and HRGC002 W 4 8 3 2 HRGC005 A and HRGC005 W 5 8 4 Flow Chart HRGC00 A 6 8 5 Flow Chart HRGC00 W 7 8 6 Applicable Regulations 8 8 7 Daily Check Sheet 9 Chapter 9 Product Warranty 1 ...

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Page 7: ...s which become hot and rotate If a component needs to be replaced or repaired contact a specific vendor for parts and service The operate s maintence personnel and other people working nearby the unit should read and understand the safety related descriptions in this manual carefully before starting work Safety manager is responsible to strictly observe safety standards but responsibility in respe...

Page 8: ...ould be carefully observed DANGER WARNING and CAUTION signs are in order according to seriousness DANGER WARNING CAUTION 1 3 2 Definition of Serious injury and Light injury Serious injury The injury that gives aftereffects including loss of eyesight burnt electrical shock fracture poisoning etc and requires long term treatment or hospitalization Light injury The injury that does not need long term...

Page 9: ...ng fingers or hand or entanglement by rotating fan The unit has a cooling fan that rotates during operation of the unit The fan can start and stop intermittantly and without warning DO NOT operate the unit without cover panels fitted This symbol stands for a possible risk of burn or hot surface The unit has surfaces that can reach high temperatures during operation Even after the power is turned o...

Page 10: ... 1st edition Jun 2007 Error Style not defined 4 1 3 4 Locations of Hazard Labels There are various warning labels on the unit to show the dangers Sign for warning related to heat Fig 1 1 Warning label position HRGC001 and HRGC002 Fig 1 2 Warning label position HRGC001 and HRGC002 Front Hazards Inside Rear Hazards Inside only for HRGC00 A ...

Page 11: ...002 A HRGC005 A Error Style not defined Error Style not defined 1st edition Jun 2007 Error Style not defined 5 Fig 1 3 Warning label position HRGC005 Fig 1 4 Warning label position HRGC005 Rear Hazards Inside only for HRGC005 A Front Hazards Inside Hanging warning 1 3 Hazard ...

Page 12: ...nit be sure to lock out and tag out the breaker of user s power supply If operating the unit during maintenance be sure to inform all workers nearby Use only the correct tools and procedure when installing or maintaning the unit Use personal protective equipment where specified 1 5 2 Personal Protective Equipment Check all parts and screws are fitted correctly and securely after maintenance Avoid ...

Page 13: ...e Equipment This manual specifies personal protective equipment for each work Transport Setting up and Removal Handling of recirculating fluid Operation Always use safety shoes gloves and head protection when transporting installing or removing the unit Always use safety shoes gloves mask apron and eye protection when handling the recirculating fluid Always use safety shoes and gloves when operati...

Page 14: ... and earthquake or injury occurs turn off the power supply The switch for the power supply is located at the front of the unit Press the switch for the power supply at the front of unit to stop the operation of the unit Fig 1 6 Location of the switch for the power supply Front OFF Even when the power supply is turned off the power circuit keeps energized partically unless the user s power supply i...

Page 15: ...ste disposal regulations within the country of disposal 1 8 Material Safety Data Sheet MSDS If the material safety data sheets of chemicals used in this unit are needed contact an SMC s sales distributor Any chemicals used by the user must be accompanied by an MSDS Only service personnel or qualified people are allowed to open the cover panels of the unit Do not mix the compressor oil with domesti...

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Page 17: ...entry Grommet Back Drain port Rc1 4 Manual bypass valve Recirculating fluid Supply Rc1 2 Right Recirculating fluid Return Rc1 2 Tank level indicator Operation panel Control box panel internal Tank lid top Overflow port Rc1 2 Air vent IN Air vent OUT Air vent OUT Front Cooling water outlet Rc1 2 Cooling water Inlet Rc1 2 Left Signal cable entry Grommet Power supply cable entry Grommet Back Drain po...

Page 18: ... cable entry Grommet Signal cable entry Grommet Drain port Rc1 2 Recirculating fluid Return Rc1 2 Manual bypass valve Recirculating fluid Supply Rc1 2 Back Air vent OUT Air vent OUT Eye bolt M12 accessory Overflow port Rc1 2 Front Left Control box panel internal Power supply cable entry Grommet Top Right Tank level indicator Operation panel Tank lid Drain port Rc1 2 Recirculating fluid Return Rc1 ...

Page 19: ...ecially pay attention to personal safety If a fork lift is used for transport check the fork is inserted in place as specified in Fig 3 1 Fork insertion position and hanging method At that time do not get the fork contact to the caster If eyebolt is used for lifting ensure all four eyebolts are used Keep hanging angle from each eyebolt 45 to 60o with attention to the postion of the center of gravi...

Page 20: ...HRGC001 A HRGC002 A HRGC005 A 1st edition Jun 2007 Error Style not defined 2 Fig 3 1 Fork insertion position and hanging method Fork insertion position Fork insertion position Fork insertion position Fork insertion position Hanging position only for HRGC005 Approx 60 o Approx 60 o Center of gravity of HRGC005 ...

Page 21: ...ith altitude over 1000m Conditions where the unit is subjected to vibrations or impact Condition where the unit is subjected to load or forces so much as to deform the unit Place without sufficient space available for maitenance Place where the air vents on the unit are blocked or covered A location outside of a building A place such as a clean room where the generation of dust and heat from equip...

Page 22: ...ion is under air conditioning make a duct for heat radiation on the air vent OUT of the unit At this time do not mount the inlet of the duct flange directly to the air vent of the unit and keep a space larger than the diameter of the duct Additionally consider the resistance of the duct when making the air vent port for the duct Table 3 1 Amount of radiation and required ventilation Required venti...

Page 23: ...GC002 A HRGC005 A Error Style not defined Error Style not defined 1st edition Jun 2007 Error Style not defined 5 3 2 3 Installation and Maintenance Space Considering the ease of maintenance it is recommended to keep the space shown in Fig 3 2 Fig 3 2 Maintenance space Front ...

Page 24: ...no vibrations Refer to 8 2 Outline Dimensions for dimensional information of the unit How to install the unit 1 Move the product in an installation area 2 Adjust the caster with adjuster A spanner with 17mm width across flat is required Ensure the product is in horizontal by using a level gauge Ensure the contact of all four casters with adjuster to the floor The caster with adjuser can be in cont...

Page 25: ...t to change the set values of safety devices such as thermal switchs It might cause the unit to become unsafe in a fault situation Do not connect the ground to water line gas pipe and lightening conductor Only qualified persons are allowed to wire the unit Be sure to cut off the user s power supply Wiring with the unit energized is strictly prohibitted The wiring must be conducted with cables comp...

Page 26: ...n 2007 Error Style not defined 8 How to conduct wiring 1 Loosen screws 6pcs and take off the front panel 8 pieces for HRGC005 2 Connect the power supply cable and signal cable as show in the figure below 図 3 4 Removal of front panel Fig 3 5 Electrical wiring Front panel Screws Screws Front Front Power supply cable entry Signal cable Power supply cable ...

Page 27: ...tput Remote operation Signal input Contact input Customer s Epuipment side Electrical unit Thermo cooler side Name Operation Close Run Open Stop Run Close Stop FOpen Power supply shut off FOpen Nomal Close Warning Open Power supply shut off Close Specification maximum load current DC24V 1A minimum load current DC5V 10mA Communication protocol Compliant EIA standard RS 485 Direction of infomation H...

Page 28: ...parately How to connect piping Hold the piping port firmly with a pipe wrench and tighten the piping Connect piping firmly Incorrect piping might cause leakage of supplied or drained leakage and wet surrounding area and facility Keep supply water pressure below 0 5MPa Be sure to correctly connect IN and OUT of recirculating fluid and cooling water only for HRGC00 W The reverse connection might pre...

Page 29: ... Rc1 2 2 Valve Rc1 4 3 Y shaped strainer or filter Rc1 2 4 Y shaped strainer accessory Rc1 2 5 Relieving valve Rc1 2 Set between 0 0 5 MPa 6 Pressure gauge 0 1 0 MPa 7 Flow meter 0 50 L min 8 Others Pipe hose etc I D φ15 or more Fig 3 8 Recommended piping circuit R e m a r k s The installation of the valve at the tank drain port makes it easier to drain the recirculating fluid from the tank The va...

Page 30: ...m there until the level of fluid reaches the range specified in liquid level indicator Fig 3 9 Opened tank lid Fig 3 10 Liquid level indicator HI G H LO W HI G H LO W Opening for level check Specified range Specified range Opening for level check HRGC001 and HRG002 HRGC005 Tank level indicator Front Ensure the fluid level in the tank stays between HIGH and LOW If the level becomes outside of the r...

Page 31: ...alified person is allowed for wiring Be sure to cut off the user s power supply The wiring with the unit energized is strictly prohibitted Drain all recirculating fluids in the unit for reinstallation Only the person who has sufficient knowledge and experience about the unit and its accessories is allowed for reinstallation Also read and understand the chapter 3 of this manual before transporting ...

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Page 33: ...y object on the unit and the external piping is not applying excessive force to the unit 4 1 2 Connection of cables Check the power cable ground and input output signal are correctly connected if used 4 1 3 Circulating fluid Check proper connection of piping at inlet and outlet 4 1 4 Facility water piping only for HRGC00 W Check proper connection of piping at inlet and outlet 4 1 5 Liquid level in...

Page 34: ... unit is switched on the operation panel displays the following conditions The POWER LED lights up The set value of recirculating fluid temperature is displayed as SV on the panel The present value of recirculating fluid temperature is displayed as PV on the panel The PV LED lights up Fig 4 1 Power supply switch Fig 4 2 Power supply POWER LED PV LED Digital display PV present recirculating fluid t...

Page 35: ...le not defined 1st edition Jun 2007 Error Style not defined 3 4 3 2 Setting of recirculating fluid temperature Press the DOWN and UP buttons on the operational panel to set the SV to required value Fig 4 3 Setting of recirculating fluid temperature UP button DOWN button Digital display SV set recirculating fluid temperature ...

Page 36: ... require a refill In that case refill the recirculating fluid in the following procedure 1 Press the PUMP button on the operation panel The PUMP LED lights up and the pump starts operating independently to supply the recirculating fluid from the tank to the user s machine and piping When the fluid level in the tank reaches the lower limit the FAULT LED lights up the alarm number AL04 low level in ...

Page 37: ...ing Port 3 Press the RESET button The alarm low level in tank is cleared and the pump can now be restarted using the PUMP button Fig 4 7 RESET button 4 Repeat the steps 1 to 3 until the user s machine piping and the unit s tank is filled with recirculting fluid Tank level must be within specified range shown on level indicator RESET button Tank lid Tank level indicator Front Ensure the fluid level...

Page 38: ...operation panel The unit starts operating to control the recirculating fluid temperature to the set value The RUN LED and PUMP LED on the operation panel light up Fig 4 8 Starting the unit 4 4 2 Stopping the unit 1 Press the STOP button on the operation panel The unit stops The RUN LED and PUMP LED on the operation panel light up Fig 4 9 Stopping the unit 2 Turn off the power supply switch All LED...

Page 39: ...w Rate The adjustment of recirculating fluid flow rate should be performed by the manual bypass valve and monitoring the pressure or flow rate in the user s machine until they reach required value If the flow rate remains higher than required even after fully opening the manual bypass valve install a valve for pressure adjustment on the discharge port of the unit and adjust it When an Alarm is see...

Page 40: ...ture 2 POWER LED Lights up when the power supply is turned on 3 RUN LED Lights up when the START button is pressed 4 PUMP LED Lights up when Pump running 5 PV LED Lights up when the recirculating fluid temperature is displayed 6 FAULT LED Lights up when fault error to stop the unit occurs 7 WARNING LED Lights up when warning error to continue the unit occurs 8 START button Start operating the unit...

Page 41: ...owing conditions When the FAULT LED lights up the unit stops and the RUN LED goes off the contact for operation signal output is opened the contact for fault error signal output is opened When the WARN indicator light turns ono the unit does not stop and continues operation the contact for alarm signal output is opened the alarm number condition of LED and signal output are as shown in Table 6 1 F...

Page 42: ...ay LED Off On Alarm number Content of alarm Set value Unit condition POWER RUN FAULT WARNING Operation signal output Fault error signal output Alarm signal output AL02 Pump overload Stop AL03 Compressor overload Stop AL04 Low level in tank Upper limit in tank Stop AL05 Refrigerant high pressure 2 6MPa Stop AL06 Fed water high temp 40 o C or more Stop Green Red Contact opened Contact opened Contact...

Page 43: ...lating fluid Leakage due failure of the pump mechanical seal Replace the mechanical seal The replacement method can be found in the maintenance manual available separately AL04 Low level in tank Level switch Failure of level switch Replace the level switch Clogging of condenser only for HRGC00 A Clean the condenser Too high ambient Temperature only for HRGC00 A Decrease the ambient temperature to ...

Page 44: ...Table 6 2 Also make the nessecarry change to the operating method and environment to aviod future alarms The pump overload AL02 and compressor overload AL03 can not be reset by only RESET button Move onto 6 3 2 The reset of high temp water in tank AL11 needs the replacement of the temperature fuse Refer to the maintenance manual available separately for the replacement Fig 6 2 Display of alarm num...

Page 45: ... front panel Front panel Screws Screws Front The unit is operated at high voltage and contains uncovered live terminals inside DO NOT operate the unit without cover panels fitted DO NOT work inside this unit unless you have been trained to do so The unit has surfaces that can reach high temperatures during operation Even after the power is turned off there can still be residual heat in the unit DO...

Page 46: ...h protection device in the electrical box Press it until it clicks Fig 6 5 Position of reset manual buttons HRGC001 A and HRGC002 A Fig 6 6 Position of reset manual buttons HRGC005 A 3 Press the RESET button The alarm is reset Reset button for pump overload AL02 Blue Reset button for compressor overload AL03 Yellow Front Reset button for pump overload AL02 Blue Reset button for compressor overload...

Page 47: ...wer supply switch is not turned on Turn on the power supply switch The GFCI is not turned on Turn on the GFCI No power supply The breaker for the power supply is not turned on Supply the power Insufficient capacity of breaker Install adequate breaker referring to Table 3 2 Trip of breaker due to short circuit and current leakage Repair the short circuited or current leaking part The POWER LED does...

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Page 49: ...s Iron mg L 0 3 or less 1 0 or less Copper mg L 0 1 or less 0 3 or less Sulfide ion mg L Not detected Not detected Ammonium ion mg L 0 1 or less 1 0 or less Residual chlorine mg L 0 3 or less 0 3 or less Referential item Separation carbonic acid mg L 4 0 or less 4 0 or less Quoted from JRA GL 02 1994 The Japan Refrigeration and Air Conditioning Industry Association Ｂ Use specified recirculating fl...

Page 50: ...is within a specified range on the indicator Check the display The numbers on the display are clear The POWER LED ligths up properly Operation panel Check the function The START and STOP buttons operate properly Recirculating fluid temperature Check on the operation panel There is no problem for use Operating conditions Check the operation condition There is no abnormal noise vibration smell and s...

Page 51: ... where the fin of the condenser gets clogged it is recommended to mount a dust proof filter set available as an accessory separately described in 7 3 Consumables 7 2 3 Inspection every 3 months Exchange of recirculating fluid Exchange of recirculating fluid if using fresh water on a regular basis to prevent the deteriation of the fluid and generation of bacteria Clean the tank on a regular basis C...

Page 52: ...ecirculating fluid with its power Then when the recirculating fluid temperature reaches 5 o C the pump will stop automatically As a result the recirculating fuid temperature is ketp between 3 and 5 o C and can be prevented from freezing 1 Keep the power supply on POWER LED ON RUN LED OFF 2 Fully open the valve and manual relief valve installed by user and make the condition where the recirculating...

Page 53: ...ding on their condition Table 7 3 Consumables Part number Name Qty Remarks HRG S0034 Mechanical seal set 1 Service part for HRGC005 7 4 Stop for a Long Time If there is concern that the unit is not operated for a long time or there is a chance of freezing conduct the following operations 1 Turn off the user s power supply breaker 2 Drain all recirculating fluid from the unit 3 After draining cover...

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Page 55: ...while alarm light remains OFF and during power off and contact opens while alarm light remains ON fault error stop function System stop function for pump overload Pump thermal relay System stop function for compressor overload compressor thermal relay System stop function for low level in tank level switch System stop function for refrigerant high pressure level switch System stop function for fed...

Page 56: ...001 A HRGC002 A HRGC005 A 1st edition Jun 2007 Error Style not defined 2 8 2 Outline Dimensions 8 2 1 HRGC001 A and HRGC002 A Fig 8 1 Outline Dimensions fig Error Style not defined 8 2 2 HRGC001 W and HRGC002 W Fig 8 2 Outline Dimensions fig Error Style not defined Error Style not defined 500 400 950 500 400 950 ...

Page 57: ...RGC002 A HRGC005 A Error Style not defined Error Style not defined 1st edition Jun 2007 Error Style not defined 3 8 2 3 HRGC005 A Fig 8 3 Outline Dimensions Error Style not defined 8 2 4 HRGC005 W Fig 8 4 Outline Dimensions Error Style not defined 595 550 1150 595 550 1150 ...

Page 58: ...2 Temp controller TIC MS2 Temperature sensor PT1 MS1 Magnetic Contactor CM Direct current power supply DCPS Capacitor Coil surge 1 4 CR Level switch Thermal relay LS1 TH1 Name CT input sensor input Temperature relay Pump RY5 relay Warning relay Run relay Fault PV change light Warning light Fault light PUMP light RUN light Power supply POWER light Stop STOP switch Run START switch EV2 EV1 input Pow...

Page 59: ...roller TIC MS2 Temperature sensor PT1 MS1 Magnetic Contactor CM Direct current power supply DCPS Capacitor Coil surge 1 4 CR Level switch Thermal relay LS1 TH1 Name CT input sensor input Temperature relay Pump RY5 relay Warning relay Run relay Fault PV change light Warning light Fault light PUMP light RUN light Power supply POWER light Stop STOP switch Run START switch EV2 EV1 input Power supply D...

Page 60: ...m ul ator Levelswi tch LevelI ndi cator Tank Pum p SV1 Sol enoi d val ve RV1 Regul ati ng val ve M anualO perati on C D R C api l l ary tube Fan m otor FAN1 EXV1 Therm ostati c expansi on val ve C D FAN1 PS1 Ai r Ai r R C M A D EV O ver f l ow PM RV1 C RV PS2 SV1 PT1 C RV C apaci ty Regurati ng val ve PRV PT1 Tem perature sensor PRV Proporti onalval ve PS1 H i gh pressure sw i tch Reci rcul ati ng...

Page 61: ...cul ati ng f l ui d Suppl y port LI LS1 EXV1 C D S PV outl et C ool i ng water i nl et C ool i ng water refri gerant C i rcui t for C i rcui t for H i gh pressure swi tch PS1 Proporti onalval ve PRV Tem perature sensor PT1 C apaci ty Regurati ng val ve C RV Therm ostati c expansi on val ve EXV1 PV W ater controlval ve C api l l ary tube R C D Regul ati ng val ve M anualO perati on RV1 Sol enoi d v...

Page 62: ... A 1st edition Jun 2007 Error Style not defined 8 8 6 Applicable Regulations The unit complies with the following regulations Table 8 2 Applicable regulations EMC directive 89 336 EEC Revised to 92 31 EEC 93 68 EEC Low voltage directive 73 23 EEC Revised to 93 68 EEC CE marking Machinery directive 98 37 EC UL E229305 UL 1995 scheduled ...

Page 63: ...heck of 6 2 1 Daily Check in Chapter 6 Control Inspection and Cleaning Check and record the condition at start right after setting up Thermo cooler Daily Check Sheet Model no Mfg code Operation conditions Presence of error Recirculating fluid temp Fluid amount Inside Outside of liquid level indicator range Humidity Temp Performed by Date Rightafter setting up initial value Result Operation Display...

Page 64: ...HRX OM L014 Error Style not defined Error Style not defined Error Style not defined Error Style not defined HRGC001 A HRGC002 A HRGC005 A 1st edition Jun 2007 Error Style not defined 10 ...

Page 65: ...The following situations are out of scope of this warranty 1 The product was incorrectly installed or connected with other equipment 2 The product was under insufficient maintenance and control or incorrectly handled 3 The product was operated outside of the specifications 4 The product was modified or altered in construction 5 The failure was a secondary failure of the product caused by the failu...

Page 66: ...he customer and SMC 6 Request to customers Proper use and maintenance are essential to assure safe use of this product Be sure to satisfy the following preconditions Please note that we may refuse to carry out warranted repair if these preconditions have been disregarded 1 Use the product following the instructions for handling described in the Operation Manual 2 Perform checks and maintenance dai...

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