HRX-OM-J049-A
1st edition: Aug. 2006
Rev. A: May. 2007
Operation Manual
Water-refrigerated Thermo cooler
HRG010-W
HRG015-W
SMC Corporation
Save This Manual Carefully for Use at Any Time
© 2006 SMC CORPORATION All Rights Reserved
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HRX-OM-J049-A
Table of Contents
Table of Contents
Chapter 1 Safety Instructions...........................................................1-1
1.1 Before Using this Unit............................................................................................. 1-1
1.2 Danger, Warning and Caution................................................................................. 1-2
1.2.1
1.2.2
1.2.3
Level of risk ......................................................................................................................... 1-2
Definitions of “Serious injury” and “Minor injury” ................................................................. 1-2
Symbols............................................................................................................................... 1-3
1.3 Hazard Warning Label............................................................................................. 1-4
1.3.1
1.3.2
1.3.3
Classification of risks........................................................................................................... 1-4
Type of hazard warning labels ............................................................................................ 1-5
Location of hazard warning label ........................................................................................ 1-6
1.4 Model label............................................................................................................... 1-6
1.5 Safety Measures...................................................................................................... 1-7
1.5.1
1.5.2
Safety Precautions .............................................................................................................. 1-7
Protective equipment........................................................................................................... 1-8
1.6 Emergency Measures.............................................................................................. 1-9
1.7 Disposition of Waste............................................................................................. 1-10
1.7.1
1.7.2
1.7.3
Recovery of refrigerant and compressor oil ...................................................................... 1-10
Circulating fluid disposal.....................................................................................................1-11
System disposal .................................................................................................................1-11
1.8 Material Safety Data Sheet (MSDS) .......................................................................1-11
Chapter 2 Appearance and Each Section........................................2-1
2.1 Appearance.............................................................................................................. 2-1
2.2 Name of Each Section............................................................................................. 2-2
2.2.1
2.2.2
HRG010-W.......................................................................................................................... 2-2
HRG015-W.......................................................................................................................... 2-3
2.3 Control panel ........................................................................................................... 2-4
Chapter 3 Transport and Installation................................................3-1
3.1 Transport.................................................................................................................. 3-1
3.1.1
3.1.2
Transporting with forklift and unit lifting............................................................................... 3-2
Transporting with caster ...................................................................................................... 3-3
3.2 Installation ............................................................................................................... 3-4
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
Installation conditions.......................................................................................................... 3-4
Installation location.............................................................................................................. 3-5
Installation location and maintenance work area ................................................................ 3-6
Installation ........................................................................................................................... 3-7
Electrical wiring ................................................................................................................... 3-9
Piping................................................................................................................................. 3-13
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
TOC-1
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HRX-OM-J049-A
Table of Contents
3.2.7
3.2.8
Supply of circulating fluid...................................................................................................3-15
Reinstallation of unit ..........................................................................................................3-16
Chapter 4 Startup and Shutdown..................................................... 4-1
4.1 Pre-check..................................................................................................................4-1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
Installation condition ............................................................................................................4-1
Electric wiring.......................................................................................................................4-1
Facility water piping .............................................................................................................4-1
Piping for circulating fluid.....................................................................................................4-1
Supply of circulating fluid.....................................................................................................4-1
4.2 Preparation for startup ............................................................................................4-2
4.2.1
4.2.2
4.2.3
Power supply .......................................................................................................................4-2
Setting of circulating fluid temperature ................................................................................4-2
Additional water supply........................................................................................................4-3
4.3 Unit Startup and Shutdown .....................................................................................4-4
4.3.1
4.3.2
Starting the unit....................................................................................................................4-4
Stopping the unit..................................................................................................................4-4
4.4 Check at startup.......................................................................................................4-5
Chapter 5 Error Message and Troubleshooting.............................. 5-1
5.1 Error Message..........................................................................................................5-1
5.2 Troubleshooting.......................................................................................................5-2
5.3 Alarm Reset (Alarm Lamp OFF)..............................................................................5-3
5.4 Recovery from Power Failure (POWER Lamp ON) ................................................5-6
Chapter 6 Unit Maintenance ............................................................. 6-1
6.1 Control of Water Quality..........................................................................................6-1
6.2 Inspection and Cleaning..........................................................................................6-2
6.2.1
6.2.2
6.2.3
6.2.4
Daily inspection....................................................................................................................6-3
Quarterly inspection.............................................................................................................6-4
Biannual inspection..............................................................................................................6-4
Check during wintertime ......................................................................................................6-5
6.3 Consumables ...........................................................................................................6-6
6.4 Long-term Storage...................................................................................................6-6
Chapter 7 Documents ....................................................................... 7-1
7.1 Standard Specifications ..........................................................................................7-1
7.2 Optional Specifications ...........................................................................................7-3
7.3 Outline Dimensions .................................................................................................7-4
7.3.1
HRG010-W, HRG010-W-B, HRG010-W-C, HRG010-W-BC HRG015-W, HRG015-W-B,
HRG015-W-C, HRG015-W-BC............................................................................................7-4
7.3.2
HRG010-W-A□, HRG015-W-A□.......................................................................................7-4
7.4 Electric Circuit..........................................................................................................7-5
7.4.1
HRG010-W, HRG015-W......................................................................................................7-5
HRG010-W HRG015-W
1st edition : Aug. 2006
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Table of Contents
7.4.2
HRG010-W-BC, HRG015-W-BC......................................................................................... 7-6
7.5 Flow Chart................................................................................................................ 7-7
7.6 Daily Inspection Sheet ............................................................................................ 7-8
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
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HRX-OM-J049-A
Table of Contents
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
TOC-4
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HRX-OM-J049-A
Chapter 1 Safety Instructions
Chapter 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
This chapter describes the safety-related items that users should be aware of upon
handling this unit.
z
This unit is an isothermal fluid circulation system housed in the tank. SMC’s
liability under this warranty shall not be available for troubles caused by use for
purposes other than the original intent.
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
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.
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
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.
Save this manual at a designated place for reference when necessary.
z
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1.1 Before Using this Unit
1-1
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HRX-OM-J049-A
Chapter 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 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 unit, facility, or devices.
[Tips]
Tips are provided when there is information personnel are required to be
aware of for system operation and maintenance. If the task carries useful
information, the relevant tips are given as well.
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
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
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HRX-OM-J049-A
Chapter 1 Safety Instructions
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
This symbol warns you of possible risk caused by a
rotating object.
„ Symbol of “Don’ts”
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.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1.2 Danger, Warning and Caution
1-3
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HRX-OM-J049-A
Chapter 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
„ High voltage hazards
The unit is operated at high voltage and may cause an electrical shock. The
attached label contains the symbol
.
Only operate the unit with the cover panel attached.
The unit contains the power supply carrying high voltage inside that is
isolated with the cover panel.
Only trained personnel are allowed to work, including unit inspection,
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
.
There is the presence of the surface in the unit that is at high
temperatures during operation. Potential burns may occur if touched.
Residual heat may cause burns despite the power being turned OFF.
Be sure of the surface reaching room temperature before work.
„ 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 contains a section which rotates when it is in action. Potential
personal injury may occur if touched. A rotator is structured to come
to a temporary stop and resume rotation.
Avoid performing work during system operation.
1.3 Hazard Warning Label
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
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HRX-OM-J049-A
Chapter 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
Fig. 1-1 Warning Label on the Front Panel
„ Warning label for high voltage
Fig. 1-2 Warning Label for High Voltage
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1.3 Hazard Warning Label
1-5
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HRX-OM-J049-A
Chapter 1 Safety Instructions
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 Left
Warning label on the
front panel
Front
Fig. 1-3 Location of Hazard Warning Label
1.4 Model label
Check the model no. described on the label.
Front
Fig. 1-4 Location of Model Label
1.4 Model label
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1-6
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HRX-OM-J049-A
Chapter 1 Safety Instructions
1.5 Safety Measures
1.5.1 Safety Precautions
While this system is protected by various safety measures, the following basic safety
precautions should be observed to assure further safe operations.
Follow the following instructions upon operation of this system.
Failure to follow the instructions can lead to personal injury or
hazardous accidents.
Read and understand this manual thoroughly before operation of this system.
z
z
Before operating the system during maintenance, inform all personnel who are
working in the vicinity of the system to alert them of your action.
Use appropriate tools and follow proper procedures.
z
z
See “1.5.2 Protective equipment”on page 1-8 to wear protective equipment
properly.
Refer to your safety manual for emergency evacuation.
Use assistance to carry object over 20 kg.
z
z
z
Check that all parts and screws are returned to the pre-work conditions at the end
of work.
Do not work when intoxicated or feeling ill. Accidents may occur if disregarded.
Do not remove a panel unless permitted in this manual.
z
z
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1.5 Safety Measures
1-7
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HRX-OM-J049-A
Chapter 1 Safety Instructions
1.5.2 Protective equipment
This manual defines protective equipment according to work type.
Wear proper protective equipment as shown below, according to work type.
Read and understand the relevant operation manual thoroughly prior
to use of protective equipment.
„ For system transportation, installation and removal
z Protective footwear
z Protective gloves
z Hard hat
„ For handling circulating fluid
z Protective footwear
z Protective apron
z Protective gloves
z Protective goggles
z Protective mask
„ For system operation
z Protective footwear
z Protective gloves
1.5 Safety Measures
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1-8
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Chapter 1 Safety Instructions
1.6 Emergency Measures
Press the [OFF] switch on the control panel located on the front of the thermo cooler
only if the need to shut off the power arises due to emergency such as natural
disaster, fire, earthquake or personal injury.
With the press of the [OFF] switch, the thermo cooler comes to a stop. The power
supply, however, is designed not to stop, which enables the motor circuit to remain
partially energized.
Make sure to turn off the main power supply (main breaker) before proceeding with
the next task.
1.
Press the [OFF] switch on the control panel to bring the thermo cooler to a stop.
[RUN] LED
[PUMP] LED
[OFF] LED
Fig. 1-5 Thermo Cooler OFF
2.
Always turn off the main breaker (for your power supply equipment).
Switch it off.
Fig. 1-6 Main Power Shutdown (Breaker OFF)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1.6 Emergency Measures
1-9
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Chapter 1 Safety Instructions
1.7 Disposition of Waste
1.7.1 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.
Only service personnel or qualified personnel are allowed to open the
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, 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.
[Tips]
The type and amount of used freon can be found on the label.
1.7 Disposition of Waste
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
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Chapter 1 Safety Instructions
1.7.2 Circulating fluid disposal
As to the disposal of a circulating fluid (ethylene glycol solution), consign the
specialized industrial waste disposal agency with the contents detailed.
1.7.3 System disposal
As to the disposal of this system, consign the specialized industrial waste disposal
agency in accordance with law on Waste Disposal and Cleaning.
1.8 Material Safety Data Sheet (MSDS)
Material Safety Data Sheet (MSDS) is supplied separately. Contact the system
supplier if you need the MSDS regarding chemicals used in this system.
For each chemical you purchased, the relevant MSDS is to be obtained under your
responsibility. Keep the MSDS along with this manual in the condition that allows
all personnel to check the contents anytime to gain the understanding of potential
hazards.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1.8 Material Safety Data Sheet (MSDS)
1-11
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Chapter 1 Safety Instructions
1.8 Material Safety Data Sheet (MSDS)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
1-12
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HRX-OM-J049-A
Chapter 2 Appearance and Each Section
Chapter 2 Appearance and Each Section
2.1 Appearance
Top
Left
Back
Front
Right
Fig. 2-1 Appearance of HRG010-W
Top
Left
Back
Front
Right
Fig. 2-2 Appearance of HRG015-W
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
2.1 Appearance
2-1
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HRX-OM-J049-A
Chapter 2 Appearance and Each Section
2.2 Name of Each Section
2.2.1 HRG010-W
Top
Y-shaped strainer Rc1/2
(accessory)
Refrigerant high
pressure gauge
Power/signal connection
terminal block
Eyebolt M12
Circulating fluid
pressure gauge
Control panel
Facility water IN Rc1/2
Facility water OUT Rc1/2
Electrical unit
Auto supply port Rc1/2
Ventilating hole
Circulating fluid OUT Rc3/4
Circulating fluid RETURN
Rc3/4
Level gauge
Manual relief valve
Power cable access
(Cable Grip)
Signal cable access
(Cable Grip)
Tank
Port for overflow Rc1/2
Handle
4-Ø13
(For anchor bolt)
Tank drain port Rc1/2
(plugged)
Right
Left
Front
Fig. 2-3 Name of Each Section (HRG010-W)
2.2 Name of Each Section
HRG010-W HRG015-W
1st edition : Aug. 2006
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Chapter 2 Appearance and Each Section
2.2.2 HRG015-W
Top
Y-shaped strainer Rc1/2 (accessory)
Eyebolt M12
Refrigerant high
pressure gauge
Power/signal connection
terminal block
Circulating fluid
pressure gauge
Control panel
Facility water IN Rc1/2
Facility water OUT Rc1/2
Electrical unit
Auto supply port Rc1/2
Ventilating
hole
Circulating fluid OUT Rc3/4
Circulating fluid RETURN
Rc3/4
Level gauge
Manual relief valve
Power cable access
(Cable Grip)
Signal cable access
(Cable Grip)
Tank
Port for overflow Rc1/2
Right
Handle
4-Ø13
(For anchor bolt)
Tank drain port Rc1/2
(plugged)
Left
Front
Fig. 2-4 Name of Each Section (HRG015-W)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
2.2 Name of Each Section
2-3
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Chapter 2 Appearance and Each Section
2.3 Control panel
The control panel on the system front allows you to perform basic system operation
including temperature adjsutment, system start and stop.
Fig. 2-5 Control Panel
Table 2-1 Control Panel
No.
Name
Function
PV
SV
Indicates actual temperature of a circulating fluid
Indicates set temperature of a circulating fluid
1
Digital display, PV / SV
2
3
4
5
6
[POWER] LED
[RUN] LED
Lights up when the power is supplied.
Lights up when the [ON] switch is pressed.
[PUMP] LED
[ALARM 1] LED
[ALARM 2] LED
[ALARM 3] LED
[ON] switch
Lights up when an alarm 1 arises.
Lights up when an alarm 2 arises.
Lights up when an alarm 3 arises.
This is used to run the unit.
7
8
9
[OFF] switch
[MODE] key
[DOWN] key
[UP] key
This is used to stop the unit.
10
11
12
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.
* See “Chapter 5 Error Message and Troubleshooting” for alarms 1 to 3.
2.3 Control panel
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
2-4
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HRX-OM-J049-A
Chapter 3 Transport and Installation
Chapter 3 Transport and Installation
The unit must be handled in correct manner.
Exercise caution to asure personnel safety during the installation,
operation, maintenance, and inspection of the unit.
Only personnel with sufficient knowledge and experiences with the
unit and unit 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 “Forklift Insertion Position and Unit
Lifting”.
z If eyebolts are used for lifting, ensure the unit is held at four points.
z Keep each eyebolt at an angle from Min. 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.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.1 Transport
3-1
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Chapter 3 Transport and Installation
3.1.1 Transporting with forklift and unit lifting
Lifting position
Min. 60°
Min. 60°
Forklift insertion side
Front
Forklift insertion side
Fig. 3-2 Forklift Insertion Position and Unit Lifting
3.1 Transport
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-2
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Chapter 3 Transport and Installation
3.1.2 Transporting with caster
„ HRG010-W-A / HRG015-W-A (caster-mounted option)
This unit is heavy, which requires assistance for this work. Exercise
caution and look out for sloped surfaces including ramps.
Do not grab piping or panel handles when transporting the sytem with
the casters.
Potential damage to piping and panels may occur if disregarded.
1.
Push the corners of this unit with the adjusters uplifted.
The unit becomes disengaged so that it can be transported with casters.
Turn 360°.
Turn 360°.
Caster w/ adjuster
Front
Uplift the adjuster.
Handle
Pipe port
Fig. 3-3 Caster-mounted Option
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.1 Transport
3-3
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Chapter 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 unit.
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
z
z
z
z
z
z
z
Environment that is exposed to corrosive gas, flammable gas or solvent
Environment that is exposed to direct sun light or radiant heat
Environment where ambient temperature is out of the specified range between 5°C to 40°C
Environment that is subjected to abrupt changes in temprature
Environment that is subjected to strong electromagnetic noise (incl. strong electrical field,
strong magnetic field, or surge voltage)
Environment that generates static electricity, or condition in which static electricity
discharges to the unit
z
Environment that generates strong high frequencies
Environment at high altitudes of over 1000m
z
z
z
z
z
z
Condition which allows strong vibrations and impacts to transmit to the unit
Condition with external force or load to deform the unit
Condition with an insufficient maintenance space as required
Condition with no adequate space for ventilation
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-4
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.2 Installation location
A water-refrigerated thermo cooler is designed to exhaust heat
through a supply of facility water.
Secure water sources listed below.
„
Required water sources
Table 3-1 Heat Discharge and Required Quantity of Facility Water (HRG010-W, HRG015-W)
Heat discharge
(kW)
Required water
quantity (L/min)
Model
Facility water temp. range (°C)
HRG010-W
HRG015-W
Approx. 16
Approx. 23
34
40
5 to 32
(Rated temp.: 25)
„
Outside installation
HRG010 and HRG015 are IPx3-compliant rainproof systems but not rendered complete
waterproof. Install the system out of direct sunlight as well as direct rain and snow (e.g. under
the eaves).
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.2 Installation
3-5
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.3 Installation location and maintenance work area
Installation with maintenance space is recommended. (See Fig. 3-4)
Ensure an adequate ventilation space for the temperature controller.
Failure to create sufficient space may lead to improper cooling and/or
controller stop.
Access maintenance work area should be required for maintenance.
Top
Min. 800mm
Min. 800mm
Front
Fig. 3-4 Recommended Installation Location
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-6
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.4 Installation
Preparation of anchor bolts suitable for floor material is your
responsibility.
Prepare M12-anchor bolts (4 pcs.) for installation. See “ 7.3 Outline
Dimensions” for mounting of the anchor bolts.
Keep the unit away from vibration. Install the unit on a flat and stable surface.
Refer to “7.3 Outline Dimensions” for the dimensions of the unit.
z
z
„ Procedure for Installation
1.
The anchor bolts (foundation bolts) are mounted on the level concrete foundation.
Lower this unit, inserting the anchor bolts into the unit.
2.
3.
Tighten the hexagonal nut to secure the unit onto the foundation.
Make sure of no looseness between the anchor bolts and foundation.
Anchor bolt mounting hole (Ø13)
Base
Hexagonal nut
Anchor bolt
Front
Concrete foundation
Fig. 3-5 Procedure for Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.2 Installation
3-7
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HRX-OM-J049-A
Chapter 3 Transport and Installation
„ HRG010-W-A / HRG015-W-A (caster-mounted option)
As to the HRG010-W-A or HRG015-W-A (caster-mounted option), the
adjusters should be lowered to secure the system after installation.
Lower the adjusters to secure the system.
Caster w/ adjuster
Fig. 3-6 HRG010-W-A / HRG015-W-A (Caster-mounted Option)
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-8
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.5 Electrical wiring
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 unit 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
Standard Specifications”.
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.
Table 3-2 Cable for Power Supply and Current Leakage
Item
HRG010-W
4- core 8 mm2
8 - 4S
HRG015-W
4- core 14 mm2
14 - 5S
Size
Power cable
Signal cable
Round crimp contact size
Size
6- core 0.75 mm2
1.25Y - 3
Y-shaped crimp contact size
Capacity of GFCI breaker *
40A
60A
* Use the breaker with current sensitivity of 30mA at minimum.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.2 Installation
3-9
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HRX-OM-J049-A
Chapter 3 Transport and Installation
„ How to conduct wiring
1.
Undo the screws (6 pcs.) and take off the front panel.
Screw
Electrical unit
Screw
Front panel
Front
Fig. 3-7 Removal of Front Panel
2.
Connect the power supply cable and signal cable as shown in the figure.
Power cable
Signal cable
Signal cable access
Front
Power cable access
Fig. 3-8 Electrical Wiring
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-10
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HRX-OM-J049-A
Chapter 3 Transport and Installation
„ 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 “7.4 Electric Circuit” for the electrical circuit of the unit.
•
HRG010-W
User’s preparation
Electrical unit
ELB/Current leakage breaker
Power supply input
Power supply
cable
Electrical circuit
FG (Frame ground)
Remote operation signal input
(Remote start upon input of DC+24V)
Remote stop upon input of DC 0V)
Remote operation input circuit
Error deteced stop signal output, relay contact
(normally open, closed for error
Contact closed during power-off)
Operation signal output, relay contact
(normally close, opened for error
Contact open during power-off)
Signal cable
Error detected stop
signal output circuit
Operation signal output circuit
I/O board
Fig. 3-9 Electrical Wiring Diagram (HRG010-W)
•
HRG015-W
Electrical unit
User’s preparation
ELB/Current leakage breaker
Power supply input
Power supply
cable
Electrical circuit
FG (Frame ground)
Remote operation signal input
(Remote start upon input of DC+24V)
Remote stop upon input of DC 0V)
Remote operation input circuit
Remote operation input circuit
Signal cable
Error detected stop signal output, relay contact
(normally open, closed for error
Contact closed during Power-off)
Operation signal output, relay contact
(normally close, opened for error
Contact open during power-off)
Operation signal output circuit
I/O board
Fig. 3-10 Electrical Wiring Diagram (HRG015-W)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.2 Installation
3-11
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HRX-OM-J049-A
Chapter 3 Transport and Installation
„ Procedures for communication cable wiring installation (RS485)
HRG010-W-C / HRG015-W-C (communication feature-laden option)
The communication cables are to adhere to specifications shown below.
Table 3-3 Communication Cable
Item
Specifications
Shielded twisted-pair wire (0.75mm2)
1.25Y-3
Size
Y-shaped crimp contact size
Communication cable
1.
Connect the power cables properly, as shown below.
Communication cable
Signal cable access
(communication cable access)
Front
Fig. 3-11 Communication Cable Wiring
2.
Have the converters listed below available. Establish connection with the computer (with a
RS232C terminal).
Table 3-4 Converter (Example)
Item
Specifications
Part number: KS-485
Manufacturer: System Sacom
RS232C ⇔ RS485 converter
Connecting connector
D-sub 9-pin (male)
Part number:AR-305
Manufacturer: Arvel
Computer ⇔ Converter coupling cable
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-12
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.6 Piping
Only expert engineers or personnel who have adequate knowledge of
and experiences with piping installation are allowed to install piping.
Potential fluid leakage or stagnant fluid may occur if disregarded.
z Install piping properly. Failure to conduct proper piping installation
may result in the entry of supplied and drained water into the inside
of the building, which may cause the work area and equipment to
get wet.
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.
z Hold the piping connected port with a pipe wrench when tightening
piping.
„ Pipe diameter
Table 3-5 Pipe diameter
Diameter
Recommended
tightening torque
28 to 30N·• m
28 to 30N·• m
28 to 30N·• m
28 to 30N·• m
28 to 30N·• m
28 to 30N·• m
28 to 30N·• m
Pipe
HRG010-W HRG015-W
Facility water IN
Facility water OUT
Auto supply port
Circulating fluid OUT
Circulating fluid RETURN
Port for overflow
Rc1/2
Rc1/2
Rc3/4
Rc3/4
Rc1/2
Rc3/4
Rc3/4
Rc1/2
Rc1/2
Port for drain in tank
„ How to install piping
1.
Hold the piping connected port with a specific wrench and tighten the pipe.
Pipe coupling hole
Sealant
Fig. 3-12 Tightening of Pipe
[Tips]
Install a valve at the drain port to facilitate the replacing and draining of the circulating fluid from the
tank described in chapter 6 “Unit Maintenance”. (The valve needs to be prepared separately.)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.2 Installation
3-13
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HRX-OM-J049-A
Chapter 3 Transport and Installation
„ Recommended piping installation
Facility water IN
Facility water
Fluid supply
Facility water OUT
Auto supply port
Circulating fluid OUT
Circulating fluid RETURN
Load device
Port for overflow
Tank drain port
To the drain port
Fig. 3-13 Recommended Piping Installation
Table 3-6 Recommended Piping Installation
Size
No.
Name
HRG010-W
Rc1/2
HRG015-W
1
2
3
4
5
6
7
Valve
Rc3/4
Rc3/4
Y-shaped strainer
Pressure gauge
Valve
Relieving valve
Y-shaped strainer
Flow meter
Rc1/2
0 to 1.0 MPa
Rc3/4
Rc3/4, set from 0 to 0.5 MPa
Rc3/4
Rc3/4, 0 to 100 L/min
[Tips]
Optional accessories listed below are available for the relieving valves shown
in Fig. 3-12 “Recommended Piping Installation”. Separate order for optional
accessories is to be placed upon designing the piping system if used for
piping installation.
Table 3-7 Allied Products
Part No.
Name
Qty.
1 set
1 set
Note
HRG-BP010 Bypass (relieving valve) piping set
HRG-BP015 Bypass (relieving valve) piping set
HRG010 optional accessory
HRG015 optional accessory
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-14
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.7 Supply of circulating fluid
1.
Open the supply valve laid with pipes.
The fluid supply takes place with the use of the ball tap housed in the tank and stops automatically.
Keep the fluid level in the tank between “HIGH” and “LOW”.
If the circulating fluid is out of the range, the fluid may overflow.
Ensure piping is installed to the overflow outlet and drain pit.
Indicating range
Level gauge
Fig. 3-14 Level Gauge
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3.2 Installation
3-15
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HRX-OM-J049-A
Chapter 3 Transport and Installation
3.2.8 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.
3.2 Installation
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
3-16
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HRX-OM-J049-A
Chapter 4 Startup and Shutdown
Chapter 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.
4.1.1 Installation condition
Make sure the unit is installed horizontally.
z
z
Do not put any heavy object on the unit or apply excess force by piping.
4.1.2 Electric wiring
Check that the power cable, ground and I/O signal cables are correctly connected.
4.1.3 Facility water piping
Check the I/O piping of the facility water is installed correctly.
4.1.4 Piping for circulating fluid
Check the I/O piping of the circulating fluid is installed correctly.
4.1.5 Supply of circulating fluid
Check the fluid level is within the specified range shown on the level indicator.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
4.1 Pre-check
4-1
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HRX-OM-J049-A
Chapter 4 Startup and Shutdown
4.2 Preparation for startup
4.2.1 Power supply
1.
Supply the power.
The following conditions are observed on the control panel upon power-ON.
After 4-sec display of the initial screen on the digital displays PV and SV, temperature and set temperature
of the circulating fluid will be displayed..
z
The [POWER] lamp comes on in 6 sec.
z
Digital display PV (circulating fluid temp.)
[POWER]LED
Digital display SV (set temp.)
Fig. 4-1 Power Supply
4.2.2 Setting of circulating fluid temperature
1.
Press the [UP] and [DOWN] keys to set a desired temperature in the digital display SV.
Digital display SV (set temp.)
[DOWN]key
[UP] key
Fig. 4-2 Setting of Circulating Fluid Temperature
Note: Circulating fluid setting temp.range is 5 to 35°C.
z
4.2 Preparation for startup
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
4-2
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HRX-OM-J049-A
Chapter 4 Startup and Shutdown
4.2.3 Additional water supply
„ [TS] switch (pump manual operation switch)
This unit 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
(green)
Front
Fig. 4-3 [TS] switch (pump manual operation 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.
The [ALARM1] lamp comes on (error). The lamp goes out with the press of the [RS] switch after the
circulating fluid reaches the range specified on the level indicator.
z
See “Chapter 5 Error Message and Troubleshooting” for error messages.
z
Control panel
Reset SW [RS]
(yellow button)
Front
Fig. 4-4 Location of Reset Switch (Yellow Button)
2.
Supply the circulating fluid again according to section “3.2.7Supply of circulating fluid”.
If leakage occurs due to faulty piping including an opened fitting of eternal piping,
stop manual operation of the pump and fix the leak.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
4.2 Preparation for startup
4-3
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HRX-OM-J049-A
Chapter 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.
[RUN] LED
[PUMP] LED
[ON] switch
Fig. 4-5 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. 4-6 Stopping the Unit
4.3 Unit Startup and Shutdown
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
4-4
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HRX-OM-J049-A
Chapter 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 main power supply off.
No leak from circulating fluid piping
z
z
z
No circulating fluid flowing out of the overflow outlet and tank drain port
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, circulating fluid 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
Fig. 4-7 Bypass Valve
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
4.4 Check at startup
4-5
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HRX-OM-J049-A
Chapter 4 Startup and Shutdown
„ Bypass (relieving valve) piping set
[Tips]
Bypass (relieving valve) piping sets listed in table 3-7 “Allied Products” are of
use for the omission of manual bypass valve adjustment.
[Tips]
Relieving valve
The relieving valve automatically opens when the circulating fluid outlet
pressure of the thermo cooler surpasses the set value. The relieving valve is
designed to bypass the circulating fluid that prevents a pressure rise during
fluid flow at low rate.
4.4 Check at startup
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
4-6
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
Chapter 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.
or
or
[POWER] LED
[ALARM 2] LED
or
[POWER] LED
[ALARM 3] LED
or
[ALARM 1] LED
Fig. 5-1 Control Panel
Table 5-1 Error Message
LED
(z: Off, {: On)
POWER RUN ALARM1 ALARM2 ALARM3
Operation Error stop
Setting
range
System
status
Alarm
signal
output
signal
output
Open
contact
Closed
contact
Open
Closed
contact
Closed
contact
Open
Power error
-
-
Stopped
{
{
{
{
{
{
{
{
{
{
{
{
Start-up failure
Stopped Greenz
Reverse of pump
and compressor
-
Stopped Greenz
Redz
contact
contact
Lower limit of
fluid level in Stopped Greenz
Tank fluid level
drop
Open
contact
Open
contact
{
{
Redz
{
{
{
{
the tank
Suspension of
facility water
supply
Open
contact
Open
contact
-
Stopped Greenz
Redz
Open
contact
Open
contact
Open
Open
contact
Open
contact
Open
Pump overload
-
Stopped Greenz
Stopped Greenz
Stopped Greenz
{
{
{
{
{
{
Redz
Redz
{
{
{
High temp. of
supplied fluid
Compressor
overload
40°C and
over
-
Redz
contact
contact
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5.1 Error Message
5-1
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Chapter 5 Error Message and Troubleshooting
5.2 Troubleshooting
See “5.3 Alarm Reset” for error recovery.
Table 5-2 Troubleshooting
Alarm reset
Error
Cause
Remedies
Detector
HRG
．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
With the switch in its ON position, supply the
．．．．
main power. Only qualified personnel are
No power is supplied.
allowed for power wiring.
-
Supply 3-phase power (R- and
．．．．
Power error
-
Open phase
S-phases).Only qualified personnel are
allowed for power wiring.
Overcurrent
Ground fault
Request for service. Turn ON the breaker.
Manual reset
*1)
Request for service. Turn ON the breaker.
．．．．
Start-up
failure
Supply a rated voltage. Only qualified
personnel are allowed for power wiring.
Low voltage
-
-
Reverse of
pump and
compressor
Incorrect phase
sequence of power
wiring
Inadequate quantity of
the fulid in the tank, or
drop in the tanked fluid
level
Rewire the power cable for two of three
phases (phase sequence). Only qualified
personnel are allowed for power wiring.
．．．．
Manual reset
(yellow
button)
*3)
Auto reset
*2)
Tank fluid
level drop
Replenish the circulating fluid (fresh water).
Press the reset button of the high pressure
Manual reset
(yellow
button)
*3)
Suspension of Supplied facility water
facility water falls short of its specified cutoff switch.
supply
Manual reset
(red button)
*1)
volume.
Supply facility water standing at 5 to 32°C.
Press the reset button of the pump
Abnormal rise in fluid
supply pressure
electromagnetic switch (MS1). Adopt a pipe
size suitable for circulating fluid flow, or,
adjust the opening of the manual relief valve.
Manual reset
(yellow
button)
*3)
Manual reset
(blue button)
*1)
Pump
overload
Failure in the pump
motor
Request for service.
Improve ambient conditions to provide
ventilation and exhaust heat. Keep the unit
out of direct sunlight and radiant heat.
Abnormal rise in ambient
temperature
Excessive calorific value
of the chiller
Refrigerant leak
Compressor error
Failure in the
electromagnetic switch
Other errors in the
refrigerating circuit
Failure in the temp.
controller
Reduce a calorific value output from your unit.
Manual reset
(yellow
button)
*3)
Request for service.
Request for service.
High temp. of
supplied fluid
Auto reset
*2)
Request for service.
Request for service
Request for service.
Press the [RESET] button of the compressor
electromagnetic switch (MS2). Reduce a
calorific value output from your system.
Excessive calorific value
Compressor of the chiller
Manual reset
(yellow
button)
*3)
Manual reset
(blue button)
*1)
overload
Failure in the
compressor motor
Request for service.
*1)
*2)
*3)
The recovery from an error capable of manual alarm reset takes place with the use of the switch and reset
button after the cause (such as fluid level drop or abnormal temperature) is eliminated.
The recovery from an error capable of automatic alarm reset takes place when the cause (such as fluid level
drop or abnormal temperature) is eliminated after waiting period.
With the tripped detector located, be sure to press the [RESET] button (yellow button) of the system electrical
unit after the elimination of the error cause. The alarm lamp goes out that enables the unit to resume.
5.2 Troubleshooting
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5-2
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
5.3 Alarm Reset (Alarm Lamp OFF)
„ Error check
1.
Check the alarm number currently activated, and eliminate the error cause (see Table 5-2).
Adjust the unit usage and service condition.
or
[POWER] LED
[ALARM2] LED
or
[RUN] LED
[ALARM3] LED
or
[ALARM1] LED
Fig. 5-2 Alarm Lamps (ON)
[ALARM1] ON ......................... Installation error
[ALARM2] ON ......................... Circulating fluid circuit error
[ALARM3] ON ......................... Refrigerating circuit error
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5.3 Alarm Reset (Alarm Lamp OFF)
5-3
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
2.
Undo the screws (6 pcs.) to remove the front panel.
Only operate the unit with the cover panel attached.
The unit contains the power supply carrying high voltage inside that is
isolated with the cover panel.
Only trained personnel are allowed to work, including unit inspection,
around the power supply.
There is the presence of the surface in the unit that is at high
temperatures during operation. Potential burns may occur if touched.
Residual heat may cause burns despite the power being turned OFF.
Be sure of the surface reaching room temperature before work.
The unit contains a section which rotates when it is in action. Potential
personal injury may occur if touched. A rotator is structured to come
to a temporary stop and resume rotation.
Avoid performing work during system operation.
Screw
Electrical unit
Screw
Front panel
Front
Fig. 5-3 Removal of Front Panel
5.3 Alarm Reset (Alarm Lamp OFF)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5-4
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
3.
Press the Reset switch [RS] (yellow button) on the control panel and make sure that the
alarm lamp goes out.
Control panel
Reset switch [RS]
(yellow button)
Front
Fig. 5-4 Location of Reset Switch [RS] (Yellow Button)
„ When the alarm lamp goes out by performing steps 1. to 3.
4.
5.
Attach the front panel.
Implement system startup and shutdown according to “Chapter 4 Startup and Shutdown”.
„ When the alarm lamp remains on after performing steps 1. to 3.
6.
7.
Press the reset button of each detector in the electrical unit.
Follow step 3. to press the Reset switch [RS] (yellow button).
The alarm lamp goes out accordingly.
8.
Implement system startup and shutdown according to “4.3 Unit Startup and Shutdown”.
Pump overload reset button
(blue button)
Compressor overload reset
button (blue button)
Front
Facility water supply suspension
reset button (red button)
Fig. 5-5 Location of Reset Switch [RS] (Yellow Button)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5.3 Alarm Reset (Alarm Lamp OFF)
5-5
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
5.4 Recovery from Power Failure (POWER Lamp ON)
„ Power error check
1.
Request an expert engineer to eliminate the cause of a power failure (such as a ground
falut and overcurrent).
[POWER] LED
[ALARM2] LED
[RUN] LED
[ALARM3] LED
[ALARM1] LED
Fig. 5-6 POWER Lamp (OFF)
[POWER] lamp OFF ............. Power supply error (power failure)
2.
Turn on the main power breaker of your unit, and ensure the [POWER] lamp comes on.
5.4 Recovery from Power Failure (POWER Lamp ON)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5-6
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
„ [HRG010-W-B / HRG015-W-B (earth leakage breaker-mounted option)]
1.
Undo the screws (6 pcs.) to remove the front panel.
Only operate the unit with the cover panel attached.
The unit contains the power supply carrying high voltage inside that is
isolated with the cover panel.
Only trained personnel are allowed to work, including unit inspection,
around the power supply.
There is the presence of the surface in the unit that is at high
temperatures during operation. Potential burns may occur if touched.
Residual heat may cause burns despite the power being turned OFF.
Be sure of the surface reaching room temperature before work.
The unit contains a section which rotates when it is in action. Potential
personal injury may occur if touched. A rotator is structured to come
to a temporary stop and resume rotation.
Avoid performing work during system operation.
Screw
Electrical unit
Screw
Front panel
Front
Fig. 5-7 Removal of Front Panel
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5.4 Recovery from Power Failure (POWER Lamp ON)
5-7
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HRX-OM-J049-A
Chapter 5 Error Message and Troubleshooting
2.
Check the earth leakage breaker on the electrical board of the electrical unit.
Earth leakage breaker
(optional)
Electrical unit
Front
Fig. 5-8 Location of Earth Leakage Breaker (Optional)
3.
4.
Switch off the earth leakage breaker once.
Switch in the OFF position
Front
Fig. 5-9 Earth Leakage Breaker (OFF)
Switch on the earth leakage breaker, and make sure that the [POWER] lamp comes on.
Switch in the ON position
Front
Fig. 5-10 Earth Leakage Breaker (ON)
5.4 Recovery from Power Failure (POWER Lamp ON)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
5-8
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HRX-OM-J049-A
Chapter 6 Unit Maintenance
Chapter 6 Unit Maintenance
6.1 Control of Water Quality
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)
Facility water
Substances
Circulating fluid spec.
spec.
pH (25°C)
Electrical conductivity (25°C) (µs/cm)
Chloride ion (mgCl-/L)
6.5 to 8.2
6.0 to 8.0
100 (*1) to 300 (*2)
50 and below
50 and below
50 and below
70 and below
50 and below
30 and below
0.3 and below
1.0 and below
100 (*1) to 800
200 and below
200 and below
100 and below
200 and below
150 and below
50 and below
1.0 and below
0.3 and below
2-
Sulfuric acid ion (mgSO4 /L)
Acid consumption (pH4.8) (mgCaCO3/L)
Total hardness (mgCaCO3/L)
Calcium hardness (mgCaCO3/L)
Ion silica (mgSiO2/L)
Standard
Iron (mgFe/L)
Copper (mgCu/L)
Sulfide ion (mgS2-/L)
Not detected
+
Ammonium ion (mgNH4 /L)
1.0 and below
0.3 and below
4.0 and below
0.1 and below
0.3 and below
4.0 and below
Residual chlorine (mgCl/L)
Free carbon dioxide (mgCO2/L)
Filtering (μm)
5 and below
* Refrigeration and Air Conditioning Equipment Water Quality
Guideline JRA-GL-02-1994
(*1) Electrical conductivity: Min. 100[μS/cm]
(*2) 0.003 to 0.01 if the unit of M[Ω•cm] is used.
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.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
6.1 Control of Water Quality
6-1
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HRX-OM-J049-A
Chapter 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.
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
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
6-2
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HRX-OM-J049-A
Chapter 6 Unit Maintenance
6.2.1 Daily inspection
Perform daily inspection of the items listed in the Table 6-2. If the check finds any
abnormal event, stop system operation and turn off the main power supply.
Request for service promptly.
Table 6-2 Daily Inspection
Inspection item
Inspection method
No heavy object is placed on this unit. This unit
should not be subjected to external force.
Installation
condition
Check of the condition of
unit installation
Temperature and humidity fall within the specified
range.
Check of the piping
connector section
No leak of facility water and circulating fluid from the
piping connector sections
Fluid leak
Confirm the reading on the
level indicator
Water supply
The fluid level falls within the specified range.
The diplsay assures sharp image and numbers.
The lamp is ON.
Display check
Function check
Operation panel
Circulating fluid
temperature
Confirm the reading on the Normal temperature should be assured for system
LCD screen
use.
Confirm the reading on the
circulating fluid pressure
gauge
Circulating fluid
outlet pressure
Normal pressure should be assured for system use.
Confirm the reading on the
refrigerant high pressure
gauge
Refrigerant high
pressure
Normal flow rate should be assured for system use.
No abnormal noise, vibration, odor and smoke
Operating
condition
Operating condition check
Check of facility water
condition
Temperature, flow rate, and pressure fall within the
specified range.
Facility water
If the above check finds any abnormal event, bring the unit to a halt and turn off
the main breaker. Make sure to perform lockout and tagout before requesting
technical service.
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
6.2 Inspection and Cleaning
6-3
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HRX-OM-J049-A
Chapter 6 Unit Maintenance
6.2.2 Quarterly inspection
„ Replacement of circulating fluid
Periodic replacement of circulating fluid (fresh water)
z
Potential algae growth or aqueous corrosion may occur if the old fluid is reused.
Assure a periodic replacement of the fluid according to the situation.
Cleaning of tank
z
Check the circulating fluid in the tank for impurities and foreign matters, and
the tank for slime inside. Assure a periodic cleaning of the tank.
„ Cleaning of facility water
Water quality standards for faciliry water should fall within specifications.
z
z
Assure a periodic cleaning of faciliry water equipment and a periodic
replacement of faciliry water.
6.2.3 Biannual inspection
„ 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.
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).
6.2 Inspection and Cleaning
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
6-4
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HRX-OM-J049-A
Chapter 6 Unit Maintenance
6.2.4 Check during wintertime
„ Antifreeze of circulating fluid
This unit is resistant to freezing of the circulating fluid during wintertime and
nighttime.
Ensure the following measures are taken in advance if potential frost damage may
occur in response to changes in the installation and use environments (including
operating period and weather).
1.
2.
Leave the power on (the [POWER] lamp remains on, and the [RUN] lamp remains off).
Fully open valves laid with pipes on your unit to allow the circulating fluid to flow upon
automatic pump operation.
„ Antifreeze function (automatic pump operation)
(1) After performing steps 1.and 2., automatic pump operation takes place when the circulating
fluid drops 3°C or below.
(2) The circulating fluid is heated by pump power output.
The pump comes to an automatic stop when the circulating fluid reaches 5°C or higher.
(3) The circulating fluid is allowed to be in the 3- to 5-°C range in temperature that is resistant to
freezing.
z Contact expert engineers.
Complete prevention of freezing the fluid may if the unit is installed
in an intensely cold place.
The above usage conditions require an addition of other antifreezing
unit (such as a commercial tape heater).
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
6.2 Inspection and Cleaning
6-5
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HRX-OM-J049-A
Chapter 6 Unit Maintenance
6.3 Consumables
Replace the following parts in response to the level of wearing out at inspection.
Table 6-3 Consumables
Part number
HRG-S0034
HRG-S0035
Part
Qty.
1 set
1 set
Remarks
Service part for HRG010
Service part for HRG015
Mechanical seal set
Mechanical seal set
6.4 Long-term Storage
Follow the procedures below for long-term storage of the unit or for anti-freezing
of the fluid during wintertime.
1.
2.
3.
Turn off the main power breaker.
Undo the tank drain hole plug to drain the fluid.
Remove the top front panel. Open the internal valve (for draining facility water) to drain
facility water. Drain facility water from the overflow outlet completely.
4.
Cover the unit with a plastic sheet for storage after draining is completed.
6.3 Consumables
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
6-6
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HRX-OM-J049-A
Chapter 7 Documents
Chapter 7 Documents
7.1 Standard Specifications
Table 7-1 Standard Specifications (1/2)
HRG010-W
Item
HRG015-W
32°C (5 to 40°C)
Fluid used
45 to 75%RH (No condensation)
Circulating fluid/fresh water (tap water) or fluids resistant to corrosion of a wetted surface
(such as SUS304 and PVC)
Rated capacity of tank
Supply voltage
40L
50L
3-phase AC200(50Hz), AC200 to 220V (60Hz)
60A, 30mA
4.7/5.8 - 5.8 kW
18.0/19.0 – 19.0A
4.7/5.8 - 5.8kWh/h
Supply temp.: 25°C (5 to 32°C),
Flow rate: Max. 38/40L/min,
IN/OUT differential pressure: Max. 0.25/0.2MPa,
Max. supply press.: 0.3 to 0.4MPa, Exhaust heat:
Approx. 23W
Remote operation starts upon application of DC24V and 8 mA, and stops at DC0V.
20±1.0°C (only under given load condition)
5 to 35°C
14.5/16.5kW
(50/60 Hz, 20°C at outlet, 42/54L/min of flow)
Pumping capacity
- (0.75kW of pump motor output only)
Max. head: 50/50m (50/60Hz, 0/0L/min of flow, 0.49/0.49MPa of supply pressure)
42/54L/min
(50/60Hz, 25/25m of the max. head,
0.28/0.31MPa of supply pressure)
54/65L/min
(50/60Hz, 0/0m of the max. head,
0.05/0.09MPa of supply pressure)
Relay contact ( AC250V of contact capacity, 1A, resistance load. Contact closes during operation,
and contact opens during stop and during power-off.)
Output
Relay contact (AC250V of contact capacity, 1A, resistance load. Contact closes while alarm light
remains OFF and during power-off, and contact opens while alarm light remains ON.)
Combined use of temperature control through compressor operation (ON/OFF) and capacity
control through solenoid valve control (ON/OFF)
Temperature control
7segment digital display, capable of display in 0.1°C increments
PV (operating temp.): 4-digit display in green, SV (set temp.): 4-digit display in red
Other display lamps: ALARM1 to 3 individual display in the event of an error)
Range: -0.1 to 3.5 MPa
Range: 0 to 1.0 MPa
Level indicator
SMC Ø-10 tube TU1065C (transparent)
HRG010-W HRG015-W
7.1 Standard Specifications
1st edition : Aug. 2006
Rev. A: May. 2007
7-1
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HRX-OM-J049-A
Chapter 7 Documents
Table 7-1 Standard Specifications (2/2)
HRG010-W
Item
HRG015-W
System stop function for low tank level (tank level switch),
pump/compressor reverse rotation detection (phase relay)
Protection against refrigerant pressure rise
(with a high pressure cutoff SW configured to control pressure to 3.0MPa)
System stop function for pump overload (overcurrent relay), system stop function for abnormal
circulating fluid temperature rise (set temp. of the temperature controller: 43°C)
System stop function for compressor overload (overcurrent relay)
Protection against supply pressure rise (with a manual relief valve), Antifreezing temperature
control (with an auto pump opera on temperature controller)
SGCC (Munsell 10Y8/0.5 Urban white)
Emergency
stop
External panel
Operation panel
Base
SGCC (DIC183 Blue)
SECC (Munsell 10Y6/0.5 Urban gray)
SUS (tank, circulating fluid IN/OUT), BC (pump
impeller, pump casing, hose fitting), PVC Nylon
12, Synthetic rubber (pipe hose), Polyurethane
(limnimeter)
Refrigerant used
C1220T
R407C (HFC)
1700±20g
Eye bolt M12 × 4 pcs., Y-shaped strainer Rc3/4
× 1 pcs., nipple for strainer piping 3/4 × 1 pcs
(A power supply, signal cable and connection terminal must be prepared under your responsibility.)
Accessories
Weight
200kg
220kg
7.1 Standard Specifications
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7-2
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Chapter 7 Documents
7.2 Optional Specifications
„ Caster
Table 7-2 Caster with Brake
Specifications
Item
For HRG010-W-A, HRG015-W-A
63mm
Wheel diameter
Turning radius of the caster
Adjuster height adjustable
range
59mm (single)
0 to 12.5mm
Caster: SPCC,
Wheel: Nylon
Materials
(Base with casters: SUS304)
Allowable load
520kg (130kg per caster, 4 pcs.)
„ GFCI breaker
Table 7-3 GFCI Breaker
Specifications
Item
For HRG010-W-B
For HRG015-W-B
Pole
3
Rated sensed current
Rated interrupting current
Operating time in the event of a
ground fault
30mA
40A
60A
0.04s (rated sensed ground-fault current)
Mechanical button
Display type
„ Communication
Table 7-4 RS485 Communication
Specifications
Item
For HRG010-W-C, HRG015-W-C
Adhering to EIA specification and RS-485
Enabled (default)
Spec.
BCC check function
Data length
8 bits (default)
Parity check function
Stop bit length
Disabled (default)
2 bits (default)
Baud rate
9600bps (default)
Communication address
Delay transmission
Communication mode
Connector number
Connector type
1 station (default)
0msec (default)
Writing and reading enabled (default)
37, 38
M4 terminal block
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7.2 Optional Specifications
7-3
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Chapter 7 Documents
7.3 Outline Dimensions
7.3.1 HRG010-W, HRG010-W-B, HRG010-W-C, HRG010-W-BC
HRG015-W, HRG015-W-B, HRG015-W-C, HRG015-W-BC
Top
Left
Front
Right
Fig. 7-1 Outline Dimensions
7.3.2 HRG010-W-A□, HRG015-W-A□
Top
Left
Front
Right
Fig. 7-2 Outline Dimensions
7.3 Outline Dimensions
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7-4
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HRX-OM-J049-A
Chapter 7 Documents
7.4 Electric Circuit
7.4.1 HRG010-W, HRG015-W
Fig. 7-3 Electric Circuit (HRG010-W, HRG015-W)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7.4 Electric Circuit
7-5
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Chapter 7 Documents
7.4.2 HRG010-W-BC, HRG015-W-BC
Fig. 7-4 Electric Circuit (HRG010-W-BC, HRG015-W-BC)
7.4 Electric Circuit
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7-6
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Chapter 7 Documents
7.5 Flow Chart
„ HRG010-W, HRG015-W
Sym
bol
Name
Pressure water
regulating valve
PV
S
Strainer
Auto supply
CM Compressor
Facility water IN
CD Water condenser
HPS High pressure SW
D
Refrigerant dryer
Thermal expansion
valve
EXV
EV Evaporator (cooler)
Accumulator
SV Solenoid valve
Capillary tube
A
Facility water OUT
Circulating fluid OUT
R
Circulating fluid RETURN
CRV Capacity control valve
Tank drain
Over flow
Refrigerant high
pressure gauge
P1
T
Tank
Facility water and Circulating fluid flow
Refrigerant flow
BT Ball tap
LS Level SW
PM Pump
RV Manual relief valve
LI
TI
Limnimeter
Temperature sensor
Circulating fluid
pressure gauge
P2
Fig. 7-5 Flow Chart (HRG010-W, HRG015-W)
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7.5 Flow Chart
7-7
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Chapter 7 Documents
Daily Inspection Sheet
7.6 Daily Inspection Sheet
HRG010-W HRG015-W
1st edition : Aug. 2006
Rev. A: May. 2007
7-8
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Product Warranty
1. Warranty
If a failure is observed in our Thermo Cooler, repair shall be provided in accordance with the warranty period
and preconditions defined below at SMC’s option.
Repair involves the inspection and/or replacement and/or modification of a defective part.
Removed parts shall become the possession of SMC.
2. Warranty period
The warranty period of the product shall be 1 year from the date of your purchase.
3. Warranty exemption
SMC’s liability under this warranty shall not be available for the following troubles and damages.
(1) Troubles or damage caused by the neglect of our designated inspection (daily inspection, periodic inspection)
(2) Troubles or damages caused by mishandling such as using improper operating procedure and using with our
specifications violated
(3) Troubles or damages caused by unauthorized modification.
(4) Troubles or damages caused by the use of a not-designated circulating fluid and facility water
(5) Troubles or damages caused by wearing out such as fading on the coated or plated surface
(6) Sensory phenomena that are considered no effect on the functions (such as noise, vibration)
(7) Troubles or damages caused by natural disaster such as earthquake, typhoon, water, inevitable events and fire
(8) Troubles or damages occurred under the installation conditions defined in the Operation Manual
(9) Troubles or damages that are not compliant with the “5. Warranty preconditions”
4. Escape clause
(1) Expenses of daily inspection and periodic inspection
(2) Expenses of repair consigned with neither SMC nor our authorized service station
(3) Expenses of transport, installation, and removal of this system
(4) Expenses of removal of non-genuine parts and replenishment of non-genuine fluids
(5) Unavailability and loss due to this system being disabled
(such as telephone bill, leave compensation, commercial loss)
(6) Expenses and compensation for terms other than provided in “1. Warranty”
5. Warranty precondition
Proper use and inspection of this system is required to assure safe use of this system. System warranty shall
satisfy the following preconditions. Please take note that warranted repair shall not be available if these
preconditions are disregarded.
(1) System operation shall be conducted by following operating procedure defined in the Operation Manual.
(2) Daily and periodic inspections designated in the Operation Manual shall be made as scheduled.
(3) Inspection record shall be entered in the Daily Inspection Sheet provided in the Operation Manual.
6. Request for warranted repair
As to warranted repair, please contact the supplier you purchased this system from for service.
Warranted repair shall be on request basis.
Unrequited repair shall be provided in accordance with the warranty period, preconditions and terms defined above.
Therefore, the repair service shall be available on a chargeable basis if a failure is detected after the warranty period.
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