SMC Networks HRG001-W User manual

HRX-OM-J022
1st edition：Jul. 2005
Rev. A：Sep.2006
Operation Manual
Water-refrigerated Thermo cooler
HRG001-W
HRG002-W
HRG005-W
SMC Corporation
Save This Manual Carefully for Use at Any Time
© 2005 SMC CORPORATION All Rights Reserved

To the Customers
Thank you for purchasing our THERMO COOLER (hereinafter called “This unit”).
For efficient and long use of the unit, be sure to read and understand this operation manual (hereinafter
referred to as “this manual”) and ensure well understanding of the contents.
●All warnings and precautions defined in this manual shall be observed.
●This manual provides instructions for the installation and operation of the unit. Only personnel who
understand basic operation described in this manual are qualified to perform the installation and
operation of 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.
●All SMC’s obligation is covered by Sales Agreement, which is only document to guarantee the content
described on the agreement.
●Any description of this manual will not be additional guaranteed item and modify existing document for
warranty.
●Copying, duplicating or transferring any part of or whole contents of this manual without SMC
Corporation’s permission is strictly prohibited.
Note: The contents of this manual are subject to change without notice.

HRX-OM-J022
Table of Contents
HRG001-W HRG002-W HRG005-W
1st edition :Jul. 2005 Table of Contents-1
Table of Contents
1. Safety Instructions......................................................................1-1
1.1 BEFORE USING THIS UNIT...............................................................................................1-1
1.2 DANGER,WARNING AND CAUTION .................................................................................1-2
1.2.1 Level of risk......................................................................................................................... 1-2
1.2.2 Definitions of “serious injury” and “minor injury”.................................................................. 1-2
1.2.3 Symbols............................................................................................................................... 1-3
1.3 HAZARD WARNING LABEL .............................................................................................1-4
1.3.1 Classification of risks........................................................................................................... 1-4
1.3.2 Type of hazard warning labels ............................................................................................ 1-5
1.3.3 Location of hazard warning label ........................................................................................ 1-6
1.4 MODEL LABEL ...............................................................................................................1-6
1.5 DISPOSITION OF WASTE .................................................................................................1-7
1.5.1 Recovery of refrigerant and compressor oil........................................................................ 1-7
1.5.2 Disposal of unit.................................................................................................................... 1-7
2. Descriptions of Components......................................................2-1
2.1 APPEARANCE OF UNIT ...................................................................................................2-1
2.1.1 HRG001-W / HRG002-W.................................................................................................... 2-1
2.1.2 HRG005-W.......................................................................................................................... 2-1
2.2 DESCRIPTIONS AND FUNCTIONS OF COMPONENTS...........................................................2-2
2.2.1 HRG001-W / HRG002-W.................................................................................................... 2-2
2.2.2 HRG005-W.......................................................................................................................... 2-3
2.2.3 Control panel....................................................................................................................... 2-4
3. Transport and Installation...........................................................3-1
3.1 TRANSPORT ..................................................................................................................3-1
3.2 INSTALLATION................................................................................................................3-3
3.2.1 Installation conditions.......................................................................................................... 3-3
3.2.2 Installation ........................................................................................................................... 3-4
3.2.3 Electrical wiring ................................................................................................................... 3-4
3.2.4 Piping................................................................................................................................... 3-7
3.2.5 Supply of circulating fluid.....................................................................................................3-8
3.2.6 Reinstallation of unit............................................................................................................ 3-9
4. Startup and Shutdown ................................................................4-1
4.1 PRE-CHECK...................................................................................................................4-1
4.1.1 Installation condition............................................................................................................ 4-1
4.1.2 Connection of cable.............................................................................................................4-1
4.1.3 Piping for cooling water....................................................................................................... 4-1

HRX-OM-H043
Table of Contents
HRG001-A HRG002-A HRG005-A
1st edition : Dec. 2003
Table of Contents-2
4.1.4 Piping for circulating fluid.....................................................................................................4-1
4.1.5 Level indicator (for level in the tank)....................................................................................4-1
4.2 PREPARATION OF STARTUP............................................................................................4-2
4.2.1 Power supply.......................................................................................................................4-2
4.2.2 Setting of circulating recirculating fluid temperature............................................................4-2
4.2.3 Additional water supply........................................................................................................4-3
4.3 UNIT STARTUP AND SHUTDOWN.....................................................................................4-4
4.3.1 Starting the unit....................................................................................................................4-4
4.3.2 Stopping the unit..................................................................................................................4-4
4.4 CHECK AT STARTUP.......................................................................................................4-5
5. Error Message and Troubleshooting.........................................5-1
5.1 ERROR MESSAGE..........................................................................................................5-1
5.2 TROUBLESHOOTING.......................................................................................................5-2
6. Unit Maintenance.........................................................................6-1
6.1 CONTROL OF WATER QUALITY........................................................................................6-1
6.2 INSPECTION AND CLEANING ...........................................................................................6-2
6.2.1 Daily inspection....................................................................................................................6-3
6.2.2 Monthly inspection...............................................................................................................6-4
6.2.3 Biannual inspection..............................................................................................................6-4
6.3 STORAGE......................................................................................................................6-5
6.4 CONSUMABLES .............................................................................................................6-5
7. Documents................................................................................... 7-1
7.1 SPECIFICATIONS LIST.....................................................................................................7-1
7.2 OUTLINE DIMENSIONS....................................................................................................7-2
7.2.1 HRG001-W and HRG002-W ...............................................................................................7-2
7.2.2 HRG005-W..........................................................................................................................7-2
7.3 ELECTRIC CIRCUIT DIAGRAM ..........................................................................................7-3
7.3.1 HRG001-W and HRG002-W ...............................................................................................7-3
7.3.2 HRG005-W..........................................................................................................................7-4
7.4 FLOW CHART.................................................................................................................7-5
7.4.1 HRG001-W and HRG002-W ...............................................................................................7-5
7.4.2 HRG005-W..........................................................................................................................7-5

HRX-OM-J022
1 Safety Instructions
HRG001-W HRG002-W HRG005-W 1.1 Before using this unit
1st edition :Jul. 2005 1-1
1. Safety Instructions
1.1 Before using this unit
zThis chapter describes the safety-related items that users should be
aware of upon handling this unit.
zThe unit is a circulating water chiller. SMC’s liability under this warranty
shall not be available for troubles caused by mishandling.
zThe unit operates under high voltage and contains components that
cause a rise in temperature and rotate. If a component needs to be
replaced or repaired, contact to a specific vendor.
zAll personnel who work on or around this unit are required to read and
understand the safety-related items in this manual before working with
this unit.
zThis manual is not for comprehensive safety and hygiene education.
Such a manual should be provided by a safety training manager.
zAll 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.
zA safety manager is responsible to strictly observe safety standards.
Operators and service technicians have individual responsibilies for their
safety during operation of this unit in his/her daily work.
zOperators must individually take account of safety and assure a proper
working area and working environment.
zSave this manual at a designated place for reference when necessary.
Be sure to read and understand all the important precautions in this
manual before operating the unit.

HRX-OM-J022
1 Safety Instructions
1.2 Danger, Warning and Caution HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
1-2
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.
1.2.2 Definitions of “serious injury” and “minor injury”
“Serious injury”
This term describes injuries such as loss of eyesight, wound, burns,
electrical shock, fracture, 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)
"DANGER" means that there is an immimence hazard that will cause serious
personal injury or death during operation.
"WARNING" means that there is a hazard that may cause serious personal injury or
death during operation.
"CAUTION" means that there is a hazard that may cause minor personal injury
during operation.
"CAUTION" without an exclamation symbol means that there is a hazard that may
cause damage or failure of this unit, facility, or devices.

HRX-OM-J022
1 Safety Instructions
HRG001-W HRG002-W HRG005-W 1.2 Danger, Warning and Caution
1st edition :Jul. 2005 1-3
1.2.3 Symbols
This manual provides the following symbols in addition to “DANGER” ,”WARNING”, “CAUTION” and
“IMPORTANT” to present the warning details in easy-to-understand manner.
Symbol of electrical hazard
Symbol of heat hazard
Symbol of rotating shaft hazard
Symbol of “Don’ts”
Symbol of “Dos”
This symbol denotes the items that must not be
implemented.
This symbol denotes the “obligation” items which
you must follow in operation of this unit.
This symbol warns you of possible risk of electrical
shock.
This symbol warns you of potential burns.
This symbol warns you of possible risk caused by a
rotary object.

HRX-OM-J022
1 Safety Instructions
1.3 Hazard Warning Label HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
1-4
1.3 Hazard Warning Label
The hazard warning labels indicate where potential hazards are present
during unit operation and maintenance. Be sure to read the labels and
recognize the locations of the labels before starting work.
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 .
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
.
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 .
Do not operate the unit without the cover panel mounted.
The unit contains the power supply carrying high voltage inside that is
isolated with the cover panel. Unit operation without the cover panel
allows the high votage to apply outside and cause injuries.
Only trained personnel are allowed to work around the power supply.
This symbol indicates the presence of a section where temperature
reaches high and the operator sustains burns when coming in contact.
Even after the power is turned off, residual heat may still cause burns.
The work must not be started until the section drops to sufficiently low
temperature.
The unit includes several parts which rotate during operation, and the
operator who comes in contact may get injured. Even if that part
seems to stop rotating, avoid touching it because the condition may
be tem
p
orar
y
and the rotation ma
y
restart.

HRX-OM-J022
1 Safety Instructions
HRG001-W HRG002-W HRG005-W 1.3 Hazard Warning Label
1st edition :Jul. 2005 1-5
1.3.2 Type of hazard warning labels
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
Do not remove or deface the warning labels.
Read the contents of the hazard warning labels with care to keep them
in mind.

HRX-OM-J022
1 Safety Instructions
1.4 Model label HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
1-6
1.3.3 Location of hazard warning label
Fig. 1-3 Location of hazard warning label
1.4 Model label
Check the model no. described on the label.
Fig. 1-4 Location of model label
Front
Warning label for high
voltage
Warning label on the
front panel
zRecognize where the hazard warning labels are attached.
zThe 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.
Front

HRX-OM-J022
1 Safety Instructions
HRG001-W HRG002-W HRG005-W 1.5 Disposition of waste
1st edition :Jul. 2005 1-7
1.5 Disposition of waste
1.5.1 Recovery of refrigerant and compressor oil
The unit belongs to Class 1 in the “Fluorocarbon Recovery and Destruction Law” and uses freon type
refrigerant (HFC) and compressor oil. When these fluids need to be recovered, read the instructions
below and ensure thorough understanding of them. If you have any questions, contact the local
distributor or SMC’s sales branch.
1.5.2 Disposal of unit
If the unit needs to be discarded, consign a specialized industrial waste
disposal agency in accordance with local laws and regulations.
Remarks
The type and amount of used freon can be found on the label.
Only service personnel or qualified personnel are allowed to open the
cover panel of the unit.
Only personnel with sufficient knowledge and experiences with the
unit and associated equipment are allowed to recover refrigerant and
compressor oil.
Do not mix the compressor oil with domestic waste for disposition.
Also, incineration is permitted only at an authorized incinerator.
Comply with municipal ordinances or regulations to dispose of waste.
The release of refrigerant to atmosphere is banned by law. If the
refrigerant needs to be removed for repair of the unit, recover it with
specific equipment and request a specialized waste disposal agency
for disposal of the recovered refrigerant. A person must have proper
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se
to
pe
rf
o
rm r
e
fri
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r
a
n
t
r
eco
v
er
y
.

HRX-OM-J022
1 Safety Instructions
1.5 Disposition of waste HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
1-8

HRX-OM-J022
2 Descriptions of Components
HRG001-W HRG002-W HRG005-W 2.1 Appearance of unit
1st edition :Jul. 2005 2-1
2. Descriptions of Components
2.1 Appearance of unit
2.1.1 HRG001-W / HRG002-W
Fig. 2-1 Appearance of unit (HRG001-W / HRG002-W)
2.1.2 HRG005-W
Fig. 2-2 Appearance of unit (HRG005-W)
Front Right
Back
Left
Top
Right
Back
Top
Left
Front

HRX-OM-J022
2 Descriptions of Components
2.2 Descriptions and functions of components HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
2-2
2.2 Descriptions and functions of components
2.2.1 HRG001-W / HRG002-W
Fig. 2-3 Piping connection port (HRG001-W/ HRG002-W)
Y-strainer 1/2
Top
FrontLeft Right
4-φ13
（For anchor bolt）
Tank drain port Rc1/2
Port for overflow Rc1/2
Circulating fluid return Rc1/2
Bypass valve
Circulating fluid OUT Rc1/2
Tank lid
Level indicator
Control panel
Electrical unit
Power cable access
(Filmed grommet)
Single cable access
(Filmed grommet)
Cooling water OUT Rc1/2
Cooling water IN Rc1/2

HRX-OM-J022
2 Descriptions of Components
HRG001-W HRG002-W HRG005-W 2.2 Descriptions and functions of components
1st edition :Jul. 2005 2-3
2.2.2 HRG005-W
Fig. 2-4 Piping connection port (HRG005-W)
Y-strainer
1/2
Top
FrontLeft 4φ13
（
for anchor bolt）） Tank drain port Rc1/2
（
plugged）
Cooling water IN Rc1/2
Port for overflow Rc1/2
Bypass valve
Circulating fluid OUT Rc1/2
Supply port Rc1/2
Level indicator
Control panel
Electrical unit
Power cable access
(Filmed grommet)
Signal cable access
(Filmed grommet)
Circulating fluid return Rc1/2
Eye bolt M12
Cooling water OUT Rc1/2
Tank lid
Right

HRX-OM-J022
2 Descriptions of Components
2.2 Descriptions and functions of components HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
2-4
2.2.3 Control panel
The control panel is common to all models.
Fig. 2-5 Control panel
Table 2-1 Control panel
No. Name Function
PV Indicates actual temperature of a circulating fluid
1 Digital display, PV / SV SV Indicates set temperature of a circulating fluid
2 [POWER] LED Lights up when the power is supplied.
3 [RUN] LED
4 [PUMP] LED Lights up when the [ON] switch is pressed.
5 [ALARM] LED Lights up when an alarm arises.
6 [ON] switch This is used to run the unit.
7 [OFF] switch This is used to stop the unit.
8 [MODE] key This is used to switch the screens between PV and SV.
9 [DOWN] key This is used to decrease set temperature.
10 [UP] key This is used to increase set temperature.

HRX-OM-J022
3 Transport and Installation
HRG001-W HRG002-W HRG005-W 3.1 Transport
1st edition :Jul. 2005 3-1
3. Transport and Installation
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.
The unit must be handled in correct manner.
Exercise caution to assure personnel safety during the installation,
operation, maintenance, and inspection of the unit.
Only personnel with sufficient knowledge and experiences with the
unit and system are allowed to transport, install and conduct
maintenance possibly exposed to dangerous situations.
zIf eyebolts are used for lifting, ensure the unit is held at four points.
zKeep each eyebolt at an angle from 45 to 60 degrees with repect to
the postion of the center of gravity when lifting the unit.
If the forklift is used for transporting, ensure that the fork is inserted in
a place as specified in Fig. 3-1 “Fork insertion position and unit
lifting ”.
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 the 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.

HRX-OM-J022
3 Transport and Installation
3.1 Transport HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
3-2
Fig. 3-1 Fork insertion position and unit lifting
HRG001-W/HRG002-W
HRG005-W Lifting position
Approx. 60deg.
Approx. 60deg.°
Fork insertion
position
Fork insertion
position
Fork insertion
position
Fork insertion
position Fork insertion position
Fork insertion
position
Fork insertion
position

HRX-OM-J022
3 Transport and Installation
HRG001-W HRG002-W HRG005-W 3.2 Installation
1st edition :Jul. 2005 3-3
3.2 Installation
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.
zEnvironment that is exposed to water vapor, salt water or oil mist
zEnvironment that is exposed to dust or powdery materials
zEnvironment that is exposed to corrosive gas, flammable gas or solvent
zEnvironment that is exposed to direct sun light or radiant heat
zEnvironment where ambient temperature is out of the specified range
zEnvironment that is subjected to abrupt changes in temprature
zEnvironment that is subjected to strong electromagnetic noise (incl. strong
electrical field, strong magnetic field, or surge voltage)
zEnvironment that generates static electricity, or condition in which static
electricity discharges to the unit
zEnvironment that generates strong high frequencies
zEnvironment at high altitudes of over 1000m
zCondition which allows strong vibrations and impacts to transmit to the unit
zCondition with external force or load to deform the unit
zCondition with an insufficient maintenance space as required
zCondition with an insufficient maintenance space as required
Do not install the unit in a place possibly exposed to flammable gas.
Ignition may occur if leaked gas is collected around the system.
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.
This unit is NOT designed for outside use. The unit exposed to
moisture may develop a short circuit which can result in an electrical
s
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,
fir
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a
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e
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ni
t
.
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.

HRX-OM-J022
3 Transport and Installation
3.2 Installation HRG001-W HRG002-W HRG005-W
1st edition : Jul. 2005
3-4
3.2.2 Installation
zKeep the unit away from vibration. Install the unit on a flat and stable surface.
zRefer to “7.2 Outline dimensions” for the dimensions of the unit.
3.2.3 Electrical wiring
Power supply cable and GFCI breaker
Select a cable for power supply and GFCI breaker corresponding to the
model no. provided in the following table.
Table 3-1 Cable for power supply and current leakage
Item HRG001-W HRG002-W HRG005-W
Size 4-core 3.5mm24-core 5.5mm2Power
supply
cable Round compressive
terminal size 3.5−4S 5.5−4S
Size 6-core 0.75 mm2
Signal
cable Y-shaped compressive
terminal size 1.25Y−3
Capacity of GFCI breaker* 5A 10A 20A
* Use the breaker with current sensitivity of 30mA at minimum.
zOnly qualified personnel are allowed for wiring.
zBe sure to cut off the power supply for safety. Wiring installation with
the unit energized is strictly prohibitted.
zUse 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.
zSupply the power to the unit from a reliable power source (without
surge voltage).
zBe sure to use a GFCI breaker to prevent an electrical shock and
burnt compressor motor. The breaker with adequate capacity of
current leakage and load should be selected in accordance with “7.1
Specification list”.
zEnsure that the power supply meets the specification of the unit.
zAlways establish a ground for safety.
zDo not connect the ground to a water line, gas pipe and lightening
conductor.
zDo not branch off the wiring to multiple. Potential hot spots or fire
may occur if disregarded.
zDo not modify the electrical wiring. Incorrect wiring can cause an
electrical shock and fire. Failure to do so will void any warranty.
zThe set value of the safety device must not be changed. Changing
the set value can cause system failure and fire.