SMC Networks HRGC001-A Series User manual

HRX-MM-L012
1st edition: Oct. 2007
Rev. A：Feb. 2008
Service Manual
Refrigerant Type Thermo-cooler
Air-cooled refrigerating type Water-cooled refrigerating type
HRGC001-A
∗ HRGC001-W ∗
HRGC002-A
∗ HRGC002-W ∗
HRGC005-A
∗ HRGC005-W ∗
Keep this manual available whenever necessary.
© 2008 SMC CORPORATION All Rights Reserved

To users
Thank you for purchasing our THERMO-COOLER HRGC Series (hereinafter called “This system”).
For safe use of this system and personal safety, be sure to read and understand this manual thoroughly
before performing repair of this system.
●Warnings and precautions defined in this manual shall be observed.
●This manual provides the explanations of the troubleshooting and in-depth remedies of this system.
This manual is intended for service personnel that completed service training SMC provides. Only
those who fall under the above condition are allowed to perform maintenance and repair of this system
with the use of the Service Manual.
●The contents of this manual and related documents supplied with this system shall be neither regarded
as a provision of the contract nor utilized to correct or modify the existing agreements, commitments
and relations.
● Copying, duplicating or transferring any part of or whole contents of this manual without the prior
written consent of SMC Corporation is strictly prohibited.
● The Operation Manual is supplied in addition to this manual and provides the explanations of the
installation and operation of this system. This manual does not contain the fundamental information
and operating procedures that are provided in the Operation Manual.
Note: The contents of this manual are subject to change without notice.

HRX-MM-L012
Contents
HRGC Series
Contents-1
Contents-1
Contents
Chapter 1 Safety Instructions............................................................ 1-1
1.1 Before using unit .......................................................................................................1-1
1.2 Reading the Manual ...................................................................................................1-1
1.3 Hazards .......................................................................................................................1-2
1.3.1 Level of hazards................................................................................................................... 1-2
1.3.2 Definition of “Serious injury” and “Light injury”..................................................................... 1-2
1.3.3 Types of hazard labels ......................................................................................................... 1-3
1.3.4 Locations of Hazard Labels ................................................................................................. 1-4
1.4 Other Labels ...............................................................................................................1-6
1.4.1 Product Label ....................................................................................................................... 1-6
1.5 Safety Measures.........................................................................................................1-6
1.5.1 Safety Instructions for Use................................................................................................... 1-6
1.6 Note for disposal........................................................................................................1-8
1.6.1 Recovery of refrigerant and compressor oil ......................................................................... 1-8
1.6.2 Discarding the unit ............................................................................................................... 1-8
1.7 Material Safety Data Sheet (MSDS) ..........................................................................1-8
Chapter 2 Name of Parts .................................................................... 2-1
2.1 Appearance ................................................................................................................2-1
2.1.1 HRGC001-∗, HRGC002-∗.................................................................................................... 2-1
2.1.2 HRGC001-W∗, HRGC002-W∗............................................................................................. 2-1
2.1.3 HRGC005-∗.......................................................................................................................... 2-2
2.1.4 HRGC005-W∗...................................................................................................................... 2-2
2.2 Component Parts .......................................................................................................2-3
2.2.1 HRGC001-∗, HRGC002-∗.................................................................................................... 2-3
2.2.2 HRGC005-∗.......................................................................................................................... 2-4
Chapter 3 Error Display and Remedy ............................................... 3-1
3.1 Error Display ..............................................................................................................3-1
3.2 Remedy for Error .......................................................................................................3-3
3.3 How to Reset Alarm ...................................................................................................3-4
3.3.1 Reset by using [RESET] button ........................................................................................... 3-4
3.3.2 Reset of pump overload (AL02) and compressor overload (AL03) ..................................... 3-5
3.4 Other Errors................................................................................................................3-7
Chapter 4 Service Procedure............................................................. 4-1
4.1 Precautions for whole work ......................................................................................4-1
4.1.1 Preparation for work............................................................................................................. 4-1
4.1.2 Check after work .................................................................................................................. 4-1

HRX-MM-L012
Contents
HRGC Series
Contents-2
4.2 Icons for necessary tools and specifications .........................................................4-2
4.3 Replacement procedure ............................................................................................ 4-4
4.3.1 Replacement of temperature sensor .................................................................................... 4-4
4.3.2 Replacement of pump ........................................................................................................4-10
4.3.3 Replacement of pump mechanical seal (< HRGC001-∗-T,HRGC002-∗-T,HRGC005-∗)....4-17
4.3.4 Replacement of fan motor .................................................................................................. 4-19
4.3.5 Replacement of level switch ............................................................................................... 4-24
4.3.6 Replacement of magnetic contactor for pump....................................................................4-28
4.3.7 Replacement of magnetic contactor for compressor.......................................................... 4-32
4.3.8 Replacement of magnetic contactor for fan motor (HRGC005-A∗) ...............................4-36
4.3.9 Replacement of temperature adjuster (operation displa panel) .........................................4-38
4.3.10 Replacement of DC24V power supply ............................................................................... 4-40
4.3.11 Replacement of 3-way proportional valve assembly.......................................................... 4-42
Chapter 5 Service Parts List .............................................................. 5-1
5.1 Before using service parts list..................................................................................5-1
5.2 Service parts list ........................................................................................................ 5-1
5.3 Illustration of service parts ....................................................................................... 5-2
5.3.1 Temperature sensor..............................................................................................................5-2
5.3.2 Pump .................................................................................................................................... 5-3
5.3.3 Pump mechanical seal ......................................................................................................... 5-5
5.3.4 Fan motor ............................................................................................................................. 5-6
5.3.5 Level switch .......................................................................................................................... 5-8
5.3.6 Magnetic contactor for pump................................................................................................ 5-9
5.3.7 Magnetic contactor for compressor ....................................................................................5-10
5.3.8 Magnetic contactor for fan motor........................................................................................ 5-12
5.3.9 Temperature adjuster (operation display panel)................................................................. 5-13
5.3.10 DC24V power supply.......................................................................................................... 5-15
5.3.11 3-way proportional valve assembly ....................................................................................5-16
Chapter 6 Documents......................................................................... 6-1
6.1 Specifications List .....................................................................................................6-1
6.2 Outline Dimensions ................................................................................................... 6-2
6.2.1 HRGC001-∗, HRGC002-∗.................................................................................................... 6-2
6.2.2 HRGC001-W∗, HRGC002-W∗............................................................................................. 6-2
6.2.3 HRGC005-A∗........................................................................................................................ 6-3
6.2.4 HRGC005-W∗....................................................................................................................... 6-3
6.3 Electric Circuit Diagram ............................................................................................6-4
6.3.1 HRGC001-A∗, HRGC002-A∗, HRGC001-W∗, HRGC002-W∗............................................. 6-4
6.3.2 HRGC005-A∗, HRGC005-W∗.............................................................................................. 6-5
6.4 Flow Chart (HRGC00∗-A)...........................................................................................6-6

HRX-MM-L012
Contents
HRGC Series
Contents-3
Contents-3
6.5 Flow Chart（HRGC00∗-W）......................................................................................6-7
6.6 Applicable Regulations .............................................................................................6-8
Chapter 7 Product Warranty .............................................................. 7-1

HRX-MM-L012
Contents
HRGC Series
Contents-4

HRX-MM-L012
Chapter 1 Safety Instructions
HRGC Series 1.1.Before using unit
1-1
Chapter 1 Safety Instructions
1.1 Before using unit
zThis chapter is intended to specifically describe the safety related issues
for handling the unit.
zThe unit is a cooling device using recirculating fluid. SMC does not take
any responsibility for any problems that may arise from using the unit for
other purposes.
zThis product is for the indoor use and not available outdoor.
zThis product is not designed for a clean room. It generates dust from the
internal components such as pump and fan motor (for air-cooled type).
zThe unit is operating at high voltage and contains components which
become hot and rotate. If a component needs to be replaced or repaired,
contact a specific vendor for parts and service.
zThe operate’s, maintence personnel and other people working nearby the
unit should read and understand the safety related descriptions in this
manual carefully before starting work.
zSafety manager is responsible to strictly observe safety standards, but
responsibility in respect to safety standard during daily work resides with
each individual operator and personnel for maintainance.
zThis manual must be kept available to operator’s whenever necessary..
1.2 Reading the Manual
This manual contains symbols to help identify important actions when
installing, operating or maintain the unit.
•Symbols for important Actions
Read most critical instruction to be considered carefully and ensure well understanding of the
content before operating the unit
This sign stands for actions that must be followed.
This sign stands for prohibited actions.

HRX-MM-L012
Chapter 1 Safety Instructions
1.3Hazards HRGC Series
1-2
1.3 Hazards
1.3.1 Level of hazards
The instructions given in this manual aim to assure safe and correct
operation of the unit and to prevent injury of operators or damage to the unit.
These instructions are grouped into three categories, Danger, Warning and
Caution, which indicate the level of hazard, damage and also the degree of
emergency. All texts that contain safety critical matter and should be
carefully observed.
DANGER, WARNING and CAUTION signs are in order according to
seriousness (DANGER> WARNING> CAUTION).
1.3.2 Definition of “Serious injury” and “Light injury”
“Serious injury”
The injury that gives aftereffects including loss of eyesight, burnt, electrical
shock, fracture, poisoning, etc. and requires long-term treatment or
hospitalization.
“Light injury”
The injury that does not need long term treatment or hospitalization. (Others
excluded from serious injury.)
“WARNING”: Hazard that may cause serious personal injury or death during
operation.
“CAUTION”: Hazard that may cause minor personal injury.
“CAUTION without exclamation symbol”: Hazard that may cause damage or failure
of the unit, facility, ect.
“DANGER”: Hazard that will cause serious personal injury or death during
operation.

HRX-MM-L012
Chapter 1 Safety Instructions
HRGC Series 1.3.Hazards
1-3
1.3.3 Types of hazard labels
The unit has various potential hazards and they are marked with warning
labels. Be sure the read this section before starting any work on the unit.
Warning related to electricity
Warning related to high temperatures
Warning related to rotating objects
Warning related to other general dangers
This symbol stands for a possible risk of electric shock.
The unit is operated at high voltage and contains uncovered live
terminals inside.
zDO NOT operate the unit without cover panels fitted
zDO NOT work inside this unit unless you have been trained to do so.
This symbol stands for a possible risk of cutting fingers or hand, or
entanglement by rotating fan.
The unit has a cooling fan that rotates during operation of the unit. The
fan can start and stop intermittantly and without warning.
zDO NOT operate the unit without cover panels fitted.
This symbol stands for a possible risk of burn or hot surface.
The unit has surfaces that can reach high temperatures during
operation. Even after the power is turned off, there can still be residual
heat in the unit.
zDO NOT operate the unit without cover panels fitted.
zDO NOT start working inside the unit until the temperature has
decreased sufficiently.
This symbol stands for general danger.
On the unit this symbol has different meanings.
1. Hazards Inside
Hot Surfaces Inside – See Hot Surface symbol
Rotating Fan Inside – See Rotating Fan symbol
Pressurized Sytem Inside – The unit contains pressurised fluid
systems.
zDO NOT operate the unit without cover panels fitted.
2. Lifting Hazard
Lifting the unit from eyebolts can be dangerous
zDO NOT lift the unit without having read the manual.
(onlyforHRGC005-∗)

HRX-MM-L012
Chapter 1 Safety Instructions
1.3Hazards HRGC Series
1-4
1.3.4 Locations of Hazard Labels
There are various warning labels on the unit to show the dangers.
Sign for warning related to heat
Fig. 1-1 Warning label position (HRGC001-∗, HRGC002-∗) (1)
Fig. 1-2 Warning label position (HRGC001-∗, HRGC002-∗) (2)
Front side
(Hazards Inside)
Back side
(Hazards Inside)
(only for HRGC00∗-A-∗)

HRX-MM-L012
Chapter 1 Safety Instructions
HRGC Series 0.
1-5
Fig. 1-3 Warning label position (HRGC005-∗) (3)
Fig. 1-4 Warning label position (HRGC005-∗) (4)
Back side
(Hazards Inside)
(only for HRGC005-∗)
Front side
(Hazards Inside)
（Hanging warning）
1.3 Hazard

HRX-MM-L012
Chapter 1 Safety Instructions
1.4Other Labels HRGC Series
1-6
1.4 Other Labels
1.4.1 Product Label
When contacting SMC's sales distributor, inform them of serial number
(SERIAL No.) and model number (MODEL No.) of the unit. They are
described on the product label shown below.
Fig. 1-5 Position of product label
1.5 Safety Measures
1.5.1 Safety Instructions for Use
zRead and undestand this manual carefully before using the unit.
zBefore starting maintenance of the unit, be sure to lock out and tag out
the breaker of user's power supply.
zIf operating the unit during maintenance, be sure to inform all workers
nearby.
zUse only the correct tools and procedure when installing or maintaning
the unit.
zUse personal protective equipment where specified (“エラー! ブックマ
ークが定義されていません。 Icons for necessary tools and
specifications ”).
zCheck all parts and screws are fitted correctly and securely after
maintenance.
zAvoid working in a drunken or sick condition, which might cause an
accident.
zDo not remove the panels except for the cases permitted in this manual.
Follow the instructions below when using the unit. Failure to follow
might cause an accident and injury.
Serial Number (SERIAL No.)
Model Number (MODEL No.）
The type and quantity of freon
(REFRIGERANT)
Front side

HRX-MM-L012
Chapter 1 Safety Instructions
HRGC Series 1.5.Safety Measures
1-7
zDo not remove the panels during operation.

HRX-MM-L012
Chapter 1 Safety Instructions
1.6Note for disposal HRGC Series
1-8
1.6 Note for disposal
1.6.1 Recovery of refrigerant and compressor oil
The unit uses freon type refrigerant (HFC) and compressor oil. Comply with
the law and regulation in each region for the disposal of compressor oil. The
type and quantity of freon is described on the product label. (P1-6)
If these fluids need to be recovered, read and understand the instructions
below carefully. If there is any unclear point, contact an SMC's sales
distributor.
1.6.2 Discarding the unit
When discarding the unit, follow all waste disposal regulations within the
country of disposal.
1.7 Material Safety Data Sheet (MSDS)
If the material safety data sheets of chemicals used in this unit are needed,
contact an SMC's sales distributor.
Any chemicals used by the user must be accompanied by an MSDS.
zOnly service personnel or qualified people are allowed to open the
cover panels of the unit.
zDo not mix the compressor oil with domestic waste for disposal. Also,
the incineration of the waste must only be conducted by specific
facilities that are permitted for that purpose.
zComply with the law and regulation in each region for the disposal of
compressor oil.
zThe release of refrigerant in to atmosphere is banned by law. Recover
it with specific equipment and dispose of it correctly.
zOnly persons who has sufficient knowledge and experience about the
unit and its accessories are allowed to recover the refrigerant and
compressor oil.

HRX-MM-L012
Chapter 1 Safety Instructions
HRGC Series 1.7.Material Safety Data Sheet (MSDS)
1-9

HRX-MM-L012
Chapter 2 Name of Parts
HRGC Series 2.1 Appearance
2-1
Chapter 2 Name of Parts
2.1 Appearance
2.1.1 HRGC001-∗, HRGC002-∗
Fig. 2-1 Name of Parts (1)
2.1.2 HRGC001-W∗, HRGC002-W∗
Fig.2-2 Name of Parts (2)
Left
Air vent OUT
Signal cable entry
(Grommet)
Power supply
cable entry
(
Grommet
)
Back
Drain port
Rc1/4
Manual bypass
valve
Recirculating
fluid Supply
Rc1/2
Right
Air vent OUT
Recirculating
fluid Return
Rc1/2
Tank level indicato
r
Front
Air vent IN
Operation panel
Control box
（panel internal）
Tank lid
top Overflow port
Rc1/2
Air vent OUT
Left
Signal cable entry
(Grommet)
Power supply
cable entry
(Grommet)
）
Back
Drain port
Rc1/4
Manual bypass
valve
Recirculating
fluid Supply
Rc1/2
Right
Recirculating
fluid Return
Rc1/2
Tank level indicator
Front
Operation panel
Control box
（panel internal）
Tank lid
top Overflow port
Rc1/2
Cooling water
Inlet Rc1/2
Cooling water
outlet Rc1/2

HRX-MM-L012
Chapter 2 Name of Parts
2.1 Appearance HRGC Series
2-2
2.1.3 HRGC005-∗
Fig. 2-3 Name of Parts (3)
2.1.4 HRGC005-W∗
Fig 2-4 Name of Parts (4)
Left
Air vent IN
Signal cable entry
(Grommet)
Power supply cable entry
(Grommet)
Back
Air vent OUT
Operation panel
Top
Front
Tank lid
Control box
(panel internal)
Tank level
indicator
Drain port
Rc1/4
Manual bypass
valve
Recirculating
fluid Supply
Rc1/2
Recirculating
fluid Return
Rc1/2
Right
Eye bolt M12 (accessory)
Air vent OUT
Left
Signal cable entry
(Grommet)
Power supply cable entry
(Grommet)
Back
Operation panel
Top
Front
Tank lid
Control box
(panel internal)
Tank level
indicator
Drain port
Rc1/4
Manual bypass
valve
Recirculating
fluid Supply
Rc1/2
Recirculating
fluid Return
Rc1/2
Right
Eye bolt M12 (accessory)
Overflow port
Rc1/2
Cooling water
outlet Rc1/2
Cooling water
inlet Rc1/2
Overflow port
Rc1/2

HRX-MM-L012
Chapter 2 Name of Parts
HRGC Series 2.2 Component Parts
2-3
2.2 Component Parts
2.2.1 HRGC001-∗, HRGC002-∗
※HRGC001-*＊と HRGC002-*＊はファンモータの形状が異なります。
Fig. 2-4 Component Parts
Level switch
Magnetic contactor
for pump
Magnetic contactor
for compressor
Temperature adjuster
(operation display panel)
Fan and Fan motor
（only for HRGC001,002-A∗）
DC24V power supply
Temperature sensor
Pump
Front side
3-way proportional
valve assembly
(only for HRGC00∗-∗5)

HRX-MM-L012
Chapter 2 Name of Parts
2.2 Component Parts HRGC Series
2-4
2.2.2 HRGC005-∗
Fig. 2-5 Component Parts
Level switch
Magnetic contactor
for pump
Magnetic contactor
for compressor
Temperature adjuster
(operation display panel)
Fan and Fan motor
(only for HRGC005-A∗)
DC24V power supply
Temperature sensor
Mechanical seal
Front side
Magnetic contactor
for fan motor
3-way proportional
valve assembly
(only for HRGC00∗-∗5)
Pump