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-∗)