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Sierra Monitor Corporation HRG010-W Operation Manual

Water-refrigerated thermo cooler
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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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Summary of Contents for Sierra Monitor Corporation HRG010-W

  • Page 1: Operation Manual

    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...
  • Page 2 To the Customers Thank you for purchasing our THERMO COOLER HRG Series (hereinafter called “This unit”). For safety and efficiency, be sure to read and understand this manual thoroughly before performing operation of this unit. All warnings and precautions defined in this manual shall be observed. This manual provides instructions for the installation and operation of the unit.

  • Page 3: Table Of Contents

    Material Safety Data Sheet (MSDS) ...1-11 Chapter 2 Appearance and Each Section ... 2-1 Appearance... 2-1 Name of Each Section... 2-2 2.2.1 HRG010-W ... 2-2 2.2.2 HRG015-W ... 2-3 Control panel ... 2-4 Chapter 3 Transport and Installation... 3-1 Transport... 3-1 3.1.1...
  • Page 4 Consumables ...6-6 Long-term Storage ...6-6 Chapter 7 Documents ... 7-1 Standard Specifications ...7-1 Optional Specifications ...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 Electric Circuit...7-5 7.4.1 HRG010-W, HRG015-W... 7-5 TOC-2 HRG010-W HRG015-W 1st edition : Aug.
  • Page 5 7.4.2 HRG010-W-BC, HRG015-W-BC... 7-6 Flow Chart... 7-7 Daily Inspection Sheet ... 7-8 HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 HRX-OM-J049-A Table of Contents TOC-3...
  • Page 6 HRX-OM-J049-A Table of Contents HRG010-W HRG015-W 1st edition : Aug. 2006 TOC-4 Rev. A: May. 2007...

  • Page 7: Chapter 1 Safety Instructions

    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. HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 HRX-OM-J049-A Chapter 1 Safety Instructions 1.1 Before Using this Unit...

  • Page 8: Danger, Warning And Caution

    “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...

  • Page 9: Symbols

    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 HRX-OM-J049-A Chapter 1 Safety Instructions...

  • Page 10: Hazard Warning Label

    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...

  • Page 11: Type Of Hazard Warning Labels

    Read the contents of the hazard warning labels with care to keep them in mind. Warning label on the front panel Warning label for high voltage HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Fig. 1-1 Warning Label on the Front Panel Fig.

  • Page 12: Location Of Hazard Warning Label

    Check the model no. described on the label. Front 1.4 Model label Front Fig. 1-3 Location of Hazard Warning Label Fig. 1-4 Location of Model Label Warning label on the front panel HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 13: Safety Measures

    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. HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 HRX-OM-J049-A Chapter 1 Safety Instructions 1.5 Safety Measures...

  • Page 14: Protective Equipment

    Protective footwear For handling circulating fluid Protective footwear Protective apron For system operation Protective footwear 1.5 Safety Measures Protective gloves Hard hat Protective gloves Protective mask Protective goggles Protective gloves HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 15: Emergency Measures

    [RUN] LED 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 Fig. 1-5 Thermo Cooler OFF 前面...

  • Page 16: Disposition Of Waste

    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 1-10 HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 17: Circulating Fluid Disposal

    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 HRX-OM-J049-A Chapter 1 Safety Instructions 1.8 Material Safety Data Sheet (MSDS)
  • Page 18 HRX-OM-J049-A Chapter 1 Safety Instructions 1.8 Material Safety Data Sheet (MSDS) HRG010-W HRG015-W 1st edition : Aug. 2006 1-12 Rev. A: May. 2007...

  • Page 19: Chapter 2 Appearance And Each Section

    2.1 Appearance Left Front Left Front HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Chapter 2 Appearance and Each Section Fig. 2-1 Appearance of HRG010-W Fig. 2-2 Appearance of HRG015-W HRX-OM-J049-A Back Right Back Right 2.1 Appearance...

  • Page 20: Name Of Each Section

    Power/signal connection terminal block Level gauge Tank 4-Ø13 (For anchor bolt) Left Fig. 2-3 Name of Each Section (HRG010-W) 2.2 Name of Each Section Y-shaped strainer Rc1/2 (accessory) Eyebolt M12 Control panel Facility water IN Rc1/2 Facility water OUT Rc1/2...

  • Page 21: Hrg015-W

    Level gauge Tank 4-Ø13 (For anchor bolt) Left Fig. 2-4 Name of Each Section (HRG015-W) HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Chapter 2 Appearance and Each Section Y-shaped strainer Rc1/2 (accessory) Eyebolt M12 Control panel...

  • Page 22: Control Panel

    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. HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 23: Chapter 3 Transport And Installation

    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 HRX-OM-J049-A Chapter 3 Transport and Installation 3.1 Transport...

  • Page 24: Transporting With Forklift And Unit Lifting

    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...

  • Page 25: Transporting With Caster

    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.

  • Page 26: Installation

    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...

  • Page 27: 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 Model (kW) HRG010-W Approx.

  • Page 28: Installation Location And Maintenance Work Area

    Failure to create sufficient space may lead to improper cooling and/or controller stop. Access maintenance work area should be required for maintenance. Min. 800mm Fig. 3-4 Recommended Installation Location 3.2 Installation Min. 800mm Front HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 29: Installation

    Make sure of no looseness between the anchor bolts and foundation. Base Hexagonal nut Anchor bolt Front HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Anchor bolt mounting hole (Ø13) Concrete foundation Fig. 3-5 Procedure for Installation...
  • Page 30 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. Fig. 3-6 HRG010-W-A / HRG015-W-A (Caster-mounted Option) 3.2 Installation...

  • Page 31: Electrical Wiring

    Round crimp contact size Signal cable Y-shaped crimp contact size Capacity of GFCI breaker * Use the breaker with current sensitivity of 30mA at minimum. HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 HRG010-W Size 4- core 8 mm...
  • Page 32 Connect the power supply cable and signal cable as shown in the figure. Front 3.2 Installation 3-10 Fig. 3-7 Removal of Front Panel Power cable Signal cable access Power cable access Fig. 3-8 Electrical Wiring Electrical unit Screw Signal cable HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 33: Electrical Wiring Diagram

    (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) Fig. 3-9 Electrical Wiring Diagram (HRG010-W) HRG015-W • ELB/Current leakage breaker Power supply input Remote operation signal input...
  • Page 34 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. Item Communication cable Y-shaped crimp contact size Connect the power cables properly, as shown below.

  • Page 35: Piping

    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.

  • Page 36: 1St Edition : Aug. 2006

    Flow meter Rc3/4, 0 to 100 L/min Table 3-7 Allied Products Name Qty. 1 set 1 set Load device HRG015-W Rc3/4 Rc3/4 Note HRG010 optional accessory HRG015 optional accessory HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 37: Supply Of Circulating Fluid

    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. HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 38: Reinstallation Of Unit

    Only qualified personnel are allowed to install wiring. Be sure to cut off the power supply for safety. Wiring with the unit energized is strictly prohibitted. 3.2 Installation 3-16 HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 39: Chapter 4 Startup And Shutdown

    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 HRX-OM-J049-A Chapter 4 Startup and Shutdown 4.1 Pre-check...

  • Page 40: Preparation For Startup

    Note: Circulating fluid setting temp.range is 5 to 35°C. 4.2 Preparation for startup Digital display PV (circulating fluid temp.) Digital display SV (set temp.) Fig. 4-1 Power Supply Digital display SV (set temp.) [UP] key HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 41: Additional Water Supply

    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...

  • Page 42: Unit Startup And Shutdown

    The [RUN] LED and [PUMP] LED on the control panel go out. [RUN] LED 4.3 Unit Startup and Shutdown Fig. 4-5 Starting the Unit Fig. 4-6 Stopping the Unit [PUMP] LED [PUMP] LED [OFF] switch HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 43: Check At Startup

    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 HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Chapter 4 Startup and Shutdown Right Fig.
  • Page 44 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 Relieving valve HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 45: Chapter 5 Error Message And Troubleshooting

    40°C and Stopped Green supplied fluid over Compressor Stopped Green overload HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Chapter 5 Error Message and Troubleshooting Fig. 5-1 Control Panel Table 5-1 Error Message ( : Off, : On)

  • Page 46: Troubleshooting

    Manual reset Manual reset (yellow (red button) button) Manual reset Manual reset (yellow (blue button) button) Manual reset Auto reset (yellow button) Manual reset Manual reset (yellow (blue button) button) HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 47: Alarm Reset (Alarm Lamp Off)

    [ALARM1] LED [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 Chapter 5 Error Message and Troubleshooting Fig. 5-2 Alarm Lamps (ON)
  • Page 48 Avoid performing work during system operation. Screw Front panel Front 5.3 Alarm Reset (Alarm Lamp OFF) Fig. 5-3 Removal of Front Panel Electrical unit Screw HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...
  • Page 49 The alarm lamp goes out accordingly. Implement system startup and shutdown according to “4.3 Unit Startup and Shutdown”. Front Fig. 5-5 Location of Reset Switch [RS] (Yellow Button) HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Chapter 5 Error Message and Troubleshooting...

  • Page 50: Recovery From Power Failure (Power Lamp On)

    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) Fig. 5-6 POWER Lamp (OFF) [ALARM2] LED [ALARM3] LED HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...
  • Page 51 [HRG010-W-B / HRG015-W-B (earth leakage breaker-mounted option)] 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.
  • Page 52 Switch on the earth leakage breaker, and make sure that the [POWER] lamp comes on. Switch in the ON position 5.4 Recovery from Power Failure (POWER Lamp ON) Front Fig. 5-9 Earth Leakage Breaker (OFF) Front Fig. 5-10 Earth Leakage Breaker (ON) HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 53: Chapter 6 Unit Maintenance

    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 Facility water spec.

  • Page 54: Inspection And Cleaning

    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...

  • Page 55: Daily Inspection

    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...

  • Page 56: Quarterly Inspection

    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...

  • Page 57: Check During Wintertime

    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 HRX-OM-J049-A Chapter 6 Unit Maintenance 6.2 Inspection and Cleaning...

  • Page 58: Consumables

    Cover the unit with a plastic sheet for storage after draining is completed. 6.3 Consumables Table 6-3 Consumables Part Qty. 1 set Service part for HRG010 1 set Service part for HRG015 Remarks HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 59: Chapter 7 Documents

    Temperature control Operation panel Refrigerant high pressure gauge Refrigerant pressure gauge Level indicator HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Table 7-1 Standard Specifications (1/2) HRG010-W 32°C (5 to 40°C) 45 to 75%RH (No condensation) (such as SUS304 and PVC)
  • Page 60 12, Synthetic rubber (pipe hose), Polyurethane (limnimeter) 1700±20g Eye bolt M12 × 4 pcs., Y-shaped strainer Rc3/4 × 1 pcs., nipple for strainer piping 3/4 × 1 pcs 220kg HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 61: Optional Specifications

    Connector number Connector type HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Table 7-2 Caster with Brake Specifications For HRG010-W-A, HRG015-W-A 63mm 59mm (single) 0 to 12.5mm Caster: SPCC, Wheel: Nylon (Base with casters: SUS304) 520kg (130kg per caster, 4 pcs.)

  • Page 62: Outline Dimensions

    HRX-OM-J049-A 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 Left 7.3.2 HRG010-W-A□, HRG015-W-A□ Left 7.3 Outline Dimensions Front Fig. 7-1 Outline Dimensions Front Fig. 7-2 Outline Dimensions Right Right HRG010-W HRG015-W 1st edition : Aug. 2006...

  • Page 63: Electric Circuit

    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 7.4 Electric Circuit 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 64: Hrg010-W-Bc, Hrg015-W-Bc

    HRX-OM-J049-A 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...

  • Page 65: Flow Chart

    7.5 Flow Chart HRG010-W, HRG015-W Facility water IN Facility water OUT Fig. 7-5 Flow Chart (HRG010-W, HRG015-W) HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007 Chapter 7 Documents Auto supply HPS High pressure SW Circulating fluid OUT...

  • Page 66: Daily Inspection Sheet

    HRX-OM-J049-A Chapter 7 Documents Daily Inspection Sheet 7.6 Daily Inspection Sheet HRG010-W HRG015-W 1st edition : Aug. 2006 Rev. A: May. 2007...

  • Page 67: Product Warranty

    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.

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