SMC Networks HRW008-H, HRW002-H1, HRW030-H, HRW002-H, HRW008-H1 Operation Manual
...
HRX-OM-K003
HRW002-H
HRW008-H
HRW015-H
HRW030-H
HRW002-H1
HRW008-H1
HRW015-H1
HRW030-H1
HRW002-H2
HRW008-H1
HRW015-H2
HRW030-H2
HRW002-HS
HRW008-HS
HRW015-HS
HRW030-HS
HRW002-H1S
HRW008-H1S
HRW015-H1S
HRW030-H1S
HRW002-H2S
HRW008-H1S
HRW015-H2S
HRW030-H2S
1st Edition: July 2006
Rev. G: May 2018
Operation Manual
Original Instructions
THERMO CHILLER
Save This Manual Carefully for Use at Any Time
© 2018 SMC CORPORATION All Rights Reserved
To the Customers
Note: The contents of this manual are subject to change without notice.
Thank you for purchasing our THERMO CHILLER HRW Series (hereinafter called “This system”).
For the long-term, safe use of this system, be sure to read and understand this manual thoroughly before performing
operation of this system.
Warnings and precautions defined in this manual shall be observed.
This manual provides the explanations of the installation and operation of this system. Only those who have
thorough understanding of the fundamental operating procedure or have basic knowledge and skills of handling
industrial equipment for the installation and operation of this system are qualified to perform installation and
operation.
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 Service Manual is supplied in addition to this manual and provides the explanations of the inspection,
troubleshooting, and in-depth remedies of this system. The Service 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.
HRX-OM-K003
TOC-1
Table of Contents
Table of Contents
Chapter 1 Safety.................................................................................... 1-1
1.1 Before Using this System ....................................................................................... 1-1
1.2 Danger, Warning, and Caution Used in This Manual............................................. 1-2
1.2.1 Hazard Levels ..................................................................................................................... 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 Type of hazard warning label .............................................................................................. 1-4
1.3.2 Location of hazard warning label ........................................................................................ 1-5
1.4 Location of Model Label ......................................................................................... 1-7
1.5 Safety Measures ...................................................................................................... 1-8
1.5.1 Safety Precautions .............................................................................................................. 1-8
1.5.2 Safety Interlock system ....................................................................................................... 1-9
1.5.3 Lockout/Tagout .................................................................................................................. 1-10
1.5.4 Protective equipment ......................................................................................................... 1-12
1.6 Emergency Measures............................................................................................ 1-13
1.6.1 Emergency off [EMO] switch ............................................................................................. 1-13
1.7 Waste Disposal ...................................................................................................... 1-15
1.7.1 Circulating fluid disposal.................................................................................................... 1-15
1.7.2 System disposal ................................................................................................................ 1-15
1.8 Material Safety Data Sheet (MSDS) ...................................................................... 1-15
Chapter 2 Name of Each Section ......................................................... 2-1
2.1 Name of Each Section ............................................................................................. 2-1
Chapter 3 Transporting and Installation .............................................. 3-1
3.1 Transporting ............................................................................................................ 3-1
3.1.1 Transporting with forklift ...................................................................................................... 3-2
3.1.2 Transporting with caster ...................................................................................................... 3-3
3.2 Installation ................................................................................................ ............... 3-3
3.2.1 Installation conditions .......................................................................................................... 3-4
3.2.2 Installation location and maintenance work area ................................................................ 3-5
3.3 Procedure for Installation ....................................................................................... 3-6
3.3.1 Installation ........................................................................................................................... 3-6
3.3.2 Procedure for system securing ........................................................................................... 3-6
3.3.3 Wiring installation ................................................................................................................ 3-7
3.3.4 Procedures for wiring installation ........................................................................................ 3-9
3.3.5 Installation of circulating fluid and facility water piping ...................................................... 3-12
HRW Series
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Table of Contents
Chapter 4 System Startup and Shutdown ............................................. 4-1
4.1 Pre-check .................................................................................................................. 4-1
4.1.1 Installation condition ............................................................................................................ 4-1
4.1.2 Cable connection ................................................................................................................. 4-1
4.1.3 Installation of circulating fluid and facility water piping ........................................................ 4-1
4.1.4 Operating signal from your system ...................................................................................... 4-1
4.1.5 Check emergency off [EMO] switch .................................................................................... 4-1
4.2 Opening of Facility water Valve .............................................................................. 4-1
4.3 Supply of Circulating Fluid ...................................................................................... 4-2
4.3.1 Preparation of circulating fluid ............................................................................................. 4-2
4.3.2 Supply of circulating fluid ..................................................................................................... 4-3
4.4 Requirement for System Startup ............................................................................ 4-4
4.4.1 Turning ON power................................................................................................................ 4-4
4.4.2 Circulating fluid temperature setting .................................................................................... 4-5
4.5 System Startup and Shutdown ............................................................................... 4-5
4.5.1 System startup ..................................................................................................................... 4-5
4.5.2 System shutdown ................................................................................................................ 4-5
Chapter 5 System Operation ................................................................ 5-1
5.1 Operation Display Panel .......................................................................................... 5-1
5.2 Flow Chart of Operation Screen.............................................................................. 5-2
5.3 Operation Screen ..................................................................................................... 5-3
5.3.1 Model Indication screen ....................................................................................................... 5-3
5.3.2 Status screen 1 .................................................................................................................... 5-3
5.3.3 Status screen 2 .................................................................................................................... 5-4
5.3.4 Status screen 3 .................................................................................................................... 5-4
5.3.5 Status screen 4 .................................................................................................................... 5-5
5.3.6 Menu screen ........................................................................................................................ 5-5
5.3.7 Setting screen ...................................................................................................................... 5-6
5.3.8 Mode Selection screen ........................................................................................................ 5-6
5.3.9 Initial Setting screen ............................................................................................................ 5-7
5.3.10 Maintenance screen ............................................................................................................ 5-9
5.3.11 Option screen ...................................................................................................................... 5-9
5.3.12 Alarm Display screen ......................................................................................................... 5-10
5.3.13 Information screen ............................................................................................................. 5-10
5.4 Examples of System Operation ............................................................................ 5-11
5.4.1 Example 1: Circulating fluid set temperature is changed from 25.0°C to 34.1°C. ............. 5-11
5.4.2 Example 2: Communication mode is switched from “DIO REMOTE” to “LOCAL”. ........... 5-13
5.4.3 Example 3: Alarm signal of contact signal is changed from “N/A” to “ALARM1”. .............. 5-14
Chapter 6 Error Message and Troubleshooting ................................. 6-1
HRW Series
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Table of Contents
6.1 Error Message ......................................................................................................... 6-1
6.2 Troubleshooting ................................ ...................................................................... 6-2
Chapter 7 System Maintenance ........................................................... 7-1
7.1 Water Quality Management ..................................................................................... 7-1
7.2 Inspection and Cleaning ......................................................................................... 7-2
7.2.1 Daily inspection ................................................................................................................... 7-2
7.2.2 Quarterly inspection ............................................................................................................ 7-3
7.3 Storage ..................................................................................................................... 7-3
7.3.1 Draining of circulating fluid out of tank ................................................................................ 7-4
7.3.2 Draining of facility water ...................................................................................................... 7-5
7.4 Periodic Replacement Parts ................................................................................... 7-6
Chapter 8 Appendix .............................................................................. 8-1
8.1 Specification ............................................................................................................ 8-1
8.1.1 System specification ............................................................................................................ 8-1
8.1.2 Communication specification............................................................................................... 8-4
8.1.3 Alarm signal selection ......................................................................................................... 8-6
8.2 Outer Dimensions ................................................................................................... 8-7
8.3 Flow Chart ................................................................................................................ 8-8
8.3.1 Part 1 ................................................................................................................................... 8-8
8.3.2 Part 2 ................................................................................................................................... 8-8
8.4 Offset Function ........................................................................................................ 8-9
8.4.1 Example of offset function ................................................................................................. 8-10
8.5 BAND/READY function ......................................................................................... 8-12
8.6 Anchor Bolt Mounting Position ............................................................................ 8-13
8.7 Compliance ............................................................................................................ 8-14
8.8 Thermo Chiller Daily Inspection Sheet ................................................................ 8-15
Product Warranty ............................................................................................................ 8-19
HRW Series
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Table of Contents
HRW Series
1-1
Chapter 1 Safety
Be sure to read and understand the important precautions defined in
this manual thoroughly prior to system use.
1.1 Before Using this System
This "Safety" chapter describes the safety-related items that users should be
aware of upon handling this system.
This system, which is operated under high voltage, is outfitted with the parts
that cause a rise in temperature and rotating parts when it is in action, All
personnel who work with or around this system are required to thoroughly read
and understand the safety-related items in this manual prior to working with or
around this system.
This manual is not intended to be used as a manual for comprehensive safety
and hygiene education. Such a manual should be provided by a safety training
manager.
HRX-OM-K003
Chapter 1 Safety
All personnel who work on or around this system are to have proper training
and education on dangers specific to this system and safety measures against
potential hazards.
A safety manager is responsible for observing safety standards. Operators and
maintainers, however, are to have individual responsibilies for complying with
the safety standard in his/her daily work.
Operators and maintainers must individually take account of safety and assure a
proper working area and working environment.
The relevant personnel must receive proper safety education prior to work
training on this system. Otherwise, personnel may be exposed to hazards. Never
conduct work training without giving proper consideration to safety.
Save this manual at a designated place for reference when necessary.
HRW Series 1.1 Before Using this System
HRX-OM-K003
1-2
"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 system, facility, or devices.
Chapter 1 Safety
1.2 Danger, Warning, and Caution Used in This
Manual
1.2.1 Hazard Levels
This system is designed with its first priority being the safety of workers and the
prevention of system damage. This manual classifies the risks into the following
three categories according to the severity and level of the hazard; Danger, Warning,
and Caution. Read the statements carefully, thoroughly understand them before
operating this system.
DANGER, WARNING and CAUTION signs are in order according to hazard
severity (DANGER > WARNING > CAUTION). See below for the details.
[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 leave aftereffects, and/or injury
requiring hospitalization and/or prolonged staying in a hospital.
“Minor injury”
This term describes injuries that do not require hospitalization or prolonged staying
in a hospital (injuries other than “serious injuries” described above).
1.2 Danger, Warning, and Caution Used in This Manual HRW Series
1-3
1.2.3 Symbols
This symbol denotes “Don’t” item which you must
not do in operation of this system.
This symbol denotes the “obligation” items which
you must follow in operation of this system.
This symbol warns you of potential electrical shock.
This symbol warns you of potential burns.
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
Symbol of heat hazard
HRX-OM-K003
Chapter 1 Safety
Symbol of “Don’ts”
Symbol of “Dos”
HRW Series 1.2 Danger, Warning, and Caution Used in This Manual
HRX-OM-K003
1-4
[High voltage hazard]
This warning label is affixed on the part isolated with the cover panel of the system
panel in which high voltage is applied.
Do not remove cover panels that are not designated in this manual.
Figure 1-1 Hazard warning label No.1
Figure 1-2 Hazard warning label No.2
Figure 1-3 Hazard warning label No.3
[Hot surface hazard]
This warning label is affixed on the surface that is at high temperatures carrying
potential burns if touched. Residual heat may cause burns despite the power being
turned OFF. Be sure of the surface reaching room temperature before work.
Figure 1-4 Hazard warning label No.4
Figure 1-5 Hazard warning label No.5
Chapter 1 Safety
1.3 Hazard Warning Label
The hazard warning labels are applied to the sections of this system where
potential hazards are present during system operation and maintenance.
The hazard warning labels are in appropriate sizes and colors to get attention of the
operator. They contain symbols in addition to the descriptions of warnings.
1.3.1 Type of hazard warning label
The hazard warning labels affixed on this system are listed below.
Labels of high voltage hazard
Labels of hot surface hazard
1.3 Hazard Warning Label HRW Series
1-5
1.3.2 Location of hazard warning label
Figure 1-6 High Voltage Hazard
Confirm the locations of the hazard warning labels.
Read the contents of the hazard warning labels carefully and keep them in
mind.
Do not peel off or deface the hazard warning labels.
Users are NOT allowed to change the locations of the hazard warning
labels. Make sure to affix a new label to exactly the same location of
the replaced label upon replacement of the peeled off or worn out
label.
Hazard warning label No.2
Hazard warning label No.1
Front
Hazard warning label No.3
HRX-OM-K003
Chapter 1 Safety
High voltage hazard
HRW Series 1.3 Hazard Warning Label
HRX-OM-K003
1-6
Figure 1-7 Hot Surface Hazard
Front
Rear
Hazard warning label No.4
Hazard warning label No.5
Chapter 1 Safety
Hot surface hazard
1.3 Hazard Warning Label HRW Series
1-7
1.4 Location of Model Label
Figure 1-8 Location of Model Label
Label
Front
SERIAL NO.
MODEL NO.
Rear
Information on your system such as Serial No. and Model No. need to be furnished
when you contact the store you purchased from. Serial No. and model No. are
listed on the label as shown below.
HRX-OM-K003
Chapter 1 Safety
HRW Series 1.4 Location of Model Label
HRX-OM-K003
1-8
Follow the following instructions upon operation of this system.
Failure to follow the instructions can lead to personal injury or
hazardous accidents.
Chapter 1 Safety
1.5 Safety Measures
1.5.1 Safety Precautions
While this system is protected by various safety measures including the safety
interlocks, the following basic safety precautions should be observed to assure
further safe operations.
Read and understand this manual thoroughly before operation of this system.
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.
See “1.5.4 Protective equipment”to wear protective equipment properly.
Refer to your safety manual for emergency evacuation.
Use assistance to carry object over 20 kg.
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.
1.5 Safety Measures HRW Series
1-9
1.5.2 Safety Interlock system
Figure 1-9 Front Panel
Front
Front panel
Breaker handle
Safety Interlock system
The function of the safety interlock system is not only protect personnel by
restricting operation that may cause damage to this system or the facility around it
but also eliminate the danger relating to safety. This system is outfitted with
several interlock functions that are activated when improper operation or hazardous
conditions occur. System operation shall be terminated when a safety interlock is
activated
An alarm message is displayed on the LCD screen when a safety interlock is
activated. See “Chapter 6 Error Message and Troubleshooting” for details on the
alarms and remedies or see section “Troubleshooting” in a separate volume of the
“Service Manual”.
Front panel
System repair may require the removal of the front panel.
The breaker handle operation is available only with the front panel attached.
HRX-OM-K003
Chapter 1 Safety
HRW Series 1.5 Safety Measures
HRX-OM-K003
1-10
Figure 1-10 Lockout/Tagout
Those who engage in service of this system should build an awareness of
the importance of lockout. Thorough understanding of the procedures
defined in this manual are required for system service.
Lockout is allowed only when the system come to a full stop.
A supervisor should be appointed to direct all personnel if multiple
workers engage in system service.
The supervisor is to perform lockout based on a full understanding of
overall process conditions.
Not only all personnel but new personnel that engage in service of this
system should build an awareness of the importance of lockout and
obtain thorough understanding of the lockout procedure.
Any personnel working in an area with high voltage should be assigned
with padlocks and tags. The key for the padlock is kept under the
responsibility of the supervisor, and lockout release is performed upon
completion of work.
Main breaker
Padlock
Tag
Front
Chapter 1 Safety
1.5.3 Lockout/Tagout
Summary
Lockout in this system disables the main breaker operation to prevent electric
shocks.
Tagout, to be placed on a locked out main breaker, to prevent improper breaker
operation (ON) conducted by other personnel.
See “ Lockout procedure” in the following pages for practical lockout/tagout.
1.5 Safety Measures HRW Series
1-11
Lockout procedure
Figure 1-11 Breaker Handle at ‘OFF ’
Figure 1-12 Breaker Handle at ‘RESET’
Figure 1-13 Pulling-out of Lock Mounting Part
Figure 1-14 Breaker Lock
Padlock
Lock mounting part
Lock
mounting
part
All service personnel must observe the restrictions applied during
lockout and are required to perform lockout in accordance with this
procedure. No service personnel is allowed to start, energize, or use
the locked out system.
1. Turn the breaker handle to ‘OFF ’.
HRX-OM-K003
Chapter 1 Safety
2. Turn the breaker handle to ‘RESET’.
Hold the breaker handle with hand.
The handle turns back to ‘OFF ’ if released.
3. Pull the lock mounting part out of the
breaker handle, and turn the breaker
handle to ‘OFF ’.
The lock mounting part is to remain pulled
out.
4. Lock the lock mounting part with the
padlock.
Releasing lockout
1. Remove the padlock from the lock mounting part.
2. Turn the breaker handle to ‘RESET’.
The lock mounting part is pulled in.
The handle turns back to ‘OFF ’ if released.
HRW Series 1.5 Safety Measures
HRX-OM-K003
1-12
Read and understand the relevant operation manual thoroughly prior
to use of protective equipment.
Chapter 1 Safety
1.5.4 Protective equipment
This manual defines protective equipment according to work type.
Wear proper protective equipment as shown below, according to work type.
For system transportation, installation and removal
Protective footwear Protective gloves Hard hat
For handling circulating fluid
Protective footwear Protective gloves Protective mask
Protective apron Protective goggles
For system operation
Protective footwear Protective gloves
1.5 Safety Measures HRW Series
1-13
1.6 Emergency Measures
Figure 1-15 Location of Emergency Off [EMO] Switch
1.6.1 Emergency off [EMO] switch
Press the red emergency off [EMO] switch on the front of the system only if the
need to shut off the power arises due to emergency such as natural disaster, fire,
earthquake or personal injury.
The emergency off [EMO] switch is a large, red mushroom-shaped push button
labeled with ‘EMO’ on it. The system comes to a halt if this button is pressed.
When press the emergency off [EMO] switch, the control power for this system is
shut off to bring the system to a stop. The main breaker of this system, however, is
designed not to trip, which enables the motor circuit to remain partially energized.
“8.1.2 Communication specification” in Chapter 8 Appendix on page 8-4 to view
the circuit diagram and see how the EMO switch is interconnected to the system.
Restart of this system is enabled only when this button is reset manually.
Location of emergency off [EMO] switch
HRX-OM-K003
Chapter 1 Safety
HRW Series 1.6 Emergency Measures
HRX-OM-K003
1-14
Figure 1-16 Emergency Off [EMO] Switch
No automatic recovery is applied to the emergency off [EMO] switch.
Always eliminate the cause of activating the EMO before resetting.
Potential serious accidents may occur if disregarded.
When the system is in remote mode, the remote mode is retained
despite the power outage. Thus the system operation is to resume as
the start signal is issued from your system.
Chapter 1 Safety
Reset of emergency off [EMO] switch
1. Before restarting, always make sure that the cause of the emergency off condition (The
reason why the EMO switch was activated) has been eliminated from the power supplies,
the system and peripheral equipment.
2. With the cause completely eliminated,
turn the emergency off [EMO] switch
clockwise to reset.
The EMO button returns to its original position.
3. The screen then changes from the “Model Indication screen” to “Status screen 1” as power
is being restored to the system.
1.6 Emergency Measures HRW Series
1-15
1.7 Waste Disposal
Disposal of the fluid and system must be in accordance with
regulations and rules of local authorities.
1.7.1 Circulating fluid disposal
As to the disposal of a circulating fluid (ethylene glycol solution, fluorinated fluid),
consign the specialized industrial waste disposal agency with the contents detailed.
1.7.2 System disposal
As to the disposal of this system, consign the specialized industrial waste disposal
agency in accordance with local laws and regulations.
HRX-OM-K003
Chapter 1 Safety
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.
HRW Series 1.7 Waste Disposal
HRX-OM-K003
1-16
Chapter 1 Safety
1.8 Material Safety Data Sheet (MSDS) HRW Series
Chapter 2 Name of Each Section
2-1
Caster w/ brake
Rotates 360°.
Operation display panel
Emergency off [EMO] switch
Main breaker
Ventilating hole
(intake side)
Power cable access
Ventilating fan (exhaust side)
Circulating fill port
Facility water inlet
Circulating fluid supply
Circulating fluid level gauge
Circulating fluid return
Tank drain port
Drain pan port
Facility water outlet
Chapter 2 Name of Each Section
2.1 Name of Each Section
HRX-OM-K003
[Tips]
Figure 2-1 Name of Each Section
HRW Series 2.1 Name of Each Section
The casters have built-in brakes. The disengagement of the brakes is
required when transporting the system.
HRX-OM-K003
2-2
Chapter 2 Name of Each Section
2.1 Name of Each Section HRW Series
HRX-OM-K003
3-1
Proper procedure must be followed when using this system.
Exercise caution to assure personnel safety during the installation,
operation, maintenance, and inspection of the system.
Only personnel, who have adequate knowledge and experiences with
not only this system but associated equipment are allowed to perform
transport, installation, and maintenance involving potential hazardous
task.
For transporting with the forklift, be sure to insert the fork into a
designated position, referring to “3.1.1 Transporting with forklift” on
page 3-2.
Do not set this system on its side during transportation.
Drain the remaining fluid out of the pipe as much as possible.
The remaining fluid may spill if disregarded.
Exercise caution not to damage the panel and piping with the forklift
when transporting the system.
Chapter 3 Transporting and Installation
Chapter 3 Transporting and Installation
3.1 Transporting
This system is heavy, which poses potential danger at transportation.
When transporting this system, the following safety precautions should be
observed to prevent system damage and breakdown.
HRW Series 3.1 Transporting
HRX-OM-K003
3-2
Figure 3-1 Transport with Forklift
This system is heavy, and requires a forklift to safely move it.
Forklift insertion positions are on either left or right side of this system.
Always insert the forks all the way through. Be careful not to hit the
casters.
Do not set this system on its side for transportation. Potential damage to
this system carrying danger of personnel injury if disregarded.
Do not insert the fork from the back as well as front.
Rear
Front
Forklift insertion side
Forklift insertion side
Chapter 3 Transporting and Installation
3.1.1 Transporting with forklift
3.1 Transporting HRW Series
3-3
3.1.2 Transporting with caster
This system is heavy, which requires assistance for this work.
Exercise caution and look out for sloped surfaces such as ramps, etc.
Do not grab piping on the back of this system or panel handles when
transporting with the casters.
Potential damage to piping and panels may occur if disregarded.
System installation should be kept from areas with the potential of
flammable gas leak. Ignition may occur if leaked gas is collected
around the system.
This system is NOT designed for outside use.
Potential electric shock, fire and system damage may occur if exposed
to rain, water and dust.
This system is to be installed on a level floor that can withstand the
weight of this system. Potential water leak and personal injury due to
system tipping over may occur if disregarded.
3.2 Installation
HRX-OM-K003
Chapter 3 Transporting and Installation
HRW Series 3.2 Installation
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