™ ® Chromalox CMX Series Circulating Water Temperature Controller System Model Number and Rating Part Number Serial Number Customer Customer Order Number Issue Date July 1996 Date User’s Manual Part Number: 161-123417-023 Sales PQ-445
Table of Contents Section Topic 1 Getting Started ........................................................................................... 1 2 Installation .................................................................................................. 5 3 Temperature Control Operation ................................................................ 13 4 System Operation ....................................................................................... 19 5 Diagnostics .................
Illustrations Figure Topic 1.1 System Photo .............................................................................................. 2 1.2 Control Panel ............................................................................................. 3 2.1 Open-Loop System Piping ......................................................................... 6 2.2 Open-Loop Piping Connections ................................................................ 7 2.3 Closed-Loop System Piping ............
Section 1 Getting Started Section Contents Introduction System Photo Model Identification Important Read and understand all instructions in this user’s manual and the enclosed 2104 temperature control instruction manual before attempting to install or operate system. Congratulations on purchasing the Chromalox CMX Series microTHERM™ Temperature Control System. This system has been thoroughly engineered, carefully built, and fully tested to assure years of service.
Figure 1.1 System Photo Operating temperatures of 50° to 250°F for a wide variety of applications ASME pressure relief valve opens if system pressure exceeds 125 psi, ensuring safe operation Incoloy® sheath Chromalox® heating elements. Integral solenoid valve for precise temperature control and optimum flow. Automatic air purge cycle removes accumulated air from water lines. Standard 3.8 sq. ft.
Figure 1.2 Control Panel Dual pressure gauges for monitoring of both to process and from process pressures.
Ordering Information Model KW Volts Total Amperage Open-Loop Cooling CMX-250-4 CMX-250-4 4.5 4.5 240 480 13.6 6.8 CMX-250-9 CMX-250-9 9 9 240 480 24.5 12.2 CMX-250-12 CMX-250-12 12 12 240 480 31.7 15.8 CMX-250-18 18 240 46.1 CMX-250-18 18 480 23.1 CMX-250-24 CMX-250-24 24 24 240 480 60.5 30.3 Closed-Loop Cooling CMX-250-4C CMX-250-4C 4.5 4.5 240 480 13.6 6.8 CMX-250-9C CMX-250-9C 9 9 240 480 24.5 12.2 CMX-250-12C CMX-250-12C 12 12 240 480 31.7 15.
Section 2 Installation Hydraulic Installation Open-Loop Cooling Section Contents Hydraulic Installation Closed-Loop Cooling Electrical Installation Before Open-Loop Hydraulic Installation Before proceeding with the installation of the open-loop system, please take note of the following important information: 1. Reduced diameter fittings may be used if they do not reduce flow rate and increase pressure drop significantly. Galvanized steel unions are recommended at all connections. 2.
Hydraulic Installation Open-Loop 1. Locate the unit as close as possible to the controlled process in order to minimize pressure drops. Make sure the unit is sitting on a solid, level foundation. 2. Using 1 1/4" NPT or larger schedule 40 pipe (flexible hose suitable for 150 psi and 250°F minimum service conditions can be used), connect the 1 1/4" NPT “FROM PROCESS” and “TO PROCESS” ports to the mold, mold manifold, or other process. 3. Pipe the entire system to minimize air pockets.
Figure 2.
Before Closed-Loop Hydraulic Installation Before proceeding with the installation of the closed-loop system, please take note of the following information: 1. Reduced diameter fittings may be used if they do not reduce flow rate and increase pressure drop significantly. Galvanized steel unions are recommended at all connections. 2. If water pressure falls below 20 psi, a pressure switch will interrupt pump motor and heater operation.
Hydraulic Installation Closed-Loop (continued) 4. Connect the cooling water supply (30 psi to 80 psi) to the unit’s 1/2" NPT “WATER SUPPLY/COOLING INLET” port with suitable pipe or hose. 5. Connect the 1/4" NPT port identified as “COOLING OUTLET” to a cooling water return line or plant drain that contains no valves or obstructions that could impede discharge. Review the condition of potential hot water going down a plant drain. Verify that local codes and materials are acceptable for this service.
Figure 2.
Electrical Installation WARNING 1. Hazard of electric shock. The heat transfer system must be grounded using grounding means provided in control box and employing wiring by a qualified electrician in accordance with National Electric Code. Failure to comply can result in electrical shock or electrocution. 2. Hazard of electric shock. Disconnect all power before servicing the heat transfer system. Failure to comply can result in electrical shock or electrocution.
Pump Rotation Check 4. With power off, check the wiring connections by tugging on the lines. Tighten all terminals in the control area. These can loosen due to vibration in shipping. 5. Close the front electrical enclosure door. Pull the top cover off of the heat transfer system and locate the top of the pump motor. 6. With the supply water connected, and adequate pressure present, press the START and STOP buttons in quick succession.
Section 3 Temperature Control Operation Control Panel Temperature Controller Operation Figure 3.1 Control Panel Layout START/STOP Pushbuttons Press START to start the pump. Indicator will illuminate while pump is running. Press STOP Outlet Pressure “To Process” Inlet Pressure “From Process” to stop the pump. Diagnostic Indicators Temperature Controller System shuts down if any diagnostic indicator is illuminated. Top Display reads current system outlet temperature.
Temperature Controller Operation The Chromalox 2104 1/4 DIN temperature controller is a highperformance, single-loop controller used in the CMX system. The 2104 controller has two control outputs for heating and cooling that can be configured separately and provide flexible temperature control for the CMX. Additional outputs give the 2104 the ability to provide an over-temperature alarm.
All control parameters, selections and calibration procedures for the temperature controller are accomplished through simple MENU selections. These MENU selections are organized into PAGES. PAGE/MENU Setup The Display PAGE (DISP) allows you to view the status of the controller. The Control Page (CTRL) allows you to change the control setpoint and security lock. Figure 3.
To change a MENU value: After the MENU is selected and displayed, use the ▲ and ▼ pushbuttons to change the value. For large adjustments (for example, 100 to 200), hold the pushbutton pressed and the display will change more quickly. ➮ ☛ 100 RESET AUX ▲ SP ▼ 200 RESET ☛ SP AUX ▲ ▼ To return to Operating Mode: Press and hold RESET for more than 3 seconds. The controller will automatically return to operating mode after 10 minutes of no pushbutton activity.
To access and enter the Security Code: 1. Press and hold RESET for more than 3 seconds to enter Setup Mode. Security Lock is the first menu that will appear (LOCH). 2. To change the Security Code, press ▲ or ▼ until the correct security code is displayed (458 to change controller setup). L OC H OCH ☛ 123 RESET AUX ▲ ▼ 3. Reference the factory preset MENU settings (Figure 8.2, page 35), when replacing the controller or if the settings have been changed.
Notes 18 ™ User Instructions
Section 4 System Operation WARNING On both open and closed-loop systems, turn on water and insure the water supply lines are free of obstructions BEFORE energizing the heater. Such obstructions could prevent the thermal expansion of water from backing up into this line, thereby increasing system pressure until the relief valve opens. Note: This system is equipped with an ASME safety pressure relief valve (factory preset at 125 psi). 1. Apply power to the system via the remote disconnect.
5. Assure that Pump Rotation Check was performed per instructions on page 12. 6. Start the pump by pressing START on the front panel. The pump indicator light will illuminate. 7. Once temperature has stabilized at the setpoint level, review controllability of the system. If the temperature (displayed in the top display of the temperature controller) is fluctuating at an unacceptable level, consult the temperature control instruction manual for details on tuning the controller.
Section 5 Diagnostics Lower Water Pressure Section Contents Pump Overload Over Temperature Figure 5.1 Diagnostic Indicators Diagnostic Functions All diagnostic functions will shut down the system and require the operator to remedy the problem before it can be restarted. Low Water Pressure Indicator The pump, heater, and cooling will not operate while the pressure is low. The Low Water Pressure Indicator will illuminate when the system pressure is below 20 psi.
Pump Overload Indicator The Pump Overload Indicator will illuminate when the pump draws too much current. Low line voltage, single phase power input, and a seized pump motor are all possible causes for pump overload. WARNING Disconnect system power, if the Pump Overload Indicator is illuminated. Hazard of electric shock or electrocution. Disconnect all power and piping to system. After the system power is disconnected, solve the electrical current problem.
Section 6 Maintenance Section Contents Shut Down Heater Removal/Replacement Pump Removal/Replacement Heat Exchanger Removal/Replacement (closed loop systems) WARNING Disconnect all power before servicing or performing maintenance to the system. Do not attempt to service system while it is operating. Failure to comply can result in: a. Electrical shock or electrocution. b. Burns from hot heating elements, piping, and hot water. c. Injury from operating or rotating pump and motor.
Draining Drain the unit before taking it out of service for a period of time, or if it is exposed to freezing temperatures while out of service. 1. To drain the unit completely, move it to an inclined position with the front of the system raised. 2. Remove the lower plugs on cast chambers (see Figure 6.1, Chamber Photo). Figure 6.
Heater Removal/Replacement WARNING Hazard of electric shock or electrocution. Disconnect all power and piping to system. 1. Disconnect all power to the system. 2. Bleed pressure and drain all water from the system. 3. Remove top panel. 4. Remove red top cover on the heater (see Figure 6.2, Heater/Chamber Photo). 5. Note location of wires on the heater, then remove wires (L1, L2, L3). 6. Loosen compression fitting on the heater power supply cable. 7. Remove cable from the heater. 8.
WARNING Hazard of electric shock or electrocution. Disconnect all power and piping to system. Pump Removal/Replacement 1. Disconnect all power to the system. 2. Bleed pressure and drain all water from the system. 3. Remove top and side panels. 4. Remove pump motor wiring cover panel (2 screws). 5. Note location of pump motor wires and remove. 6. Loosen and remove vent line (see Figure 6.3, Motor Vent Line). 7. Remove bolts holding pump motor to the casting (4 bolts), and lift motor out of casting. 8.
Heat Exchanger Removal/Replacement (closed loop system) 1. Disconnect all power to the system. 2. Bleed pressure and drain all water from the system. 3. Remove top panel. 4. Remove cover on the cooling solenoid (see Figure 6.4, Heat Exchanger). 5. Disconnect “COOLING INLET” and “COOLING OUTLET” piping. 6. Disconnect copper tubing connected to the heat exchanger. 7. Unbolt the heat exchanger and remove (4 bolts). 8. Place new heat exchanger in system and bolt down.
Figure 6.5 microTHERM™ Open and Closed-Loop Electrical Schematic 1C L1 1L1 1T1 L2 1L2 1T2 L3 1L3 1T3 Customer Supplied Voltage 1M-1 GND. 3T1 3T3 2L1 2T1 2L2 2T2 2L3 2T3 Pump Contactor Optional Door Interlock 5 Pump Motor Pump Overload 120V DI-1 1 Heater 4.
Replacement Heating Elements and Contactors Replacement Parts Model Open Loop Closed Loop Voltage CMX-4 CMX-4C CMX-9 CMX-9C CMX-12 CMX-12C CMX-18 CMX-18C CMX-24 CMX-24C 240 480 240 480 240 480 240 480 240 480 Heating Element Heater Contactor 155-554807-523 155-554807-523 155-554807-512 155-554807-512 155-554807-524 155-554807-524 155-554807-519 155-554807-519 155-554807-515 155-554807-515 072-057576-050 072-057576-050 072-057576-050 072-057576-050 072-057576-050 072-057576-050 072-057576-0
Figure 6.
Section 7 Troubleshooting Troubleshooting Guide—For qualified personnel only Symptom Probable Cause Correction Unit will not start, control display does not light. 1. Unit not wired correctly. 1. Check wiring. 2. Disconnect switch OFF. 2. Turn disconnect ON. 3. Blown fuse. 3. Check disconnect fuses and 120V fuse on terminal block (blown fuse indicator will light if fuse is blown). 4. Wrong voltage. 4. Check supply voltage and unit’s rated voltage. 1. Cooling water off, or below 20 psi. 1.
Troubleshooting Guide—For qualified personnel only Symptom Probable Cause Correction Pump Overload Indicator illuminated. 1. Pump motor overload. 1. Determine problem and press pump reset button. Over Temperature Indicator 1. System above temperature limit 1. Allow unit to cool below 260°F illuminated. of 260°F. and press RESET . Unit runs but fails to pump water. 1. Incoming phase reversed on pump motor. 1. Swap any two legs on the incoming power. Unit will not heat to setpoint. 1.
Section 8 Specifications Standard 3/4 HP Pump Pump Size (HP) 3/4 Nominal Flow (gpm) Heating Capacity (kW) Standard Voltages 4.5 240 or 480 9 240 or 480 12 240 or 480 18 240 or 480 24 240 or 480 30 Optional Pump Sizes ™ User Instructions Process Connections (inches dia.) Drain/supply (inches dia.) Approximate Dimensions (inches) 29 height 1 1/4 NPT 1/4 NPT 25 depth 15 width Optional Pump Sizes (HP) Nominal Flow (gpm) 1.5 40 3 50 5 60 7.
Other Options • Alternate Voltages: 208, 380, 575 VAC, 3 phase • Expanded Open Loop Cooling: increased cooling water flow • Expanded Closed Loop Cooling: 6.3 sq. ft.
Figure 8.
Notes 36 ™ User Instructions
Section 9 CMX Warranty and Limitation of Remedy and Liability Warranty Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and the work performed by Chromalox when performed, will meet all applicable specification and other specific product and work requirements (including those of performance), if any, and will be free from defects in material and workmanship under normal conditions of use.
Limitation of Remedy Upon Buyer’s submission of a claim as provided above and its substantiation, Chromalox shall at its option either (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii) refund an equitable portion of the purchase price.
Section 10 Index Alarm Incoloy-sheathed heater 1, 2 •latching 17 •Overtemperature 13, 14, 17 •Relay Action 17 Cabinet 2 Cavitation 2, 21 Closed-loop Heat Exchanger 1 Control Output #1 (Heat) 13, 14, 28 Control Output #2 (Cool) 13, 14, 28 Control Setpoint 13, 14, 15 Control Voltage Fusing 11, 12 Controller •Temperature Controller 3, 9, 13, 14, 19, 23, 29 Cooling Chamber 1 Cooling Control 28 Cooling Solenoid 20, 27, 28 Cooling Water Valve 31, 32 Diagnostic Functions 13, 21 Diagnostic Indicators 3, 13, 19
Replacement Heating Elements and Contactors 29 Replacement Parts 29 Security Code 16 •Access 17 •Change 17 Security Lock 15 Setpoint 13, 14, 15, 19, 20 •Change 15 •Control 15 •Temperature 14, 19 Setup Mode 15 Shutdown 20, 21, 23 Solenoid Valve 2, 9, 28 Specifications 33 Switch •Low Pressure 2 •Pressure 1, 5 •Pump Reset 22 Valve •check 5, 7 •cooling 6, 31-32 •pressure relief 1, 2, 5, 6, 8, 9, 19 •solenoid 2, 9, 28 Vent •automatic 1 •vent line 26 Water Pressure 5, 6 •diagnostic light 3, 13, 19, 21 •regulat
Chromalox® 701 Alpha Drive Pittsburgh, PA 15238 PHONE (412) 967-3800 FAX (412) 967-5148 ® 96-082 PQ-445 July 96
