Cast Aluminum Solutions CAST-X 2500 Specifications

CAST-X 2500

Circulation Heater

The CAST-X 2500 is our most compact dual-tube model, a powerful and versale mid-sized heater.

SPECIFICATIONS:

• Power:

• 2.5 kW Total to 15 kW Total

• Voltage Range: 208 - 480V

• Max Line Current: 30 A per circuit

Designed and manufactured by Cast Aluminum Solutions (CAS),
CAST-X Circulation Heaters are engineered using the latest
thermal modeling and finite element analysis technology.
CAST-X heaters feature low-watt-density heating elements cast
into aluminum bodies which also contain the helical-coiled
stainless steel flowpath tubes.

The media is sequestered in these tubes, never touching the
heating elements: a critical safety benefit, especially when heat­ing explosive or sensitive media. All CAST-X units are capable of

ating liquids and gases alike.

he

CAST-X heaters are self-draining, for safety and cleanliness. With
compact, non-welded bodies, plus NEMA & ATEX enclosures,
CAST-X units are small-footprint, high-output heaters that meet
the needs of high-purity processes, flammable operations, and
your most critical heating applications.

• Tubing:

• .625” OD (5/8") (15.9 mm)

• .065” Wall (1.7 mm)

• Overall Process Tube Length: 130” (3302 mm) each

• 316L Stainless Steel (standard)

• Inconel (optional upgrade)

• Passivated or Electro-Polished (optional upgrades)

• Max Pressure: 4000 psi (275 bar)

• Enclosures:

• NEMA 1 (general-purpose/dust-proof)

• NEMA 4 (moisture-resistant)

• NEMA 7 (explosion-proof)

• ATEX (explosion-proof)

• Max Working Temperatures:

• NEMA 1 (dust-proof/general-purpose): 662°F (350°C)

• NEMA 4 (moisture-resistant): 572°F (300°C)

• NEMA 7 (explosion-proof): 482°F (250°C)

• ATEX (explosion-proof): 482°F (250°C)

Published temperatures are for housing at 12 o’clock position; higher
temps may be possible at 6 o’clock position. See factory for details.

• Sensors:

• K or J Type Thermocouples Standard

• Snap-Action High-Limit Thermostat

• Process and High-Limit Thermocouples

• Available Accessories:

• Insulating Jackets

• Compression Fittings

APPLICATIONS:

• Paint, Solvent & Petrochem Heating

• Glycol & Heat-Transfer System Use

• Food & Beverage Pasteurization

• Industrial Gas Heating & Air Separation

• Steam Generation

• Laboratory & Analytical Applications

• Urethane / Foam System Heating

Tel: [phone] • [e-mail] • www.CastAluminumSolutions.com • 1310 Kingsland Drive • Batavia, Illinois 60510 USA

FEATURES & BENEFITS:

• SS 316L Fluid Path is Separate from Heating Elements
(allows safe heating of sensitive materials and prevents contamination)

• Very Compact Design: Replaces Much Larger Heaters

• Self-Draining, Low-Maintenance Design

• Non-Welded Body & Cast-In Heaters (for long heater life)

• Wide Application Compatibility (including high pressure)

• Operable in Single-Tube or Dual-Tube Mode

• Dual Tube Mode Can Run in Series or Parallel

5.0

127

4.0

102

6.0

153

3.00
76

12.00
305

8.2

207

3/8"-16

or

M10 x 1.5

tapped holes

102

3.00
76

12.00
305

8.2

207

3/8"-16

or

M10 x 1.5

tapped holes

7.9

201

7.9

201

CAST-X 2500 Circulation Heater

GENERAL-PURPOSE

(NEMA 1) ENCLOSURE

.625

1.5
39

12.5
318

180

160

140

120

100

5.75

146

4.6

116

15.75
400

MOISTURE-RESISTANT
(NEMA 4) ENCLOSURE

6.0

153

EXPLOSION-PROOF

(NEMA 7) ENCLOSURE

8.2

207

12.00
305

3/8"-16

5.0

127

or

4.0

M10 x 1.5

tapped holes

3.00
76

CAST-X2500 Heating Profile: Delta-T Water

(Process Fluid = Water @ 42°F / 5.6°C Inlet Temp, Single Pass Using One Tube, 100% Power, Set Point 752°F / 400°C)

EXPLOSION-PROOF
(ATEX) ENCLOSURE

100.0

Heater

Wattage:

15kW
12kW
9kW
6kW
3kW

88.9

77.8

66.7

55.6

7.9

201

80

60

40

Temperature Increase (Delta-T, °F)Pressure Drop (Delta-P, PSI)

20

0

0 1 2 3 4 5 6 7 8 9 gpm
0 3.80 7.60 11.40 15.14 18.92 22.71 26.50 30.30 34.1 l/min

Flow Rate (gpm and l/min)

CAST-X 2500 Pressure Drop Profile: Delta-P Water

(Process Fluid = Water. Change in Pressure from Inlet to Outlet, Single Pass Using One Tube)

14

12

10

8

6

4

2

0

0 1 2 3 4 5 6 7 8 9 gpm
0 3.80 7.60 11.40 15.14 18.92 22.71 26.50 30.30 34.1 l/min

Flow Rate (gpm and l/min)

44.4

33.3

22.2

11.1

0.0

96.5

82.7

68.9

55.2

41.4

27.6

13.8

0.0

Temperature Increase (Delta-T, °C)Pressure Drop (Delta-P, kPa)

NEMA 1 ENCLOSURE NEMA 4 ENCLOSURE NEMA 7 ENCLOSURE ATEX ENCLOSURE INSULATING JACKET

1L1

G

1L3

1L1

1L2

G

1L1

G

2L2

2L3

2L1

1L3

1L2

1L1

1L2

1L1

1L2

1L3

G

1 L1

1 L2

G

HEATER*

SINGLE PHASE

CIRCUIT

*Wiring schematic only shows heater elements. Refer to I&M Manual for further details on wiring of snap-action switches and thermostats (if applicable).

700

600

500

400

300

200

1L3

1L2

HEATER*

HEATER*

HEATER*

HEATER*

HEATER*

HEATER*

DELTA CIRCUITS

CAST-X 2500 Available Circuit Types

HEATER*

HEATER*

HEATER*

THREE-PHASE

WYE CIRCUIT

N

HEATER*

HEATER*

HEATER*

THREE-PHASE

DELTA CIRCUIT

1L3

1L2

TWO THREE-PHASE

The CAST-X 2500 is manufactured with these types of circuit configurations.

CAST-X 2500 Heating Profile: Delta-T Air

(Process Fluid = Air @ 100 psi (689 kPa), 70.7°F / 21.5°C, Single Pass Using One Tube, Set Point 752°F / 400°C)

1L1

HEATER*

HEATER*

HEATER*

HEATER*

HEATER*

TWO THREE-PHASE

WYE CIRCUITS

388.9

Heater

Wattage:

15kW
12kW
9kW
6kW
3kW

333.3

277.8

222.2

166.7

111.1

HEATER*

NNN

Temperature Increase (Delta-T, °F)Pressure Drop (Delta-P, PSI)

100

55.6

0

0.0

Temperature Increase (Delta-T, °C)Pressure Drop (Delta-P, kPa)

0 20 40 60 80 100 120 scfm
0 566.3 1132.7 1699.0 2265.4 2831.7 3398.0 slm

Flow Rate (scfm and slm)

CAST-X 2500 Heating Profile: Delta-P Air

(Process Fluid = Air @ 100 psi (689 kPa), 70.7°F / 21.5°C, Single Pass Using One Tube, Set Point 752°F / 400°C)

25

20

15

10

5

0

0 20 40 60 80 100 120 scfm
0 566.3 1132.7 1699.0 2265.4 2831.7 3398.0 slm

Flow Rate (scfm and slm)

172.4

137.9

103.4

68.9

34.5

0.0

CAST-X 2500 Circulation Heater

BX25-AAA-BB-CDDEF

AAA = VOLTS, POWER, CIRCUIT TYPE
BB = ENCLOSURES & THERMOSTAT
C = HIGH LIMIT SWITCH

Building a CAST-X 2500 Part Number

Use the graphs on the following pages to build
each section of the CAST-X 2500. After assigning
numbers for each section A to F, you will have a
complete part number, ready to quote.

D = THERMOCOUPLES
E = TUBING

For assistance, contact CAS directly.

F = MACHINING

Cast Aluminum Solutions (CAS) manufactures CAST-X Circulation Heaters, plus a broad range of heating, cooling, and non-thermal
components. We are relied upon by OEMs and end-users alike throughout the semiconductor, medical device, aerospace, industrial
gas, fluid-handling, food equipment, and energy markets.

Our multi-discipline team of engineers and technicians works closely with customers to develop practical solutions to complex process
challenges. We utilize industry standard applications such as Finite Element Analysis (FEA), SolidWorks® 3-D CAD technology, and a
range of structural analysis & thermal modeling tools.

CAS is an ISO 9001 Certified company with a fully-equipped R&D facility. Testing capabilities include X-Ray, ultrasound, helium leak, and
infra-red technology, plus the latest coordinate measuring machines (CMM). Our in-house casting facility utilizes a permanent mold
low-pressure casting process which reliably produces low-porosity, high-quality aluminum products. We offer an array of precision
CNC machining options, finishing options such as electroless nickel plating, Teflon® coatings, clear-coat and hard-coat anodizing, plus
high-value-added testing and inspection services.

Headquartered in Batavia, Illinois (just outside Chicago) we serve customers worldwide.
See the below map to locate a Sales Engineer, or contact CAS directly. We look forward to working with you.

1

1 - WEST REGION
Tel: [phone]

2 - MIDWEST REGION

Chicago Tel: [phone]
Minneapolis Tel: [phone]

3 - SOUTH REGION

Tel: [phone]

4 - NORTHEAST REGION

Tel: [phone]

2

4

3

ENERGY PROCESS DIVISION

Tel: [phone]

SEMICONDUCTOR DIVISION

Tel: [phone]

5

5 - MEXICO, CENTRAL
and SOUTH AMERICA
Tel: [phone]

6 - EUROPE
France

Tel: [phone]

Germany

Tel: [phone]

Italy

Tel: [phone]

Spain

Tel: [phone]

United Kingdom

Tel: [phone]

7

6

8

9

8 - ASIA
China

Tel: [phone]

Japan

Tel: [phone]

Korea

Tel: [phone]

Taiwan

Tel: [phone]

India

Tel: [phone]

9 - AUSTRALIA & NZ

Tel: [phone]

7 - RUSSIA, AFRICA & MIDDLE-EAST

Tel: [phone]

Tel: [phone] • [e-mail] • www.CastAluminumSolutions.com • 1310 Kingsland Drive • Batavia, Illinois 60510 USA

“AAA” section

The first step in building a
CAST-X 2500 part number
is determining the volt,
watt and circuit
configuration.

Select the “AAA”
number (far left column)
that best matches your
specifications.

Need Help with Part Numbers ?

Contact CAS Directly:

Tel: [phone] (USA)

Toll-Free: 888-367-3992

[e-mail]

CAS representatives are available
to walk you through the process.

www.CastAluminumSolutions.com

Designation

“AAA”

012

021

022

023

031

032

033

041

042

051

052

053

061

063

VOLTAGE, POWER, CIRCUIT TYPE

Volts refers to line volts (V

Circuit

Type

THREE-PHASE

WYE

THREE-PHASE

DE LTA

THREE-PHASE

WYE

SINGLE

PHASE

THREE-PHASE

DE LTA

THREE-PHASE

WYE

SINGLE

PHASE

THREE-PHASE

DE LTA

THREE-PHASE

WYE

THREE-PHASE

DE LTA

THREE-PHASE

WYE

SINGLE

PHASE

THREE-PHASE

DE LTA

SINGLE

PHASE

Volts (V)

). Amps refers to line current (IL).

L

Watts (kW)

480 N/A
415 14.8 20.7
400 13.8 19.9
380 12.4 18.9
240 5.0 12.0
208 3.7 10.4
480 15.0 18.0
415 1
400 10.4 15.0
380 9.4 14.3
240 3.7 9.0
208 2.8 7.8
480 5.0 6.0
415 3.7 5.2
400 3.4 5.0
380 3.1 4.8
480 N/A
415 11.2 27.0
400 10.4 26.0
380 9.4 24.7
240 3.7 15.6
208 2.8 13.5

380V
240 7.2 17.3
208 5.4 15.0
480 9.6 11.6
415 7.2 10.0
400 6.7 9.6
380 6.0 9.1
240 2.4 5.8

380V TO 480V NOT AVAILABLE
240 7.2 30.0
208 5.4 26.0

380V TO 480V NOT AVAILABLE
240 10.7 25.7
208 8.0 22.2
480 14.2 17.1
415 10.6 14.8
400 9.9 14.3
380 8.9 13.5
240 3.6 8.6
208 2.7 7.4
480 N/A
415 12.0 16.6
400 1
380 10.0 15.2
240 4.0 9.6
208 3 8.3
480 5.3 6.4
415 4.0 5.6
400 3.7 5.4
380 3.3 5.1
480 N/A
415 12.0 28.8
400 11.1 27.8
380 10.0 26.4
240 4.0 16.7
208 3.0 14.4
480 4.0 4.8
415 3.0 4.2
400 2.8 4.0
380 2.5 3.8
480 4.0 8.3
415 3.0 7.2
400 2.8 6.9
380 2.5 6.6

1.2 15.6

TO 480V NOT AVAILABLE

1.1 16.0

Amps (A)

(per circuit)

ENCLOSURE AND THERMOSTAT

The first digit corresponds to the following: 1. Standoff mounting required 2. Pipe nipple mounting required

Designation "BB" Thermostat Enclosure

11 NO THERMOSTAT NEMA 1
12 NO THERMOSTAT NEMA 4
21 NO THERMOSTAT NEMA 7
22 32° - 250°F (0° - 121°C) THERMOSTAT NEMA 7
23 0° - 100°F (-17° - 38°C) THERMOSTAT NEMA 7
24 NO THERMOSTAT ATEX
25 DOUBLE POLE SINGLE THROW (DPST) THERMOSTAT ATEX

SNAP ACTION HIGH LIMITS SWITCHES

“BB” to “F”

Designation "C" Switch

0 NONE
1 AUTO RESET, 200°F (93°C)
2 AUTO RESET, 250°F (121°C)
3 AUTO RESET, 425°F (218°C)
4 AUTO RESET, 500°F (260°C)
5 MANUAL RESET, 260°F (126°C)
6 MANUAL RESET, 185°F (85°C)
7 MANUAL RESET, 150°F (65°C)
8 MANUAL RESET, 260°F (126°C) WITH TEFLON LEADS

THERMOCOUPLES

All thermocouples are ungrounded, for optimal performance

Designation "DD"

0 NONE
1
2
3
4

NOTE: The part number has two "D" designations because the unit has two thermowells.
Always put the lowest designation number first in the part number to avoid duplicate configurations.
e.g. BX25-xxx-xx-x 1 2 x instead of BX25-xxx-xx-x 2 1 x

Description

SINGLE

DUAL

SINGLE

DUAL

J-TYPE THERMOCOUPLE IN THERMOWELL

J-TYPE THERMOCOUPLES IN THERMOWELL

K-TYPE THERMOCOUPLE IN THERMOWELL

K-TYPE THERMOCOUPLES IN THERMOWELL

After selecting your AAA num­ber, use the charts on this page
to select your BB, C, D, E and F
designations.

(always selecting your number
from the far left column)

Sections

TUBING

Option 1 is the standard option (dual 316L SS)

Designation "E" Tube Description Number of Tubes

1 5/8" (15.9 mm) OD X .065" (1.65 mm) WALL, 316L SS SEAMLESS (STANDARD OPTION)
2 5/8" (15.9 mm) OD X .065" (1.65 mm) WALL, 316L SS SEAMLESS, ELECTROPOLISHED
3 5/8" (15.9 mm) OD X .065" (1.65 mm) WALL, 316L SS SEAMLESS, PASSIVATED
4 5/8" (15.9 mm) OD X .065" (1.65 mm) WALL, 316L SS SEAMLESS
5 5/8" (15.9 mm) OD X .065" (1.65 mm) WALL, 316L SS SEAMLESS, ELECTROPOLISHED
6 5/8" (15.9 mm) OD X .065" (1.65 mm) WALL, 316L S.S. SEAMLESS, PASSIVATED

MACHINING

Designation "F" Mounting Hole Description

1 STANDARD 3/8"-16 MOUNTING HOLES
2 STANDARD M10 X 1.5 MOUNTING HOLES

available to help you work through

part number configurations, provide

2
2
2
1
1
1

Need Assistance ?

The CAS Team is ready and

engineering advice, and ensure

CUSTOM DESIGNS & COMPONENTS

CAS offers several options for special tubes, sensors, and finishes.

For these options, please call a CAS Representative for a quote.

Options

SPECIAL ALLOY TUBES SPECIAL HIGH-LIMIT SWITCHES OR RTDs
THICK WALL TUBES NPT FITTINGS

customers purchase the heater

most appropriate for their

particular application.

Contact CAS Directly:
Main Tel: [phone]
Toll-Free: 888-367-3992

[e-mail]

ACCESSORIES

www.CastAluminumSolutions.com

Part Number Description

274-55-6-8
307-0-22-1 INSULATING JACKET: TEMP. LIMIT: 800°F / 425°C

TUBE UNION COMPRESSION FITTING (5/8” / .625 INCH) / PAIR (SHIPPED LOOSE)