Chromalox CMX-250-4, CMX-250-24, CMX-250-4C, CMX-250-18C, CMX-250-9C Installation & Operation Manual
...
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
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Installation & Operation Manual
Circulating Water
Temperature Control System
i
Thermal Devices, Inc. Mount Air
PQ450
161-123417-036
March 2019
, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
y
Table of Contents
Contents Page Number
Section 1 Getting Started ......................................................................................................................................1
Section 2 Installation .............................................................................................................................................. 4
Section 3 Temperature Control Operation ........................................................................................................... 9
Section 4 System Operation ................................................................................................................................ 10
Section 5 Diagnostics .......................................................................................................................................... 11
Section 6 Maintenance ........................................................................................................................................12
Section 7 Troubleshooting ................................................................................................................................... 17
Section 8 Specifications ...................................................................................................................................... 18
Appendix A CMX Closed Loop to Open Loop Cooling Conversion ................................................................. 19
Appendix B CMX Open Loop to Closed Loop Cooling Conversion ................................................................. 20
Appendix C CMX 2104 Controller Information .................................................................................................. 23
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Section 1 – Getting Started
Installation Instructions
Read and understand all instructions in this
user’s manual and the associated temperature
control instruction manual before attempting
to install or operate system.
Introduction
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.
The CMX can be operated at a maximum temperature of 250°F at a minimum pressure of 30psi. CMX180 models do not require minimum pressure. Water
temperature is maintained by a microprocessor-based
temperature controller which applies heating and cooling as needed. Heat is applied by a long-life, INCOLY
sheathed heater. Cooling is either via direct injection, in
an open loop, or through a closed loop heat exchanger.
Every system is equipped with an automatic vent that
removes unwanted air from the system during operation, and an ASME pressure relief valve that is factoryset to 125 psi (150 psi with 7.5 hp motor.) A pressure
switch ensures adequate water pressure in the system
to help prevent pump cavitation and steam buildup on
the heater elements, which can shorten the lives of the
heater and pump. The switch is factory-set to 20 psi.
This switch is not included on CMX-180 models.
®
Electrical and hydraulic components are located in
distinctly separate areas in the system to better manage heat buildup and prevent component damage.
The pump housing, heater, and cooling chambers are
single cast pieces, designed to drastically reduce the
chance of leaks and provide ease of service and maintenance. Standard casters make it easy to move the
system from machine to machine.
Power requirements for the system are 240 or 480
volts, 3 phase, 60 cycle, and 4.5 to 24 kW. See the system nameplate for the appropriate voltage and wattage
ratings.
The System Photo and Control Panel Illustrations, on
the following pages, show the CMX and identifies all
key components.
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Figure 1.1 System Photo (Side View)
Operating temperatures of 50° to 250°F
for a wide variety of applications.
Internal system configuration separates
electronics from mechanical systems,
reducing heat buildup and providing
a safer operating system.
ASME pressure relief valve opens if system pressure exceeds 125 psi, ensuring
safe operation.
High watt density, INCOLOY
Chromalox® heating elements.
Integral solenoid valve for precise temperature control and
optimum flow.
®
sheath
Automatic air purge cycle
removes accumulated air
from water lines.
Standard 3.8 sq. ft. heat exchanger (closed loop cooling)
Pump overload circuit protects
systems from damage in event
of excessive current draw in
the motor.
Long-life mercury contactor switches
heater power for millions of cycles and
quiet, trouble-free operation.
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Cabinet design allows
access to all components without removing
a single fastener.
Custom cast pump for optimum flow,
minimum leakage and long life.
Compact, rugged cabinet fits into tight
spaces. Rolling casters allow easy
transfer between locations.
Low pressure switch disables system when
supply pressure is low, preventing cavitation in
pump and protecting the system.
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Figure 1.2 Control Panel
Pump START/STOP Pushbuttons
Du al p re ssu re g au ge s s implif y mo ni to rin g o f b ot h
to process and from process pressures.
Chromalox’s Temperature and Process Controller
features separate PID algorithms for heat and
cool control modes, dual display of setpoint and
process temperatures, and simple configuration
parameters with alphanumeric cues. Optional
digital communications expand microTHERM’s
application flexibility. (Controller model supplied
may vary from picture)
Diagnostic Indicators allow you to constantly
monitor microTHERM’s performance, giving you
early detection of potential problems before they
occur and simplifying maintenance.
Ordering Information
Open Loop Cooling
Model kW Volts Total Amperage
CMX-250-4 4.5 240 13.6
CMX-250-4 4.5 480 6.8
CMX-250-9 9 240 24.5
CMX-250-9 9 480 12.2
CMX-250-12 12 240 31.7
CMX-250-12 12 480 15.8
CMX-250-18 18 240 46.1
CMX-250-18 18 480 23.1
CMX-250-24 24 240 60.5
CMX-250-24 24 480 30.3
Closed Loop Cooling
Model kW Volts Total Amperage
CMX-250-4C 4.5 240 13.6
CMX-250-4C 4.5 480 6.8
CMX-250-9C 9 240 24.5
CMX-250-9C 9 480 12.2
CMX-250-12C 12 240 31.7
CMX-250-12C 12 480 15.8
CMX-250-18C 18 240 46.1
CMX-250-18C 18 480 23.1
CMX-250-24C 24 240 60.5
CMX-250-24C 24 480 30.3
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Section 2 – Installation
Before Open-Loop Hydraulic Installation:
Before proceeding with the installation of the openloop 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. If water pressure falls below 20 psi, a pressure
switch will interrupt pump motor and heater operation. Use an external water pressure regulator
and back pressure relief valve or regulator, set at
maximum 125 psi (150 psi with 7.5 hp motor) connected in the external fill line, to reduce excessive
water pressure. Not provided on CMX-180 models.
HAZARD OF EXPLOSION, FIRE AND SCALDING
BURNS.
The water feed line on both open and closed
loop systems must not have any obstructions
which could prevent expanding water from
backing up into the feed line.
Do not use oils or other synthetic heat transfer fluids. This system is for use with water or
ethylene glycol and water mixture for freeze
protection only as the heat transfer fluid.
When installing system, allow sufficient room
to remove the heater element and other serviceable items when necessary. 18 inches
clearance on sides of unit recommended.
If the water source is a potable water source,
a back flow preventer and back pressure relief
valve/regulator should be installed and may be
required by local code. Do not install a check
valve only on the fill line. The inability of the
system to flow back into the fill line can lead
to excessive pressure. Back pressure relief is
required.
To avoid excessive pressures, do not connect
any valves or obstructions which could prevent
free discharge from relief valve in a safe manner. Route line so water drains completely. Do
not allow drain to freeze or corrode shut.
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.
Provide air bleed valves at high points and drains
at low points.
4. Connect the plant water supply (30 psi to 80 psi)
to the unit’s 1/2” NPT “WATER SUPPLY/COOLING
INLET” port with suitable pipe or hose.
HAZARD OF EXPLOSION, FIRE AND SCALDING
BURNS.
Connect the 1/4” NPT port identified as “DRAIN
COOLING OUTLET” to an open or plant drain
that contains no valves or obstructions that
could impede discharge. Review the condition
of potential hot water or steam going down a
plant drain. Verify that local codes and materials are acceptable for this service.
Locate floor drain under unit. The air bleed and
relief valve may discharge hot water or steam
from the bottom of the unit. Do not locate materials that could be damaged by hot water or
steam adjacent to the unit.
Temperature Controller
Cooling
Valve
Drain/Cooling
(1/4 NPT)
From Process
(1-1/4 NPT)
Outlet
Auto
Air Bleed
Pressure
Relief
Valve
Pump and
Motor
Heater
Therocouple
Probe
To Process
(1-1/4 NPT)
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Water Supply/
Cooling Inlet
(1/2 NPT)
Figure 2.1 Open-Loop System Piping
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Figure 2.1 Open-Loop Cooling Piping Connections
1-7/8”
6"
12-5/16”
FROM PROCESS
WATER SUPPLY/
COOLING INLET
DRAIN/
COOLING OUTLET
TO
PROCESS
Chromalox
®
28-1/2”
6"
4"
7"
15"
Rear View
Note: Dimensions are nominal ± 3/8”
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Before Closed-Loop Hydraulic Installation
Before proceeding with the installation of the Closedloop 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. Use an external water pressure regulator
and back pressure relief valve or regulator set at
maximum 125 psi (150 psi with 7.5 hp motor) connected in the external fill line, to reduce excessive
water pressure. Not provided with CMX-180 models.
HAZARD OF EXPLOSION, FIRE AND SCALDING
BURNS. To avoid excessive pressures, do not
connect any valves or obstructions which could
prevent free discharge from relief valve in a
safe manner. Route line so water drains completely. Do not allow drain to freeze or corrode
shut.
Do not install a check valve on the fill line. The
inability of the system to flow back into the
fill line can lead to excessive pressure. If back
flow preventer or check valve is required, install back pressure regulator rated for 250°F
water with a pressure setting of 30 to 80 psi.
Back pressure regulator setting must be approximately 10 psi above water supply pressure to minimize water flow directly from supply to drain.
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. Temperature of discharge water could
reach 250°F and create steam at atmospheric
pressure.
Temperature Controller
Solenoid
Cooling Outlet
(1/2 NPT)
Water Supply/
Cooling Inlet
(1/2 NPT)
From Process
(1-1/4 NPT)
Valve
Auto
Air Bleed
Pressure
Relief
Valve
Pump and
Motor
Heater
Therocouple
Probe
To Process
(1-1/4 NPT)
Figure 2.3 Closed-Loop System Piping
Hydraulic Installation Closed-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.
Provide air bleed valves at high points and drains
at low points.
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Figure 2.1 Open-Loop Cooling Piping Connections
S” and “TO PR
1-7/8”
6"
12-5/16”
COOLING OUTLET
WATER SUPPLY/
COOLING INLET
FROM PROCESS
PROCESS
TO
Chromalox
®
28-1/2”
6"
Thermal Devices, Inc. Mount Air
4"
7"
15"
Rear View
Note: Dimensions are nominal ± 3/8”
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