Chromalox MicroTherm CMX Series User manual

User Instructions
TM
User’s Manual
Part Number: 161-123417-023
Sales PQ445-5
Issue Date
January 2012
TM
System Model Number and Rating ___________________________________________________
Part Number _______________________________________ Serial Number _______________
Customer _______________________________________________________________________
Customer Order Number _____________________________ Date _______________________

User Instructions
TM

User Instructions
TM
Table of Contents _____________________________________________
Section Topic Page
1 Getting Started............................................................................................. 1
2 Installation ................................................................................................... 5
3 Temperature Control Operation .................................................................. 13
4 System Operation......................................................................................... 19
5 Diagnostics ................................................................................................... 21
6 Maintenance................................................................................................. 23
7 Troubleshooting............................................................................................ 31
8 Specifications................................................................................................ 33
9 CMX Warranty and Limitation of Remedy and Liability............................ 37
10 Index............................................................................................................. 39
Appendix A CMX-180 Model for Low Pressure Applications......................................... 42
Appendix B CMX Closed Loop to Open Loop Cooling Conversion.............................. 43
Appendix C CMX Open Loop to Closed Loop Cooling Conversion.............................. 44
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User Instructions
TM
Illustrations___________________________________________________
Figure Topic Page
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 ........................................................................... 9
2.4 Closed-Loop Piping Connections .................................................................. 10
2.5 Power Connection Terminals......................................................................... 11
3.1 Control Panel Layout..................................................................................... 13
3.2 Controller Displays and Pushbuttons............................................................. 14
3.3 Controller PAGE/MENU Selections............................................................. 15
4.1 Control Panel ................................................................................................. 19
5.1 Diagnostic Indicators...................................................................................... 21
5.2 Pump Reset Switch......................................................................................... 22
6.1 Chamber Photo .............................................................................................. 24
6.2 Heater/Chamber Photo.................................................................................. 25
6.3 Motor Vent Line............................................................................................. 26
6.4 Heat Exchanger.............................................................................................. 27
6.5 microTHERM™ Open and Closed-Loop Electrical Schematic ................... 28
6.6 Replacement Parts Identification................................................................... 30
8.1 Pump Capacity ............................................................................................... 34
8.2 Controller MENU Settings............................................................................ 35
ii

User Instructions
TM
Section 1
Getting Started _______________________________________________
Section Contents
Introduction
䊳Introduction
䊳System Photo
䊳Model Identification
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 mi-
croTHERM™ 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. CMX-180 models do not require
minimum pressure. Water temperature is maintained by a micro-
processor-based temperature controller which applies heating and
cooling as needed. Heat is applied by a long-life, Incoloy®sheathed
heater. Cooling is either via direct injection, in an open loop, or
through a closed loop heat exchanger.
Every system is equiped with an automatic vent that removes
unwanted air from the system during operation, and an ASME
pressure relief valve that is factory-set 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.
Important
1

User Instructions
TM
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.
heat exchanger
(closed loop cooling)
Cabinet design allows access
to all components without
removing a single fastener.
Compact, rugged cabinet fits
into tight spaces. Rolling
casters allow easy transfer
between locations.
Custom cast pump for
optimum flow, minimum
leakage and long life.
Low pressure switch disables
system when supply pressure is
low, preventing cavitation in pump
and protecting the system.
(Not provided on CMX-180 models)
2

User Instructions
TM
Figure 1.2
Control Panel
Dual pressure gauges for
monitoring of both to process
and from process pressures.
Pump
START/STOP
Pushbuttons
Diagnostic Indicators Chromalox’s 2104 Temperature
and Process Controller
3

User Instructions
TM
Ordering Information
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
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
• All voltages are 3 phase. 120V control transformer provided with each unit for control power.
-C: Suffix indicates 3.8 sq. ft. heat exchanger for cooling. All systems equipped with 30 GPM 20 psi. TDH pump standard.
Optional Pump flows up to 80 GPM and 70 psi. TDH available.
• For low pressure applications - “250” in the model number is replaced by - “180”. Pressure switch is not provided.
4
Model KW Volts Total Amperage
Open-Loop Cooling
Closed-Loop Cooling

User Instructions
TM
Section 2
Installation ___________________________________________________
Section Contents
Before
Open-Loop
Hydraulic Installation
䊳Hydraulic Installation Open-Loop Cooling
䊳Hydraulic Installation Closed-Loop Cooling
䊳Electrical 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. 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.
1. 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.
2. 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.
3.
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.
4. 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.
5. 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 completly.
Do not allow drain to freeze or corrode shut.
WARNING
Hazard of Explosion, Fire and Scalding Burns
5

User Instructions
TM
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.
5. 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.
6. 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.
Figure 2.1
Open-Loop System Piping
T
T
emperature Controlle
emperature Controlle
T
T
T
T
r
r
g
g
g
Drain/Cooling
Outlet
Drain/Cooling Outlet
()
(1/4
NPT)
(1/4 NPT)
Fr
Fr
om
Pr
om Pr
ocess
ocess
W
W
W
ocoupl
ocoupl
e
e
(1 1/4
NPT)
(1
-
1/4 NPT)
6
Hazard of Explosion, Fire and Scalding Burns
WARNING

User Instructions
TM
Figure 2.2
Open-Loop Cooling
Piping Connections
Note: Dimensions are nominal ± 3/8”
7
Rear View
Chromalox
®
DRAIN/
COOLING OUTLET
FROM PROCESS TO PROCESS
1
7
/
8
"
6"
12
5
/
16
"
6"
4" 7"
15"
28
1
/
2
"
WATER SUPPLY/
COOLING INLET

User Instructions
TM
Before
Closed-Loop
Hydraulic Installation
Hydraulic Installation
Closed-Loop
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. 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.
1. 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
completly. Do not allow drain to freeze or corrode shut.
2. 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.
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.
Hazard of Explosion, Fire and Scalding Burns
WARNING
8

User Instructions
TM
Hydraulic Installation
Closed-Loop
(continued)
Figure 2.3
Closed-Loop System Piping
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.
9
Temperature Controller
Cooling Outlet
(1/4 NPT)
Water Supply
Cooling Inlet
(1/2 NPT)
From Process
(1-1/4 NPT)
Pump and
Motor
Solenoid
Valve
Auto
Air
Bleed Thermocouple
Probe
To Process
(1/4 NPT)
Pressure
Relief Valve
Heater
Closed Loop Cooling

User Instructions
TM
Figure 2.4
Closed-Loop
Piping Connections
Note: Dimensions are nominal ± 3/8”
10
Chromalox
®
COOLING OUTLET
WATER SUPPLY/
COOLING INLET
FROM PROCESS TO PROCESS
1
7
/
8
"
6"
12
5
/
16
"
6"
4" 7"
15"
28
1
/
2
"
Rear View

User Instructions
TM
Electrical
Installation
Figure 2.5
Power Connection Terminals
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.
Fusing or other over-current protection must be supplied to the
system by the user.
The unit is completely wired when shipped. The only wiring nec-
essary is to the blue colored terminals L1, L2, L3, and the green-
and-yellow colored ground. To make these connections:
1. Loosen the screw on the front electrical enclosure door to
unlock the latch.
2. Open the front electrical enclosure door. Using 90°C wire
sized per National and local codes, run each leg of the three
phase supply power and ground to the appropriate terminals
as shown in Figure 2.5.
3. A separate fused disconnect is required. Locate this fused
disconnect near the equipment. Codes may require the
location of disconnect in sight of operation standing next to
the equipment. Consult applicable codes for details.
Control Voltage fuse
WARNING
11

User Instructions
TM
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 and buttons in quick
succession. Watch the rotation on the pump motor to insure
it matches the label on its top.
7. If rotation is incorrect, disconnect power to the system and
swap any two of the supply lines. Repeat rotation check.
Close the front electrical enclosure door and retighten the
locking screw. This must be done to limit access to high voltage
components. Failure to comply could lead to electric shock or
electrocution.
Control Voltage Fusing
Terminal block #1 (see Figure 2.5) contains a 120V fuse for the
control circuitry. this fuse protects the control transformer and
circuitry.
1. Should the fuse blow, an indicator will light on the terminal
block.
2. Disconnect power from the system.
3. Determine the cause of the blown fuse.
4. Replace with an equivalent fuse.
5. Reconnect power.
START STOP
WARNING
12

User Instructions
TM
Section 3
Temperature Control Operations ______________________________
䊳Control Panel
䊳Temperature Controller Operation
Figure 3.1
Control Panel Layout
Inlet Pressure
“From Process”
Outlet Pressure
“To Process”
START/STOP Pushbuttons
Press to start the pump.
Indicator will illuminate while pump
is running. Press to stop
the pump.
Diagnostic Indicators
System shuts down if any diagnostic
indicator is illuminated.
Low Water Pressure:
• System water pressure is
below 20 psi. (Disabled on
CMX-180 models)
Pump Overload:
• Pump has drawn too much
current.
Over Temperature:
• System temperature has
exceeded 260°F.
Temperature Controller
Top Display reads current system outlet
temperature.
Bottom Display reads setpoint
temperature.
Press to increase setpoint
temperature.
Press to decrease setpoint
temperature.
OUT 1
• Heat is being applied.
OUT 2
• Cooling is being applied.
OUT 3 and OUT 4
• Indicates overtemp condition
Press to continue operation after
overtemp.
AUX
• Indicates system is in Standby.
START
STOP
RESET
▼
▲
13

User Instructions
TM
Temperature
Controller
Operation
The Chromalox 2104 1/4 DIN temperature controller is a high-
performance, 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. A dual
digital display of current process temperature and setpoint
temperature make the system easy to understand and operate.
The 2104 controller has extended capabilities and functions for
more technically advanced applications. To learn more about
how these controller capabilities may be used, consult the
enclosed 2104 Controller Technical Manual, part number,
0037-75276.
Figure 3.2
Controller Displays
and Pushbuttons
• System Outlet
Temperature Display
• Alphanumeric Menu
Display in Setup Mode
LEDs indicate °F or °C
selected for Process
Temperature
LED indicates the controller
is in Standby mode
Setpoint Temperature
Display
OUT 1
• Indicates Heat ON
OUT 2
• Indicates Cool ON
Pushbutton Resets
Overtemperature Alarm
14
RESET
LEDs indicate
Overtemperature

User Instructions
TM
PAGE/MENU
Setup
Figure 3.3
Controller
PAGE/MENU
Selections
All control parameters, selections and calibration procedures for
the temperature controller are accomplished through simple
MENU selections. These MENU selections are organized into
PAGES.
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.
Display Control
Accessing the Security Lock or Setpoint MENU is
accomplished by entering the Setup Mode, then selecting the
Control PAGE and the desired MENU.
To enter Setup Mode:
Hold down the pushbutton for longer than 3 seconds.
Hold for at least
3 seconds.
Setup Mode entered.
To change the PAGE:
Press and hold the pushbutton while pressing the or
pushbutton. the upper display will increment (or
decrement) through the PAGEs, and PAGE will be displayed in
the lower display.
After reaching the CTRL PAGE, press RESET to move through
the MENUs. The alpha cue for the MENU will appear on the
upper display, and the current value will appear in the lower
display.
Hold Press ▲or ▼
RESET
RESET
▼
▲
15
DISP
PAG E
RESET AUX
CTRL
PAG E
RESET AUX
250
250
RESET AUX
SP
250
RESET AUX
CTRL
PAG E
RESET AUX
LOCH
123
RESET AUX

User Instructions
TM
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.
To return to Operating Mode:
Press and hold for more than 3 seconds. The controller
will automatically return to operating mode after 10 minutes of
no pushbutton activity.
Hold for at least
3 seconds.
Every parameter or selection in the 2104 controller’s setup
PAGEs has an identifying MENU. The MENUs are accessible
only if the correct Security Code is entered. This allows you to
set the Security level that is apprpriate for your operating
environment, prohibiting unauthorized access to or accidential
changing of control parameters.
The microTHERM™ system is factory preset to security code
123. To adjust any of the controller’s setup parameters, the
security code must be set to 458.
The Security Code is entered on the Control PAGE CTRL, at
the MENU LOCH. This code determines which MENUs may be
adjusted.
Security Code
▼
▲
RESET
16
SP
100
RESET AUX
SP
200
RESET AUX
STBY
101
RESET AUX