CMXO - Chromalox
Contents
1. microTHERM oil Circulating Oil Temperature Control System System Model Number and Rating Part Number Serial Number Customer Customer Order Number Date Issue Date July 2012 User s Instruction Manual Part Number 161 123417 025 0446 1 Table of Contents Section Topic Page 1 SCA TE dhene et ee 1 2 d 4 3 Temperature e a ar ba EE 10 4 tee Ebr eeu eat aie 15 5 iiS 18 6 Maintenance sciet dete eno teni EEE 20 1 Fretbleshootifipne 26 8 Specifications sicca eas ie eee eb reb e nette 28 9 ee bn tue 31 microTHERM oil User Instructions Illustrations Figure Topic Page 1 1 System idee smart sein eH IHE 2 1 2 Control Pane eean E a eiecit eis 3 2 1 lae aI AE EENE toi e EEE IRE RE eet 6 2 2 Piping Conie ion Reb e el Ren 7 2 3 Power Connection 8 2 4 Control Voltage USE ee nn 9 3 1 Control Panel Layout eiecti eti reete 10 32 estes 11 3 3 Controller PAGE MENU Selections ss 12 52. 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 ee for longer than 3 seconds LOCH 123 RESET AUX M Hold for at least 3 seconds To change the PAGE Setup Mode entered Press and hold the ee while pressing the 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 microTHERM oil User Instructions To change a MENU value After the MENU is selected and displayed use the M 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 Security Code Every parameter or selection in the 2104 controller s setup PAGES
3. 1 Diagnostic Indicators 18 5 2 un sere mee iden itae iste hentai 19 5 3 Over Temperature Controller Reset Switch ss 19 6 1 Electrical Schematic Heat Cool 23 6 2 Electrical Schematic Heat Cool SCR seen 24 8 1 Pump Capacity sn mn I en etes 28 8 2 Power and Capacity Information 4444444 28 8 3 Replacement Parts Identification 29 i microTHERM oil User Instructions Section 1 Getting Started Section Contents gt Introduction pe System Photo 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 microTHERMTM Oil Temperature Control System This system has been thoroughly Introduction engineered carefully built and fully tested to assure years of service The microTHERM Oil can be operated at a maximum tempera ture of 550 F Oil temperature is maintained by a microprocessor based temperature controller which applies heating and cooling as needed Electrical and hydraulic components are located in distinctly separate areas in the system to better manage heat buildup and prevent component damage It is designed to drastically reduce the chance of oil dripping inside the product and provide ease of service and maintenance Standard casters make it
4. 8GA 250 C POWER WIRE 10GA 250 C ENCLOSURE CONTROL WIRE 16GA 90 C FAN HEATER GROUND WIRE 10GA 250 C 24 microTHERM oil User Instructions Maintenance Record Date Maintenance Record microTHERM oil User Instructions 25 Section 7 Troubleshooting Troubleshooting Guide For qualified personnel only See warnings in earlier sections Symptom Probable Cause Correction Unit will not start control 1 Unit not wired correctly 1 display does not light 2 Disconnect switch OFF 2 3 Blown fuse 3 4 Wrong voltage 4 Check wiring Turn disconnect ON Check customer disconnect fuses and 120V fuse on terminal block blown fuse indicator will light if fuse is blown Check supply voltage and unit s rated voltage Control display lights unit will not start 1 Pump motor overload 1 2 System above temperature 2 limit of 600 F Unit stops while running 1 Pump motor overload 1 2 System exceeds temperature 2 limit of 600 F restart See Section 5 Determine problem and press pump reset Allow unit to cool below 550 F and press reset on over temperature controller inside the panel See Section 5 Determine problem press pump reset and restart Allow unit to cool below 550 F press reset on over temperature controller inside the panel and See Section 5 continue
5. Overload 10 18 19 27 Display Control 11 26 Electrical Installation 8 Fusing 8 9 Control Voltage 9 30 Hazard 4 5 8 9 15 16 19 20 21 22 Heater 4 15 16 17 20 21 27 28 30 31 Removal Replacement 20 21 Indicators Cooling 10 23 Diagnostic 10 18 Heating 10 23 Overtemp 10 14 18 19 23 27 Pump Overload 10 18 19 27 KW 28 Leaks 21 Manual Cooling 10 17 MENU Selections 12 Control 12 13 14 Display 11 12 e Setup 12 MENU Value 13 ua microTHERM oil User Instructions Motor 6 9 15 19 20 22 23 26 27 30 Motor Contactor 23 30 Motor Control 10 19 Operating Mode 13 Operating Temperature 2 Output Relay 3 14 Output Relay 4 14 Overtemperature Indicator 10 14 18 19 23 27 Power Requirements 1 28 Pressure Gauges 30 Process Temperature 11 14 15 16 19 Pump 2 3 6 9 10 15 22 26 27 28 30 31 Pump Indicator Light 19 23 Removal Replacement 20 21 Rotation Check 9 Pump Capacity 28 Pump 9 15 19 20 22 23 26 27 Pump Reset Switch 19 26 Replacement Parts 29 30 Schematic Electrical 23 24 Safety Relief Valve 2 4 30 Security Code 13 14 Access 2 9 12 13 14 19 Change 2 12 13 14 28 Security Lock 12 14 Service 20 30 Setpoint 10 11 12 14 15 16 20 27 Change 10 14 27 Control 10 11 14 15 16 26 30 Temperature 1 3 5 6 10 12 14 22 26 27 30 Setup Mode 11 12 Shutdown 16 Solenoid Valve 2 30 S
6. WATER SUPPLY COOLING INLET port with suitable pipe or hose Burn hazard Hot surfaces es Do not touch ICroTHERM CMXO Series Temperature Control System icroTHERM oi CMXO Series Temperature Control System microTHERM oil User Instructions Figure 2 2 Piping Connections OIL OUTLET 1 1 2 NPT COOLING WATER INLET 1 2 NPT 45 22 3 8 microTHERM oil User Instructions 12 Back of Product HEATER DRAIN 1 2 COOLING WATER OUTLET 1 2 OIL INLET 1 1 2 Electrical Installation Figure 2 3 Power Connection Terminals L1 L2 L3 HAZARD OF ELECTRIC SHOCK 1 Disconnect all power before installing or servicing the heat transfer system This system must be installed by a qualified person in accordance with National Electric Code NFPA 70 Failure to comply can result in personal injury or equipment damage 2 The heat transfer system must be effectively grounded to the grounding means provided in control box in accordance with National Electric Code 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 neces sary 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
7. easy to move the system from machine to machine Power requirements for the system are 240 or 480 volts 3 phase 60 cycle and 6 to 24 kW See the system nameplate for the appropriate voltage and wattage ratings Oil or other synthetic fluids or mineral based fluids may be used with this product See section 4 number 1 The System Photo and Control Panel Illustrations on the following pages identifies all key components microTHERM oil User Instructions 1 Figure 1 1 System Photo Side View Operating temperatures of 50 to 550 F for a wide variety of applications Steel sheath Chromalox heating elements 3 2 sq ft heat exchanger cooling Integral with heating chamber 3hp Centrifugal Pump Cabinet design allows access Compact rugged cabinet fits to all components into tight spaces Rolling casters allow easy transfer between locations System Photo Rear View ASME safety relief valve opens if water pressure exceeds 125 psi ensuring safe operation OIL LEVEL COLD Cooling Water Outlet Integral solenoid valve for precise temperature control Cooling Water Inlet on cooling Oil Inlet 2 microTHERM oil User Instructions Figure 1 2 Control Panel CMXO Series THERM Temperature Control System Chromalox CES STE RER D E Eu A DIAGNOSTICS Refer to Instruction Manual Before Operating Pump Manual Cooling Status and Diagnostic Chromalox 2104 Temper
8. 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 appropriate 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 microTHERM oil User Instructions 13 To access and enter the Security Code 1 Press and hold 13334 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 P v Imm the correct security code is displayed 458 to change controller setup 3 Reference the factory preset MENU settings Figure 8 2 page 35 when replacing the controller or if the settings have been changed Control Page Menu Description Available Settings Factory Settings Security LOCH Security Lock 0 to 9999 123 A SP Setpoint Instrument sensor span 32 F B 14 microTHERM oil User Instructions Section 4 Operation AWARNING Burn Hazard To prevent overflow of hot oil Close fill port with steel plug Pipe vent port to an acceptable container Do not fill above cold fill level Fire Hazard Do not
9. ATOR Dre dd Om 10 8 X T C w2 12 13 l SNUBBER 14 INDICATOR OFT N COOLING 15 ums CA I COOLING SOLENOID OL 1 198 2 16 Bie IR INDICATOR 981797 PUMP OVERLOAD 17 orrlo AUA 225 00 RIS yay INDICATOR 155 3 MANUAL COOLING CONTINUED BELOW INDICATOR OVER TEMPERATURE io LIMIT 10100 microTHERM oil User Instructions 4 12KW 208V 4 18KW 240V 4 24KW 480V MOTOR WIRE 12GA 125 C HEATER WIRE 8GA 250 C POWER WIRE 10GA 250 C CONTROL WIRE 16GA 90 C ENCLOSURE FAN HEATER GND WIRE 10 GA 250 C 23 Figure 6 2 Electrical Schematic Heat Cool SCR DISCONNECT SWITCH 2GND SEE ITC LINE 9 customer H CONNECTIONS L2 o o HEATER SjPOW R REFER TO TRANSFORMER LABEL FOR VOLTAGE WIRING DIA CPT 1 B3 B1 TFT 1X1 90VA 2 W2 STOP START OL R5 R6 3 aTa MOTOR CONTACTOR 1PB 1 2PB 1 95 96 A2 D 4 1M SNUBBER 13 14 5 O INDICATOR PUMP RUNNING MANUAL COOLING OFF ON 7 SEE LINE 22 j cf 3 AA XO 9 1C HEATER CONTACTOR 53 54 155 1 8 SNUBBER 9 ITC INDICATOR HEATING 10 ATE x TIC 11 12 13 COOLING SOLENOID 14 SNUBBER 15 INDICATOR COOLING 16 OL 1 17 R11 INDICATOR 981797 m PUMP OVERLOAD 18 OX INDICATOR 1883 MANUAL COOLING CONTINUED BELOW INDICATOR OVER TEMPERATURE 4 12KW 208V 4 18KW 240V 4 24KW 480V MOTOR WIRE 12GA 250 C HEATER WIRE
10. C SHOCK AND BURN HAZARD Disconnect all power before servicing or performing maintenance to the system Do not attempt to service system while it is operating or while hot Failure to comply can result in a Electric shock b Burns from hot heating elements piping and hot oil or water c Injury from operating or rotating pump and motor Maintenance is to be performed by qualified personnel only Thoroughly read and understand these instructions Consult the factory if you have any questions To take the unit out of service the following steps must be done in sequence 1 Set the temperature controller setpoint to 90 F or lower Allow to cool 2 Turn off power to the unit The controller will turn off 3 Turn off the water supply to the unit 4 Disconnect electrical supply to the unit 5 Drain the system 6 Ifit is exposed to freezing temperatures while out of service remove water by blowing air through cooling pipe You will need to open the cooling valve by turning on manual cooling or removing it microTHERM oil User Instructions Heater Removal Replacement ELECTRIC SHOCK HAZARD Disconnect all power to system before servicing Failure to comply can result in personal injury or equipment damage BURN HAZARD Never service system while hot Allow system to cool to room tem perature before servicing 1 Check that power is disconnected from the system and remove wir ing to heater 2
11. Disconnect power from the system 3 Determine the cause of the blown fuse 4 Replace with an equivalent fuse 5 Reconnect power Figure 2 4 Control Voltage Fuse microTHERM oil User Instructions Section 3 Temperature Control Operations Figure 3 1 Control Panel Layout Inlet Pressure From Process THERM START STOP Pushbuttons Press piant to start the pump Indicator will illuminate while pump is running Press to stop the pump 10 Bb Control Panel p Temperature Controller Operation Check Pump Rotation Outlet Pressure To Process Suction Gauge should read less than Discharge Gauge CMXO Series Temperature Control System Status and Diagnostic Indicators System shuts down if any red diagnostic indicator is illuminated Pump Overload Pump has drawn too much current Over Temperature System temperature has exceeded 600 F Pump Running Xt xt XX Heating 3 Cooling 29 Manual Cooling If manual cooling is on heaters shut off and water cooling is on Normally this is off and the temperature controller determines when to heat or cool Chromalox PRECISION HEAT AND CONTROL a PAGEt PAGE Refer to Instruction Manual Before Operating Temperature Controller Top Display reads current system outlet temperature Bottom Display reads setpoint temperature Press N to increase setpoint temperature Press M to decrease setpoint temp
12. Disconnect thermocouple from control cabinet 3 Drain heater and pump 4 Remove bolts on heater and undo fittings on pipe Remove heater through the front door 5 Install new heater and retighten all bolts and fittings 6 Put all sheet metal back in place and retighten screws 7 Refill system and follow operation procedure in Section 4 LEAKS 1 Leaks should be minimized 2 CAUTION Hazard of Fire Some heat transfer fluids are flammable and if allowed to leak on hot pipes or in fibrous thermal insulation a fire hazard can be created 3 Disassemble clean and reseal the connections using high tem perature sealant Do not use TFE or other tape Sealants are to be rated for temperatures and fluids used in the system ELECTRIC SHOCK HAZARD 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 result in personal injury or equipment damage microTHERM oil User Instructions 21 Pump Removal Replacement Disconnect all power to system before servicing Failure to comply can result in personal injury or equipment damage Never service system while hot Allow system to cool to room tem perature before servicing ELECTRIC SHOCK HAZARD BURN HAZARD 10 If pump requires service drain system and remove top and side panels Pump motor can be removed from the system as an assembly for serv
13. N DO NOT SET TEMPERATURE ABOVE 600 DEGREES F SCR PWR CONTROLLER OPTIONAL EM CONNECT VOLT SUPPLY HERE microTHERM oil User Instructions 29 Replacement Heaters microTHERM oil Replacement Parts kW Voltage Heater 6 240 052 305096 001 480 052 305096 002 9 240 052 305096 007 480 052 305096 008 12 240 052 305096 005 480 052 305096 006 18 240 052 305096 003 480 052 305096 004 24 480 052 305096 001 Replacement Parts Common to All Models Identification Part 30 226 304843 002 130 118661 037 130 118661 038 309 304460 036 300 304460 012 309 123617 101 292 304687 003 292 304687 004 213 122066 041 213 122066 042 213 122066 043 072 123534 065 071 122886 055 359 122078 097 359 122078 096 315 303786 001 375 123425 006 375 123425 007 303 123432 024 072 304551 008 microTHERM oil User Instructions Section 9 Index Alarm Latching 14 Overtemperature 11 14 27 Relay Action 14 Cabinet 2 Contactor 23 30 Control Output 1 Heat 10 11 Control Output 2 Cool 10 11 Control Setpoint 10 11 14 15 16 26 30 Control Voltage Fusing 9 30 Controller Temperature Controller 1 3 10 11 12 17 19 30 Cooling Control 10 11 17 Cooling Manual 17 Cooling Solenoid 23 See Valve Cooling Cooling Water Valve 2 26 27 Diagnostic Functions 18 Diagnostic Indicators 3 10 18 Over Temperature 10 14 18 19 23 27 Pump
14. allow oil to saturate insulation or pipe surfaces OIL LEVEL COLD microTHERM O CAUTION Damage to the pump and or heater may occur if the system is oper ated without fluid Fill system prior to starting Operate in 105 F or less surrounding temperature Note Read and understand instructions on the temperature control be fore operating the system 1l Check to ensure the fluid is the same as or compatible with the fluid with which the system was factory pretested Mobiltherm 603 For disposal see fluid manufacturer s recommendations 2 The system is filled with heat transfer fluid directly from the 55 gallon drum by simply connecting a hose from the expansion tank located on the top of the system to the drum Fill expansion tank until sight glass indicates it is approximately 3 full 3 overheat temperature control is located inside the control panel Setpoint should be adjusted 50 F higher than the indicating temperature control WARNING Never exceed a setting of 600 F on the overtem perature control 4 Close control box door and turn circuit breaker on Start pump do not be alarmed if the pump is noisy during the initial startup operation this is due to air in the system 5 Bleed out all air by opening bleeder valves in the customer s piping The pump should become quiet CAUTION During the initial start up operation the liquid level in the expansion tank must be check
15. ation A WARNING HAZARD OF EXPLOSION FIRE AND SCALDING BURNS 1 Connect the 2 NPT port identified as 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 2 This system is for use only with liquid phase heat transfer fluids suitable for a max bulk temperature of 550 F at atmospheric pres sure Use with any other fluids could result in death personal injury fire or damage to the equipment 3 Do not place valves in vent line or allow vent line to become even partially clogged Vent line on the expansion tank must be piped to a safe area and or catch drum Provisions must be taken to al low constant slope on vent to allow draining and to prevent liquids from collecting in the vent pipe Vent should be periodically checked to verify it is free and clear of all obstructions Vent piping should be no smaller than connection on the system Do not place valves in vent line as system must remain vented at all times 4 Do not overfill expansion tank 5 Do not allow heat transfer oil to saturate insulation Failure to comply could result in personal injury or property damage Important Read and understand all instructions in this manual and other manuals shipped with the system prior to installation All work spe
16. ature START STOP Switch Indicators and Process Controller Pushbuttons microTHERM oil User Instructions 3 Section 2 Installation Section Contents Before Hydraulic Installation p Hydraulic Installation gt Electrical Installation Before proceeding with the installation please take note of the fol lowing information HAZARD OF EXPLOSION FIRE AND SCALDING BURNS 1 The cooling water feed line must not have any obstructions which could cause buildup in pressure 2 When installing system allow sufficient room to remove the heater element and other serviceable items when necessary 3 To avoid excessive pressures do not connect any valves or obstructions which could prevent free discharge from relief valve in a safe manner Vent outlet of pressure relief valve to a drain where steam or scalding water will not cause personal injury Do not allow drain to freeze or corrode shut 4 Useonly on concrete floor or other nonflamable surface Use in an open area with at least 1 foot clearance from walls and combustible materials This product is designed to roll over smooth flat floors Do not roll over uneven floors and on ramps Do not move while hot or containing fluid Reduced diameter fittings may be used down to 1 if they do not reduce flow rate and increase pressure drop significantly Use softened water for cooling Use and maintain oil filters microTHERM oil User Instructions Hydraulic Install
17. ature control consult instruction manual on the temperature control Note Consult Service Manual PQ410 for additional aid to help startup and to service Chromalox Heat Transfer Systems BURN HAZARD Operating systems at temperatures above 140 F will create surface tem peratures on pipes that can cause burns Precautions should be taken to prevent operator contact with hot pipes Also bleed valves should be locked down to prevent release of hot fluid Note This is a PID type controller and cycling of the heat and cool can be expected below and above setpoint 11 For system shutdown lower the setpoint to 90 F or lower see Section 3 Allow the system to cool to this temperature 12 Press to de energize the pump and disable the system 13 Disconnect power to the unit A WARNING ELECTRIC SHOCR AND BURN HAZARD Do not leave system unattended in a HOT electrical condition Do not leave system unattended while HOT microTHERM oil User Instructions Manual Cooling If manual cooling is on heaters will be off and water cooling will be on Normally manual cooling is off and the temperature controller determines when to heat or cool Manual cooling is optional To use manual cooling 1 Turn manual cooling on and observe temperature 2 Optional If at a safe temperature you may stop the pump until you are ready to run again Important even if the pump is off cooling water will run to the heater as l
18. cified within this instruction sheet should be performed by quali fied personnel as required electrician plumber or mechanic 1 System should be mounted on a solid level foundation Where required containment area should be provided in case of fluid loss The system should be installed at the same level or higher than the process to be heated 2 Before installing check that all mounting bolts on equipment are tight These sometimes loosen in shipment 3 Piping to and from the process should match the piping on the system If extremely long runs of pipe are to be used one microTHERM oil User Instructions 5 Hydraulic Installation continued Figure 2 1 Piping size larger than the system connections can be used to minimize pressure drop Piping should be arranged to be selfsupporting and not supported by the heat transfer system On long runs isolation from thermal expansion should also be provided If the above are not taken into consideration unnecessary stress will be put on the pump and or piping Thread sealant and or gaskets used on process piping should be rated for temperatures and heat transfer fluid to be used Check with manufacturer for compatibility The piping of the entire system should be arranged to minimize pockets where air may be trapped Manual bleed valves must be provided at any location where air may be trapped Connect the cooling water supply 30 psi to 80 psi to the unit s 1 5 NPT
19. ck cooling outlet for obstructions Check voltage across contactor during cooling cycle Check factory MENU settings Section 3 of this manual Refer to 2104 Controller Technical manual page 35 for further information If you continue to have problems with the system after review of the above issues please contact Chromalox Product Service at 800 443 2640 microTHERM oil User Instructions 27 Section 8 Specifications Pump Nominal Oil Water Approximate Size Flow Connections Dimensions HP gpm dia inches 45 height 3 30 1 1 2 NPT 1 2 NPT 38 depth 19 width n it Cubic Meters Per Hour ump sapaciy 0 5 10 15 20 reported by 20 pump manufacturer on Model HTO 80 0 Size 1 5 x 1 25 Speed 3450 RPM 00 S G 85 80 3 HP 60 40 0 0 0 0 40 0 60 80 Figure 8 2 Heat Power amp Exchanger Capacity BTU s Nominal Amps Volume Surface Area Information Per Hour 480V Gal GS 4 15 354 21 4 10 7 6 1 3 2 6 20 472 26 2 13 1 6 1 3 2 9 30 708 33 4 16 7 6 1 3 2 12 40 944 40 7 20 3 6 1 3 2 18 61 416 54 7 27 5 6 1 3 2 24 81 888 34 6 6 1 3 2 Total per leg based on 3 phase 60 cycle power with heater at rated voltage motor at rated output and control transformer at full load Measured value may vary depending on conditions 28 microTHERM oil User Instructions Figure 8 3 Replacement Parts Identification CAUTIO
20. d 26 microTHERM oil User Instructions Troubleshooting Guide For qualified personnel only See warnings in earlier sections Symptom Probable Cause Correction Pump Overload Indicator illuminated 1 Pump motor overload 1 See Section 5 Determine problem and press pump reset button Over Temperature Indicator illuminated System above temperature limit of 600PF Allow unit to cool below 550 F and press reset on over temperature controller inside the panel See Section 5 Unit runs but fails to pump Incoming phase reversed on pump motor Swap any two legs on the incoming power Unit will not heat to setpoint Cooling valve stuck open Heater element failure Heater output insufficient Controller needs to be tuned Manual cooling on Check for cooling water flow during heat cycle Check current at heater contactor during heating Excessive losses in process or incorrectly sized unit for application Check factory MENU settings Section 3 of this manual Refer to 2104 Controller Technical Manual page 35 for further information Turn manual cooling off Unit will not cool to setpoint 1 Inadequate cooling water flow Cooling outlet obstructed Heater contactor fused closed Controller needs to be tuned 4 Open cooling water supply line more and assure adequate pressure Che
21. ed continually This level should not ex ceed the three quarter mark on the glass nor drop below the one quarter mark Note If abnormal fluid expansion is detected this is probably due to a pocket of air or steam still present in the system Check all bleed valves If problem continues de energize pump and check bleed valves 6 Setindicating or controlling thermostat at 220 F which will energize the heater The heater is interlocked with the pump motor starter so that in the event of motor failure the heating elements will shut off automati cally microTHERM oil User Instructions 15 7 Run the system until 220 F is reached Periodically open the bleed valves in the customer s piping to remove air from the system At 220 F any moisture that has been trapped in the system will flash into steam as it goes through the heater and can be bled out through the bleed valves 8 Excessive moisture and air in the system will cause the heat transfer liquid to back up into the expansion tank thus evacuating the piping or process If this happens shut the system down bleed off the steam and air allowing the liquid to return If problem persists drain the system and recharge with new moisture free heat transfer liquid 9 After the system is completely free of air pockets and moisture set control thermostat at the desired temperature Never set temperature control above 550 F 10 For detailed operation and tuning procedure on the temper
22. 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 3 3 Aseparate 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 microTHERM oil User Instructions 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 Pump Rotation Check 5 Close the front electrical enclosure door Pull the top cover off of the heat transfer system and locate the pump motor 6 Press the and buttons in quick succession Watch the rotation on the pump motor to insure it matches the label 7 If rotation is incorrect disconnect power to the system and swap any two of the supply lines Repeat rotation check ELECTRIC SHOCK HAZARD 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 result in personal injury or equipment damage Control Voltage Fusing Figure 2 4 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
23. erature xX OUT 1 Heat is being applied XX OUT 2 Cooling is being applied AUX Indicates system is in Standby microTHERM oil User Instructions Temperature The Chromalox 2104 1 4 DIN temperature controller is a high Controller performance single loop controller The 2104 controller has two Operation control outputs for heating and cooling that can be configured separately and provide flexible temperature control 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 System Outlet Controller Displays Temperature Display Alphanumeric Menu Display in Setup Mode 3 OUT1 Indicates Heat ON LEDs indicate F or C selected for Process Temperature OUT 2 Indicates Cool ON LED indicates the controller is in Standby mode Setpoint Temperature Display a PAGEt PAGE microTHERM oil User Instructions 11 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
24. ice Disconnect piping at unions on inlet and outlet piping leading to the pump Remove four bolts which hold the pump motor base to the base of the system After verifying power is disconnected remove conduit and wiring from the motor Lift out pump motor assembly Service pump per pump manufacturers instructions If replacing the pump be sure to remove piping from old pump casing before discarding Clean thread on pipe and thread into new pump casing using high temperature oil resistant thread seal ant DO NOT USE TFE OR OTHER TAPE SEALANTS Install new pump in system reconnect piping Reconnect wiring and check rotation as indicated in INSTALLA TION section ELECTRIC SHOCK HAZARD 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 result in personal injury or equipment damage microTHERM oil User Instructions Figure 6 1 Electrical Schematic Heat Cool DISCONNECT SWITCH CUSTOMER H m CONNECTIONS L2 1T2 SjPOWER I 2GND HEATER PUMP MOTOR REFER TO TRANSFORMER LABEL FOR VOLTAGE WIRING DI 1 CPT i o BI T 4X1 90VA X24 we stop _ START OL R4 R5 R6 3 a MOTOR CONTACTOR 1PB 1 2PB 1 95 96 A2 Q A1 4 1 1 SNUBBER 131714 5 O INDICATOR PUMP RUNNING 6 MANUAL COOLING OFF ON 7 xo R9 1C HEATER CONTACTOR 155 1 8 SNUBBER 9 INDIC
25. l pow and piping to the system Failure to do so could result in personal injury or equipment damage After the system power is disconnected solve the electrical current problem To put the pump back on line open the front electrical enclosure and press the pump reset switch See Figure 5 2 A WARNING ELECTRIC SHOCR HAZARD 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 result in personal injury or equipment damage If the system temperature exceeds 600 F 315 C the Over Tempera ture Indicator will illuminate When the system temperature drops below 550 F press reset on the over temperature controller inside the panel Close door and retighten the screw The controller will not reset until the temperature is below 600 F Or remove electric ity to the product and the over temperature controller will reset after temperature is below 600 F Chromalox 40 NU Ii 1000 PRECISION HEAT AND CONTROL NNUS 4 PRESSION HEAT AND CONTROL 5 KZ 5 Pd LIMIT 10100 200 1200 Limit Control 5 bi ois BETA Output 22 L1 120V L2 NC 5o60 Hz Over Temperature Controller Reset Switch microTHERM oil User Instructions 19 Section 6 Maintenance Section Contents Take Out Of Service 20 Be Take Out Of Service pe Heater Removal Replacement gt Pump Removal Replacement ELECTRI
26. ong as manual cooling is on and there is electricity to the product 3 When ready turn pump on and turn manual cooling off The tem perature controller will heat or cool to the desired temperature Im portant even if electricity is turned off to the product when electricity is turned on the temperature controller will go back to the previous temperature before manual cooling If this is not desired it is best to use the temperature controller instead of manual cooling microTHERM oil User Instructions 17 Section 5 Diagnostics Section Contents p Pump Overload gt Over Temperature Figure 5 1 Diagnostic Indicators SYSTEM STATUS DIAGNOSTICS PUMP RUNNING OVERTEMP 12 40 12 MANUAL COOLING CooLINe ACTIVE Diagnostic Functions red light diagnostic functions will shut down the system and re quire the operator to remedy the problem before it can be restarted 18 microTHERM oil User Instructions Pump Overload Indicator Figure 5 2 Pump Reset Switch DUE 5 T2 13 14 A2 Pump Reset Switch Over Temperature Controller Figure 5 3 Over Temperature Controller Reset Switch 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 A WARNING ELECTRIC SHOCK HAZARD If the Pump Overload Indicator is illuminated disconnect al
27. pecifications 28 Switch Pump Reset 19 Troubleshooting 26 Valve Cooling 1 2 4 6 10 11 17 20 26 27 30 Safety Relief 2 4 30 Solenoid 2 30 Vent 5 Wiring Diagram Heat Cool 23 Heat Cool SCR 24 31 32 microTHERM oil User Instructions
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