CAST-X 25 Circulation Heater The CAST-X 25 is our most compact dual-tube model, a powerful and versatile mid-sized heater. Designed and manufactured by Cast Aluminum Solutions (CAS), CAST-X heaters are designed using the latest in thermal modeling and FEA (Finite Element Analysis) technology. The CAST-X 25 features two helical-coiled flowpath tubes, along with low watt density heating elements, all of which are cast into an aluminum body. The aluminum body serves as the heat transfer medium between the heating elements and the process tubes carrying the liquid or gas to be heated. The media being heated never contacts the heating elements, which is a distinct advantage of the CAST-X line: it is often used to heat flammable and hazardous liquids and gases. Another advantage is the small footprint / high output ratio. The CAST-X 25 is available with a variety of NEMA and ATEX certified electrical enclosures; and may be ordered in a wide range of volt, watt and circuitry configurations. APPLICATIONS: Paint & Solvent Heating Glycol & Heat-Transfer System Use Food & Beverage Pasteurization Industrial Gas Heating & Air Separation Steam Generation Laboratory & Analytical Applications Urethane / Foam System Heating SPECIFICATIONS: Power: 2.5 kw Total to 15 kw Total Voltage Range: 28V - 48V Max Line Current: 3 amps Tubing:.625 OD (15.9 mm).65 Wall (1.7 mm) Overall Process Tube Length: 13 (332 mm) 316L Stainless Steel (standard) Inconel (optional upgrade) Passivated or Electro-Polished (optional upgrades) Max Pressure: 4 psi (275 bar) Enclosures: NEMA 1 (general-purpose/dust-proof) NEMA 4 (moisture-resistant) NEMA 7 (explosion-proof) ATEX (explosion-proof) Max Working Temperatures: Max Casting Temp: 662 F (35 C) NEMA 1 (dust-proof/general-purpose): 662 F (35 C) NEMA 4 (moisture-resistant): 572 F (3 C) NEMA 7 (explosion-proof): 482 F (25 C) ATEX (explosion-proof): 482 F (25 C) Sensors: K or J Type Thermocouples Standard Snap-Action High-Limit Thermostat Process and High-Limit Thermocouples Options: Insulating Jacket Rated to 8 F (425 C) Compression Fittings FEATURES & BENEFITS: SS 316L Fluid Path 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 Dual Tubes Can Be Run In-Series or Parallel Robust Cast-In Construction (for long heater life) Non-Welded Design (minimizes potential leakage) Wide Application Compatibility (including high pressure) 131 Kingsland Drive Batavia, Illinois 651 USA Tel: 888-367-3992 CAS@CastAluminumSolutions.com www.castaluminumsolutions.com
CAST-X 25 Circulation Heater GENERAL-PURPOSE (NEMA 1) ENCLOSURE MOISTURE-RESISTANT (NEMA 4) ENCLOSURE EXPLOSION-PROOF (NEMA 7) ENCLOSURE EXPLOSION-PROOF (ATEX) ENCLOSURE 18 CAST-X 25 Heating Profile: Delta-T Water (Process Fluid = Water @ 42 F / 5.6 C Inlet Temp, Single Pass Using One Tube, 1% Power, Set point 752 F / 4 C) 1. Temperature Increase (Delta-T, F) 16 14 12 1 8 6 4 2 88.9 77.8 66.7 55.6 44.4 33.3 22.2 11.1 Temperature Increase (Delta-T, C) 12 1 2 3 4 5 6 7 8 9 gpm 3.8 7.6 11.4 15.14 18.92 22.71 26.5 3.3 34.1 l/min Flow Rate (gpm and l/min) CAST-X 25 Pressure Drop Profile: Delta-P Water (Process Fluid = Water. Change in Pressure from Inlet to Outlet, Single Pass Using One Tube) 82.7 Pressure Drop (Delta-P, PSI) 1 8 6 4 2 68.9 55.2 41.4 27.6 13.8 Pressure Drop (Delta-P, kpa). 1 2 3 4 5 6 7 8 9 gpm 3.8 7.6 11.4 15.14 18.92 22.71 26.5 3.3 34.1 l/min Flow Rate (gpm and l/min)
General-purpose NEMA 1 enclosure Moisture-resistant NEMA 4 enclosure Explosion-proof NEMA 7 enclosure Explosion-proof ATEX enclosure CAST-X 25 with insulatng jacket 1L1 1L1 1L1 1L2 1L2 1L2 N 1L3 1L3 DELTA CIRCUIT WYE CIRCUIT PARALLEL CIRUIT 7 CAST-X 25 Heating Profile: Delta-T Air (Process Fluid = Air @ 1 psi (689 kpa), 7.7 F / 21.5 C, Single Pass Using One Tube, Set point 752 F / 4 C) 388.9 Temperature Increase (Delta-T, F) 6 5 4 3 2 1 333.3 277.8 222.2 166.7 111.1 55.6 Temperature Increase (Delta-T, C) 25 2 4 6 8 1. 12 scfm 566.3 1132.7 1699. 2265.4 2831.7 3398. slm Flow Rate (scfm and slm) CAST-X 25 Heating Profile: Delta-P Air (Process Fluid = Air @ 1 psi (689 kpa), 7.7 F / 21.5 C, Single Pass Using One Tube, Set point 752 F / 4 C) 172.4 Pressure Drop (Delta-P, PSI) 2 15 1 5 137.9 13.4 68.9 34.5 Pressure Drop (Delta-P, kpa) 2 4 6 8 1. 12 scfm 566.3 1132.7 1699. 2265.4 2831.7 3398. slm Flow Rate (scfm and slm)
CAST-X 25 Circulation Heater BX25-A1A2A3-B1B2-CD1D2EF Building a CAST-X 25 Part Number Use the graphs on the following pages to build each section of the CAST-X 25. After assigning numbers for each section A to F, you will have a complete part number, ready to quote. AAA = VOLTS, POWER, CIRCUIT TYPE BB = ENCLOSURES & THERMOSTAT C = HIGH LIMIT SWITCH DD = THERMOCOUPLES E = TUBING F = MACHINING For assistance, contact CAS directly (see below). Cast Aluminum Solutions (CAS) manufactures the CAST-X line of circulation heaters, plus a broad range of heated and nonthermal components. Our team of engineers and technicians works closely with customers to offer practical solutions to complex process challenges. CAS is an ISO 91 Certified company with a fully-equipped R&D facility featuring extensive testing capabilities, including X-Ray, ultrasound, helium leak, and 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 finishing and precision CNC machining options, as well as high-value-added testing & inspection services. Headquartered in Batavia, Illinois (just outside Chicago) we serve customers worldwide via our network of application engineers. With offices on each continent and in several key cities, a CAS representative is never far away. See the below map to locate a sales engineer. Or contact CAS directly: Tel: 63-879-2696 Toll-Free: 888-367-3992 Email: CAS@castaluminumsolutions.com 7 1 3 5 8 9 2 6 4 6 - Southeast Tel: 573-754-486 Europe: France Tel: +33 () 1-41-32-79-7 Asia: China Tel: +86 21-3532-8532 2 - Los Angeles & SW Tel: 714-935-2999 7 - Great Lakes & Eastern Canada Tel: 248-651-5 Europe: Germany Tel: +48 7253-94- Asia: Japan Tel: +81 3-3518-663 3 - Midwest Tel: 952-892-9222 8 - Ohio Valley Tel: 513-398-55 Europe: Italy Tel: +39 2-458-8841 Asia: Korea Tel: +82 2-2169-26 4 - TOLA Tel: 972-62-63 9 - Northeast Tel: 215-345-813 Europe: Spain Tel: +34 91-675-1292 Asia: Taiwan Tel: +866 7-288-5168 Europe: United Kingdom Tel: +44 115-964-777 Asia: India Tel: +91 4-666-127 Mexico & South America Tel: +52 442-256-22 Africa & Middle East Tel: +1 63-879-2696 1 - San Francisco & Western Canada Tel: 48-754-337 5 - Chicago & Surrounding Tel: 847-458-15 Australia & New Zealand Tel: +61 3-9335-6449 131 Kingsland Drive Batavia, Illinois 651 USA Tel: 888-367-3992 CAS@CastAluminumSolutions.com www.castaluminumsolutions.com
AAA section The first step in building a CAST-X 25 part number is determining the volt, watt and circuit configuration. Select the AAA number (far left column) that best matches your specifications. www.castaluminumsolutions.com DESIGNATION AAA TABLE 1: VOLTAGE, POWER, CIRCUIT TYPE CIRCUIT TYPE AS WIRED NOM. RESISTANCE (Ω) 12 WYE 22.3 21 DELTA 29.3 22 WYE 87.8 23 PARALLEL 14.6 31 DELTA 15.3 32 WYE 45.8 33 PARALLEL 7.6 41 DELTA 1.3 42 WYE 3.8 51 DELTA 27.4 52 WYE 82.2 53 PARALLEL 13.7 61 DELTA 19.7 63 PARALLEL 54.9 LINE VOLTAGE (V) TOTAL POWER (kw) 48 N/A LINE CURRENT (A) 415 14.8 2.7 4 13.8 19.9 38 12.4 18.9 24 5. 12. 28 3.7 1.4 48 15. 18. 415 11.2 15.6 4 1.4 15. 38 9.4 14.3 24 3.7 9. 28 2.8 7.8 48 5. 6. 415 3.7 5.2 4 3.4 5. 38 3.1 4.8 48 N/A 415 11.2 27. 4 1.4 26. 38 9.4 24.7 24 3.7 15.6 28 2.8 13.5 38V TO 48V NOT AVAILABLE 24 7.2 17.3 28 5.4 15. 48 9.6 11.6 415 7.2 1. 4 6.7 9.6 38 6. 9.1 24 2.4 5.8 38V TO 48V NOT AVAILABLE 24 7.2 3. 28 5.4 26. 38V TO 48V NOT AVAILABLE 24 1.7 25.7 28 8. 22.2 48 14.2 17.1 415 1.6 14.8 4 9.9 14.3 38 8.9 13.5 24 3.6 8.6 28 2.7 7.4 28 N/A 415 12. 16.6 4 11.1 16. 38 1. 15.2 24 4. 9.6 28 3 8.3 48 5.3 6.4 415 4. 5.6 4 3.7 5.4 38 3.3 5.1 48 N/A 415 12. 28.8 4 11.1 27.8 38 1. 26.4 24 4. 16.7 28 3. 14.4 48 4. 4.8 415 3. 4.2 4 2.8 4. 38 2.5 3.8 48 4. 8.3 415 3. 7.2 4 2.8 6.9 38 2.5 6.6
TABLE 2 - ENCLOSURE AND THERMOSTAT DESIGNATION BB DESCRIPTION 11 GENERAL-PURPOSE ENCLOSURE (NEMA 1), NO TSTAT 12 MOISTURE-RESISTANT ENCLOSURE (NEMA 4), NO TSTAT 21 EXPLOSION-PROOF ENCLOSURE (NEMA 7), NO TSTAT 22 EXPLOSION-PROOF ENCLOSURE (NEMA 7), 32-25 F ( - 121 C) TSTAT 23 EXPLOSION-PROOF ENCLOSURE (NEMA 7), - 1 F (-17-38 C) TSTAT 24 EXPLOSION-PROOF HSG, ATEX CERT. ENCLOSURE, NO TSTAT 25 EXPLOSION-PROOF HSG, ATEX CERT. ENCLOSURE, TSTAT DPST The first digit corresponds to the following: 1. Standoff mounting required 2. Pipe nipple mounting required TABLE 3 - HIGH LIMIT THERMOSTAT SWITCH DESIGNATION "C" DESCRIPTION NONE 1 THERMOSTAT, AUTO RESET, 2 F 2 THERMOSTAT, AUTO RESET, 25 F 3 THERMOSTAT, AUTO RESET, 425 F 4 THERMOSTAT, AUTO RESET, 5 F 5 THERMOSTAT, MANUAL RESET, 26 F 6 THERMOSTAT, MANUAL RESET, 185 F 7 THERMOSTAT, MANUAL RESET, 15 F 8 THERMOSTAT, MANUAL RESET, 26 F w/teflon LEADS NOTE: Only castings with NEMA 7 & ATEX enclosures can accommodate high limit switches: NEMA 1 & NEMA 4 cannot. BB to F Sections 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) DESIGNATION "D" NONE DESCRIPTION TABLE 4 - THERMOCOUPLE 1 J-TYPE, 9" X.188 DIA,SINGLE UNGROUNDED, 316L S.S. 2 J-TYPE, 9" X.188 DIA,DUAL UNGROUNDED, 316L S.S. 3 K-TYPE, 9" X.188 DIA,SINGLE UNGROUNDED, ALLOY 6 4 K-TYPE, 9" X.188 DIA,DUAL UNGROUNDED, ALLOY 6 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 TABLE 5 - TUBING DESIGNATION "E" TUBING DESCRIPTION 1 DUAL, 5/8" O.D. X.65" WALL, 316L S.S. SEAMLESS 2 DUAL, 5/8" O.D. X.65" WALL, 316L S.S. SEAMLESS, ELECTROPOLISHED 3 DUAL, 5/8" O.D. X.65" WALL, 316L S.S. SEAMLESS, PASSIVATED 4 SINGLE, 5/8" O.D. X.65" WALL, 316L S.S. SEAMLESS 5 SINGLE, 5/8" O.D. X.65" WALL, 316L S.S. SEAMLESS, ELECTROPOLISHED 6 SINGLE, 5/8" O.D. X.65" WALL, 316L S.S. SEAMLESS, PASSIVATED TABLE 6- MACHINING DESIGNATION "F" MACHINING DESCRIPTION 1 STANDARD 3/8"-16 MOUNTING HOLES 2 STANDARD M1 X 1.5 MOUNTING HOLES OPTIONAL ACCESSORY COMPONENTS PART NUMBER DESCRIPTION 37--19-1 INSULATING JACKET: TEMP. LIMIT: 8 F / 425 C 274-55-6-8 TUBE UNION COMPRESSION FITTING (5/8 /.625 INCH) Need Help with Part Numbers? Contact CAS Directly: CAS@CastAluminumSolutions.com Toll-Free: 888-367-3992 Tel: 63-879-2696 (USA) CAS representatives are available to walk you through the process.