Parr Instrument 4540 User Manual

4540
High Pressure Reactors
Operating Instruction Manual
394M
4540 High Pressure Reactor System
PREFACE 3
FIXED HEAD OR REMOVABLE HEAD DESIGN 6
INSTALLATION 7
IDENTIFY THE VALVES 9
HOW TO USE THE VESSEL 13
Fixed Head Vessels 13 Removable Head Vessels 13
MAINTENANCE 15
General Maintenance Notes 15 Periodic Pressure Tests 16 Technical Support 16
4540 SERIES REACTION VESSEL PARTS LIST 17
Standard Vessel Fittings 17 Heaters Parts List 19 Overarm Parts List 20
4540 SERIES DRAWINGS 22
4540 Series Vessel with Fittings 22 1/4 HP Light Duty FH/RH Overarm and Motor 24 1/8 HP Light Duty FH/RH Vessel Overarm and Motor 25 4544 600 mL Removable Head Reactor 26 4545 600 mL Fixed Head Reactor 27 4544/4544A 600 mL Removable Head Reactor 28 4545/4545A 600 mL Fixed Head Reactor 29 4546 1200 mL Removable Head Reactor 30 4547 1200 mL Fixed Head Reactor 31
OTHER VESSEL HEAD FITTINGS 10
Safety Rupture Disc 10 Type J Thermocouple 10 Pressure Gage 10 Gage and Valve Adapters 10
ACCESSORIES 11
Serpentine Cooling Coil 11 Spare Parts Kit 11 Liners 11 Variable Speed Electric Motor 11 Air Motor 11 Pneumatic Lift for Fixed Head Vessels 12
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Parr Instrument Company
Customer Service
Questions concerning the installation or operation of this instrument can be answered by the Parr Customer Service Department:
1-309-762-7716 • 1-800-872-7720
Fax: 1-309-762-9453
E-mail: parr@parrinst.com
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4540 High Pressure Reactor System

PREFACE

Scope

These instructions describe the installation, opera­tion and maintenance of Parr Series 4540 Pressure Reactors offered in two sizes, 600 mL and 1200 mL. They cover the basic steps to be followed when installing these reactors and describe the function of all standard components. They are intended to be used in conjunction with several related instruction sheets listed in the following section. This information describes several components which are common to most Parr pressure reaction equipment, and includes safety precautions and other related information ap­plicable to all reaction laboratories. The users should study all of these instructions carefully before starting to use these vessels so that they will fully understand the capabilities and limitations of the equipment.

Related Instructions

The following Parr publications are also included to further your understanding of this instrument and its component parts:
No. Description
201M Limited Warranty 230M Safety Precautions to be Observed when
Operating Pressure Reaction Equipment
231M Operating Instructions for Parr Safety
Rupture Discs
234M Operating and Maintenance Instructions
for Parr Magnetic Drives
323M Operating Instructions for Parr Pressure
Relief Valves
548M Operating Instructions for 4848 Reactor
Controllers
FX004 Health & Safety Assurance Certification

Intended Usage

This system has been designed for use as a high pressure reactor system. It has been designed, built, and tested to strict physical and electrical standards. However, it is the user’s responsibility to install and operate it in conformance with local pressure and electrical codes.
If this equipment is used in a manner beyond its intended usage, the protection provided by the equipment may be impaired.

Safety Information

To avoid electrical shock, always:
1. Use a properly grounded electrical outlet of correct voltage and current handling capability.
2. Ensure that the equipment is connected to electrical service according to local national electrical codes. Failure to properly connect may create a fire or shock hazard.
3. For continued protection against possible hazard, replace fuses with same type and rating of fuse.
4. Disconnect from the power supply before maintenance or servicing.
To avoid personal injury:
1. Do not use in the presence of flammable or combustible materials; fire or explosion may result. This device contains components which may ignite such material.
2. Refer servicing to qualified personnel.
General Specifications
Electrical Ratings
Controller ratings are found in the Operating Instruc­tions for the controller supplied with your reactor.
Before connecting a controller to an electrical outlet, the user must be certain that the electrical outlet has an earth ground connection and that the line, load and other characteristics of the installation do not exceed the following limits:
Voltage: Fluctuations in the line voltage should not exceed 10% of the rated nominal voltage shown on the data plate.
Frequency: Controllers can be operated from either a 50 or 60 Hertz power supply without affecting their operation or calibration.
Current: The total current drawn should not exceed the rating shown on the data plate on the controller by more than 10 percent.
Thermocouple: Unless otherwise specified, all Series 4848 Controllers operate with a Type J (iron­constantan) thermocouple. The total resistance of the thermocouple and the lead wires should not exceed 100 ohms. If the resistance of the thermo­couple circuit is higher, it will reduce the sensitivity of the control system.
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4540 High Pressure Reactor System

Explanation of Symbols

II On position, full power heater switch
I On position, half power heater switch
O Off Position
~ Alternating Current (AC)
This CAUTION symbol may be present on the Product Instrumentation and literature. If present on the product, the user must consult the appropriate part of the accompanying product literature for more information.
This CAUTION symbol indicates that the surface may be hot.
Protective Earth (PE) terminal. Provided for connection of the Protective Earth (green or green/yellow) supply system conductor.

Environmental Conditions

This instrument is intended to be used indoors.
Caution! Do not use in hazardous atmospheres.
Operating: 15 ºC to 35 ºC; maximum relative humid­ity of 80% non-condensing. Installation Category II (over voltage) in accordance with IEC 664. Pollution degree 2 in accordance with IEC 664.
Altitude Limit: 2,000 meters.
Storage: -25 °C and 65 °C; 10% to 85% relative humidity.

Unpack Carefully

Unpack the equipment carefully and check all the parts against the, packing list. If shipping damage is discovered, report it immediately to the delivering carriers. The vessel, motor, heater, and temperature controller may be packed separately for convenience in shipping, but these parts are easily reassembled. Examine the components closely for any loose parts or shipping damage and be sure to check all layers of packing materials thoroughly so as not to overlook any parts which might otherwise be discarded.

Provisions for Lifting and Carrying

Before moving ensure all cables are disconnected. Use proper and safe lifting techniques when installing or moving the 4540 Reactor and/or its components.

Cleaning & Maintenance

Periodic cleaning may be performed on the exterior surfaces of the controller with a lightly dampened cloth containing mild soap solution. All power should be disconnected and the power cord should be unplugged when cleaning the instrument.
There are no user serviceable parts inside the prod­uct other than what is specifically called out and discussed in this manual. Advanced troubleshooting instructions beyond the scope of this manual can be obtained by calling Parr Instrument Company in order to determine which part(s) may need to be replaced or serviced.
Ensure that any hot surfaces have had adequate time to cool before cleaning or maintaining the reactor and/or its components.
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Parr Instrument Company
4540 High Pressure Reactor System

User’s Responsibility

All Parr reactors and pressure vessels are designed and manufactured with great care to assure safe opera­tion when used within their prescribed temperature and pressure limits.
But . . . the basic responsibility for safety when using this equipment rests entirely with the user; who must:
1. Select a reactor or pressure vessel that has the capability, pressure rating, corrosion resistance and design features that are suitable for its intended use. Parr engineers will be glad to discuss available equipment and material options with prospective users, but the final responsibility for selecting a reactor or pressure vessel that will perform to the user’s satisfaction in any particular reaction or test must rest with the user – not with Parr.
In exercising the responsibility for the selection of pressure equipment, the prospective user is often faced with a choice between over-or under­designed equipment. The hazards introduced by under-designed pressure vessels are readily apparent, but the penalties that must be paid for over-designed apparatus are often overlooked.
Recognizing these criteria, Parr reactors and pressure vessels are offered in several different styles, each designed for convenient use in daily operation within certain temperature and pres­sure limits, using gaskets, closures and other elements carefully selected for safe operation within the limits specified for that design. But in order to preserve the validity of these designs, all temperature and pressure limits must be observed, and no attempt should be made to increase these limits by making alterations or by substituting components which are not recom­mended by Parr Instrument Company.
2. Install and operate the equipment within a suitable barricade, if required, with appropriate safety accessories and in full compliance with local safety codes and rules.
All standard Parr pressure vessels are provided
with either suitable relief device or a means to attach one (typically in the form of a plugged opening). When a pressure vessel is delivered without a pressure venting device, it is the customer’s responsibility to provide pressure relief in order to protect the operator and the equipment from destructive high pressures. If you need more information or need help in selecting a proper relief device, please contact Parr Instrument Company.
3. Establish training procedures to ensure that any person handling the equipment knows how to use it properly.
4. Maintain the equipment in good condition and establish procedures for periodic testing to be sure the vessel remains structurally sound.
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4540 High Pressure Reactor System

FIXED HEAD OR REMOVABLE HEAD DESIGN

Parr Series 4540 High Pressure Reactors are furnished with two structural options in addition to the size, pressure range, stirrer motor, controller and similar options. These are:
Fixed Head Moveable Head

Vessel Head Design

There is no difference in the pressure or temperature limits or basic operating instructions based upon the fixed head or movable vessel options. There are dif­ferences in the design of the stand components which adapt the vessels to the support system.
In the fixed head design, the head of the vessel may remain fixed in the reactor support stand. All attach­ments to the head, gas and liquid feed and discharge lines, cooling water, vapor take-off and condenser, thermocouple, and any electrical leads can remain permanently in place. The reactor is opened by removing the cover clamp sections and lowering the cylinder away from the head.
In the removable head vessel design, all connections to the head are removed to allow the vessel to be opened.

PTFE Flat Gasket

The flat gasket is held in a recess in the vessel head and a machine pilot on the cylinder closes the recess to completely contain the gasket. The split ring closure used with this gasket has eight com­pression bolts which must be tightened to develop the loading on the gasket.
Maximum temperatures of a given system are dependant upon the material of construction and type of seal. Other accessories may limit operating temperature. The PTFE flat gasket can be used to operating temperatures as high as 350 °C.
Metal gaskets can be furnished for special applica­tions. The metal gaskets are not interchangeable with the flat gasket design, but require special grooves machined into the head and cylinder.
Parr recommends the PTFE flat gaskets for most applications.
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Parr Instrument Company

INSTALLATION

Pressure and Temperature Limits

The working pressure and temperature at which any reactor or pressure vessel can be used will depend upon the design of the vessel and the materials used in its construction. Since all materials lose strength at elevated temperatures, any pressure rating must be stated in terms of the temperature at which it applies. The standard material of construc­tion for Parr Instrument Company is Type 316 Stain­less Steel.
Limits for vessels made of other materials and for other operating temperatures can be obtained from Parr Customer Service. No attempt should be made to increase these limits by making alterations or by substituting components that are not recommended by the Parr Instrument Company. It must also be understood that lower pressure and temperature limits may be required for modified reactors and for vessels made of special alloys.
4540 High Pressure Reactor System
Limits for vessels will be determined by the physi­cal characteristics of the vessel material and will be prescribed on an individual basis.
The maximum working pressure and temperature for any vessel is governed by the design of the vessel and the strength of the material from which it is constructed. There is also a close relationship between working pressure and temperature since the strength of any material will normally fall off as the temperature is increased. Temperature and pressure limits are also affected by the physical properties and temperature limits of the gaskets and seals used in the vessel, and by any valves, gages or other fittings attached to the vessel. Obviously, the safe operating pressure of any system can be no higher than that of its lowest rated component.
All Parr reactors show the maximum safe operating pressure and temperature imprinted on the cylinder.
Pressure Vessel and Temperature Limits
The standard material of construction for Parr Instrument Company is Type 316 Stainless Steel. The working pressure and temperature in these one and two liter reactors must not exceed the following maximum limits:
Vessel Material Maximum Pressure Maximum Temperature
T316 SS 5000 psig 350 °C PTFE Flat Gasket
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4540 High Pressure Reactor System

Assemble the Reactor

These reactors require at least 10 square feet of work­space in a well-ventilated area with convenient access to an electric outlet, running water and a drain. This unit needs to be placed at least 10 inches away from walls or flammable materials.
1. Set the Reactor Controller near the reactor, leaving a space of at least six inches between the controller and the base of the reactor so that the controller will not be unduly affected by radiant heat. Con­nect the reactor to the controller using information contained in its Instruction Manual No. 548M or follow the steps below.
Labeled connections are provided on the rear panel of the controller.
Parr Cooling Only:
The Parr Cooling output connector is to be used only with Parr Instrument Company cooling sole­noid valve assemblies supplied with the appropri­ate cooling power cord.
Parr Heating Only:
2B. Vessels on stationary stand.
Bolt the stand to the bench/floor using the holes in the base plate.
Loosen the panel screw holding the vessel retainer to the front midplate. Open the vessel retainer to allow the placement of the vessel assembly. If fixed head style, position the head in the slot located in the front midplate. If removable head style, place vessel assembly such that the split ring rests on midplate bracket. After installing the vessel, close the vessel retainer and retighten the panel screw. Pull up on the release knob located at the top of the belt guard. This knob is attached to the upper drive shaft and the universal coupling. Lifting the knob will allow the alignment of the universal coupling and the drive adapter attached to the magnetic drive. Turn the knob to align the slot in the drive adapter with the universal coupling.
3. Connect the power cord from the heater into the heater socket on the rear panel of the controller.
4. Plug the motor power cord into the motor socket on the rear of the controller.
Secure the clamp on the motor cord with the provided screw next to the motor socket for safety purposes.
The Parr Heating output connector is to be used only with Parr Instrument Company heater assem­blies supplied with the appropriate heater power cord.
Note: Do not make connections to a Variac, Powerstat or the like to attempt to control the heating output. The heavy inductive load on the primary side of such devices can destroy the internal sold state relay located in the 4848 controller.
Parr Motor Only:
The Motor output connector is to be used only with Parr Instrument Company motor assemblies sup­plied with the appropriate motor power cord.
2A. Vessels on movable cart.
The motor is contained in the overarm assembly attached to the cart. The overarm assembly pivots to the rear to allow the vessel to be placed in the heater. The overarm is then aligned atop the vessel. Pull up on the release knob to allow the upper drive shaft to be connected to the magnetic stirrer.
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Parr Instrument Company
5. Note the voltage requirement on the controller identification label on the back panel, and then plug the power cord into an appropriate outlet. Power for these reactors should be drawn from a 3-slot, grounded outlet capable of carrying up to the full current rating of the system.
6. Connect the thermocouple extension wire to both the thermocouple and to the controller in the “Primary Temp Input” position on the rear panel. Insert the thermocouple into thermowell.
7. Connect leads from accessory packages such as tachometer, pressure transducer and high temp cut-off to the designated positions on the back panel of the 4848 Reactor Controller.
8. Connect cooling water to internal cooling coil if installed.
9. Connect cooling water to the magnetic stirrer. See manual no. 234M.
10. Connect tubing to the rupture disc outlet and run to a safely vented area. See manual no. 231M.
11. Using the switch on the Reactor Controller, turn on the motor for a short run to check the stirrer drive system.

IDENTIFY THE VALVES

4540 High Pressure Reactor System

Gas Inlet Valves

The gas inlet valve is easily identified when the bomb is open by noting that it is connected to a dip tube which extends to a point near the bottom of the bomb cylinder. This is an angle valve with an attached fitting which provides a socket for attaching the pressure hose furnished with the reactor.

Gas Release Valve

The gas release valve is connected to a plain opening on the underside of the bomb head. Gas released from this valve will be drawn from the top of the reactor.
Gage Adapter

Liquid Sampling Valve

The liquid sampling valve is attached to the same fitting as the gas inlet valve and connected to the same dip tube. With this arrangement, incoming gas is always introduced below the surface of the liquid and the operator is provided with a means for clear­ing the dip tube to be sure that any liquid sample taken during a run will be representative of the charge. This can be done by opening the upper gas inlet valve momentarily to allow the inlet gas to force any liquid in the dip tube back into the reactor before withdrawing a sample from the sampling valve.
Pressure Gage
Thermocouple
Gas Inlet Valve
Gas Hose Connection
Gas Release Valve
Split Ring Assembly
Shaft Assembly
Liquid Sampling Valve
Thermowell
Dip Tube
Cooling Coil
Stirrer Bracket
Impeller
Removable Head Vessel Vessel with Standard Magnetic Drive Shown
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4540 High Pressure Reactor System

OTHER VESSEL HEAD FITTINGS

Safety Rupture Disc

There is a safety rupture disc attached to the head that is intended to rupture and release the pressure before it reaches a dangerous level. A metal tag wired to the safety head identifies the burst pres­sure at room temperature for that particular disc. A similar tag is furnished with each replacement disc. This tag must remain with the apparatus at all times so that both present and future operators will be aware of the disc rating. Users should read the discussion of rupture discs given in the Instruction Sheet No. 231M for a complete description of the characteristics of rupture discs and the precautions to be observed when operating pressure equipment protected by this type of safety device.
A typical pre-bulged disc can be used to 90% of the rating on the tag. For additional protection, the user should install an adequate and safe venting system for removing any toxic, flammable or volatile mate­rial which would be released if the rupture disc should burst. A connector for attaching 3/8” OD tubing to the discharge port of the rupture disc is provided for this purpose.

Type J Thermocouple

A Type J thermocouple in a 1/8” dia. Stainless steel sheath is furnished with the reactor. Insert this ther­mocouple into the head thermowell and connect it
to the thermocouple socket on the rear panel of the temperature controller using the A470E2 extension wire furnished with the controller.

Pressure Gage

A pressure gage, usually 0-7500 psi with a T316 stainless steel Bourdon tube, is mounted on the head using attachment fittings similar to those used for the inlet/sampling valve assembly.

Gage and Valve Adapters

The pressure gage and the combined gas inlet and sampling valves are attached to the head with an adapter which allows these fittings to be drawn up tightly when facing in any direction. To attach these fittings to the head, screw the gage or valves firmly into the adapter, then run the 209HC4 bushing onto the threaded stem as far as it will go. Screw this assembly into the head until the nose of the adapter is seated; then back it off until the valve or gage is facing in the desired direction. Now hold the fitting firmly in place and close the joint by tightening the 209HC4 bushing. This connection can be made and broken repeatedly without destroying the sealing faces. A light coating of thread lubricant, such as Parr No. 424HC2 High Temperature Anti-Seize Lube, applied to the threads and to the nose of the adapter will help to obtain a tight joint.
Note: PTFE tape should be used only on all tapered (NPT) threads, not on the straight threads of the 209HC4.
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56HCPH
208HC15
1446HC
209HC4
PRESSURE GAGE
Parr Instrument Company
A451VB
A455VB2
491HCAD
208HC6
209HC4
INLET SAMPLING VALVE
A455VB2
208HC11
209HC4
GAS RELEASE VALVE
4540 High Pressure Reactor System

ACCESSORIES

Serpentine Cooling Coil

A Serpentine Cooling Coil can be installed in any of these reactors. The reactors are not drilled for a cooling loop unless so ordered. Reactors purchased without a serpentine cooling coil can have this fea­ture added by returning the head assembly to Parr Instrument Company.
If ordered the serpentine cooling coil is mounted to
the underside of the head and sealed with a ferrule and compression nut arrangement.
A slow continuous flow of cold water through the cooling loop is an effective means for controlling temperature overshoot, particularly when operating at temperatures below 150 °C. Alternately the cool­ing loop is used to effectively cool the system at the completion of a reaction.
An optional solenoid valve package is available to automate the cooling process. This package coordi­nates with the internal coil, with the water supply and connects to the temperature control.
If the internal cooling is not required, the coil may be removed and the alternate plugs installed.

Spare Parts Kit

Parr can furnish spare parts kits for these reactors which will provide a reserve supply of parts and tools sufficient to handle most normal replacements and emergency repairs during a year of heavy usage.
These kits contain replacement gaskets, packing, O-rings, shafts, bearings, and rupture discs. They can be ordered from any Parr Dealer or direct from the Parr Instrument Company. The order must specify the reac­tor size and indicate type of rupture disc, stirrer drive and whether it has a flat-gasket or O-ring closure.

Liners

Glass or PTFE liners can be furnished to fit most Parr reactors. These liners slide into the cylinder. Although they will not keep corrosive vapors from reaching the surfaces of the cylinder and head, they make it much easier to add and remove liquid reac­tants, and they give some protection to the cylinder when working with corrosive solutions. It must be noted, however, that adding a PTFE liner will slow the heat transfer rate into the vessel, and it may be necessary to adjust the temperature control method to prevent overheating.
Liner Part Numbers
Fits ID
Cylinder
Size
Glass
Liner
PTFE Liner
3.25” 600 mL 2312HC 2312HC3HA
3.25” 1200 mL 2312HC2 2312HC4HA

Variable Speed Electric Motor

Reactors are normally equipped with a DC variable speed motor supplied and controlled through the 4848 Reactor Controller. Instructions for connect­ing and operating these motors are included in the controller instruction sheet No. 232M. This motor is usually installed in a drive system designed to produce stirring speeds from 0 to 600 rpm. Higher speeds up to 1700 rpm can be obtained by substitut­ing larger diameter motor drive pulleys.

Air Motor

Variable stirring speeds from 100 to 2000 rpm with no spark hazard can be obtained by replacing the standard motor with an air motor. This motor oper­ates on compressed air which must be supplied at 40 psig minimum pressure with at least 10CFM available at that pressure. It is furnished with a speed control valve and oiler, all assembled on a mounting bracket.
To operate reactors equipped with an air motor, mount the drive system firmly on the heater and connect the air hose to a compressed air line. Fill the oiler with SAE 10 motor oil and adjust the oiler to feed one drop per minute into the air stream. For long continuous runs at high speeds the oiling rate should be increased to three drops per minute. If the motor becomes sluggish, flush it with a non­flammable solvent in a well ventilated area. Discon­nect the air line and muffler and pour a small amount of solvent into the inlet port. Rotate the shaft by hand in both directions for a few minutes; then connect the air line and run the motor until there is not further trace of solvent in the exhaust.
If the muffler felts are dirty, wash them in solvent or replace them. Relubricate the motor with a squirt of oil into the chamber and reassemble.
If it becomes necessary to disassemble the motor to replace the vanes, follow directions given in the instruction sheet published by the Gast Manufacturing Corp., Benton Harbor, Michigan.
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4540 High Pressure Reactor System

Pneumatic Lift for Fixed Head Vessels

For those models equipped with a pneumatic lift package, the following instructions apply:
Technical Support
This pressure reactor assembly uses an A2760HC3 Pneumatic Lift Package to raise and lower the Cylinder.
Cylinder Lift Assembly
Contact our customer service department with questions concerning the Pneumatic Lift Package.
Toll Free: 1(800) 872-7720
E-mail: parr@parrinst.com
Hand Lever Valve Assembly “Joystick”
Lift up on joystick to go “UP” or Push down on joystick to go “DOWN”.
Hose Bulkhead Flow Control Connector
A (1/4”) quick disconnect fitting has been provided for the air line connection.
Pneumatic Lift Cylinder
Pressure Regulator with Gage
The air pressure has been preset to 50 psi. The regulator can be adjusted by lifting up on this cap and then turning “clockwise” to increase or “counterclockwise” to decrease the amount of pressure being sent to the pneumatic cylinder.
Press cap back down after setting pressure, this will prevent the cap from being unintentionally turned.
User is responsible for connecting to their air supply.
Heater Assembly
Hose Coupler
Flow Control Valves
The flow control valves have been preset for optimum performance. Both the speed and lifting capacity of the Pneumatic lift package can be adjusted with the flow control valves located on the input and output ports of the pneumatic cylinder.
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Parr Instrument Company
4540 High Pressure Reactor System

HOW TO USE THE VESSEL

Fixed Head Vessels

First, lower the heater and push it aside before at­tempting to remove the split ring and cylinder. Raise the support cylinder holder to the bottom of the cylinder and open the gas release valve to discharge any internal pressure.
To open the Vessel
Remove the split rings. For vessels with a confined, flat PTFE gasket, loosen the six bolts. For vessels with an O-ring closure, loosen the latches on each side of the split rings. The split ring halves can now be removed, and the head with all attached fittings will remain in place. The cylinder can now be low­ered away. Handle the cylinder carefully so as not to damage the stirring shaft and other internals.
Before Closing the Vessel
Examine the head seal carefully to be sure that it is in good condition. The seal should not have any nicks or be hardened, discolored or deformed. Examine the mating surfaces on the cylinder and head to be sure they are clean and free from burrs; then raise the cylinder up to the head.
To Open the Vessel
Remove the split rings. For vessels with a confined, flat PTFE gasket, loosen the six bolts. For vessels with an O-ring closure, loosen the latches on each side of the split rings. The split ring halves can now be removed, and the head with all attached fittings wilt remain in place. The head with all attached fit­tings is free to be lifted from the cylinder. Handle the head carefully so as not to damage the stirring shaft and other internals.
Before Closing the Vessel
Examine the head seal carefully to be sure that it is in good condition. The seal should not have any nicks or be hardened, discolored or deformed. Examine the mating surfaces on the cylinder and head to be sure they are clean and free from burrs. Then carefully set head on cylinder.
To Close the Vessel
Slide the two split ring halves around the cylinder and head flanges. If equipped with a drop band, position the split ring halves such that the indenta­tion for one of the halves is located 180 degrees away from the pressure gage. Slide the drop band over the split ring halves and tighten the set screw lightly to hold the band in place.
To Close the Vessel
Put the two split ring halves around the head and cylinder flanges and fasten the latches or tighten the bolts as assembled before.

Removable Head Vessels

First, open the gas release valve to discharge any internal pressure. For vessels on a movable floor cart, lift the vessel out of the heater before attempt­ing to remove the split ring and head. For vessels on a stationary stand, loosen the panel screw hold­ing the vessel retainer, remove the vessel from the stand and set it on a table.
For vessels on a movable floor cart, place the vessel into the heater with the gage facing forward and swing the drive arm into position, connecting the splined coupling onto the stirrer drive. For vessels on a stationary stand, place the vessel onto the midplate such that the drop band set screw fits into the slot on the back of the midplate.
Recommended Bolt Torque
Material Pressure (psi) Torque (ft-lb)
PTFE 0 - 3000 35 ft-lbs PTFE 4000 - 5000 40 ft-lbs
Pick a starting bolt and tighten it to approximately 15 ft-lbs. Then by-pass the adjacent bolts and move around the closure to a bolt approximately 180 de­grees from the starting bolt. Torque all bolts to the initial 15 ft-lbs. Then proceed with the same pattern increasing the torque in 10 ft-lbs increments.
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4540 High Pressure Reactor System
Note: The following steps are common to both head configurations.
Gas Connections
Gas connections are dependent on applications. For general usage, use the pressure hose furnished with the reactor. Screw the Type “A” coned pressure fitting into the adapter attached to the gas inlet valve and tighten the compression nut firmly. Do not use any thread dope on the coned fitting.
Pressurizing the Vessel
Check all valves carefully before admitting gas into the system. The liquid sampling valve must remain closed throughout the charging procedure. The gas release valve must also be closed unless the vessel is to be purged, or unless there is to be a continuous flow through the reactor during a run. Always make certain that the pressure in the gas tank is greater than the pressure in the vessel; otherwise liquid will be forced out of the vessel and into the gas tank when the inlet valve is opened. If there is any possibility that the tank pressure might not be high enough to force gas into the reactor, install a one way check valve (optional) in the gas line to prevent any reverse flow. With the inlet valve open and the flow control valve on the gas tank closed, open the main valve on the gas tank only about one-quarter turn; then use the flow control valve or the valve on a pressure regulator to control the flow of gas into the vessel. After the desired pressure has been reached, close the tank valves and the vessel inlet valve and disconnect the hose at the vessel end.
Do Not Overfill the Vessel
Always watch the pressure gage closely when admitting gas so as not to exceed the maximum working limit. Remember that any subsequent increase in temperature will raise the pressure. Also, be sure that the amount of liquid placed in the vessel is carefully controlled. As a general rule, the liquid charge should not exceed two-thirds of the ca­pacity of the cylinder. Too much liquid in the vessel can lead to development of dangerous pressures if sufficient space is not provided for expansion when the liquid is heated. This hazard is explained in greater detail in a warning statement included in the Instruction Manual No. 230M.
Releasing Pressure
Use the gas release valve to reduce the pressure in the vessel if the reactor is accidentally overcharged when filling. Use this valve also to release any excess pressure during a run and to exhaust the vessel at the end of a run. If the discharge gases are flammable or toxic, discharge to an exhaust hood or to any other safe release point.
Withdrawing Liquid Samples
Liquid samples may be withdrawn from the sampling valve attached to the same adapter as the gas inlet valve whenever the vessel is pressurized. Always close the inlet valve before withdrawing a liquid sample and open the sampling valve cautiously because liquid will be discharged with considerable force. Be particularly careful if the temperature of the sample is above its boiling point at atmospheric pressure. If so, it will “flash” and be lost as soon as it is released from the vessel. This problem can be avoided by connecting an optional 4352 Sample Collection Vessel to the sampling valve to collect the liquid into an appropriate receiver. The addition of a small amount of gas can be used to clear the dip tube between liquid samples so that the next sample drawn through the tube will truly be representative of the mixture.
Initial Operating Test
Read all operating instructions carefully so as to be well acquainted with the correct procedures for han­dling the vessel and for operating the controller and other accessories. An initial operating test should be made, with only water, to check the apparatus before starting the first experimental runs. For this initial test, fill the cylinder not more than half full of water and run the temperature up to 150ºC while checking the apparatus for leaks and observing the performance of the temperature controller
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Parr Instrument Company
4540 High Pressure Reactor System

MAINTENANCE

General Maintenance Notes

1. Periodically inspect all electrical wiring and pres­sure connections for excessive corrosion. Sus­pect parts should be replaced by components
only supplied by Parr Instrument Company.
2. Always use appropriate wrenches on all fittings and valves. Never use pliers or pipe wrenches.
3. Head and cylinder service fixtures are available for convenience and protection of components
during maintenance of your reactor.
4. To reinstall straight thread (NPS) fittings to the head, screw the gage or valves firmly into the
adapter.
Run the bushing onto the threaded stem as far as it will go. Screw this assembly into the head until the nose of the adapter is seated; then back it off until the valve or gage is facing in the desired direction (no more than one full turn). Hold the fitting firmly in place and close the joint by tightening the bushing. This connection can be made and broken repeatedly without destroying the sealing surfaces. A light coating of thread lubricant, such as Parr High Tempera­ture Anti-Seize Lubricant, applied to the straight threads and to the nose of the adapter will help to obtain a tight joint.
Note: PTFE tape should be used only on all tapered (NPT) threads not NPS straight threads.
5. NPT (National Pipe Taper) threads should not be disassembled any more than necessary. It will become increasingly difficult to maintain a tight seal with these tapered threads if the joint is
made and broken repeatedly.
6. Do not use oil or anti-seize lubricant on threads or fittings if the vessel is to be used with oxygen.
7. If your vessel is equipped with a loose compres­sion ring be sure that it is in place on the head before attaching any head fittings. The compres­sion ring cannot be installed after fittings have
been screwed into the head.
8. Clean all threads and gas passages thoroughly and remove all tape fragments when overhaul­ing a vessel. An ultrasonic bath is excellent for cleaning metal parts, but do not place a thermo­couple probe, pressure gage, face seals or ball bearings in an ultrasonic bath. Periodic cleaning may be performed on the exterior surfaces of the reactor stand a lightly dampened cloth containing mild soap solution. All power should
be disconnected when cleaning.
9. Routinely inspect cap screws on split ring closure for lubrication and cleanliness. These screws should not be allowed to dry because the threads will seize. Regularly apply Parr High Temperature Anti-Seize Lubricant before this
happens.
10. To operate reactors equipped with an air motor, connect air hose to a compressed air line. For best torque and speed control the piping to the motor should be at least 3/8” IPS or larger. Fill the oiler with SAE 10 motor oil and adjust the oiler feed one drop per minute into the air stream. For long continuous runs at high speeds the oiling rate should be increased to three drops per minute. If the motor becomes slug­gish, flush it with a non-flammable solvent in a
well ventilated area.
Disconnect the air line and muffler and pour a small amount of solvent into the inlet port. Rotate the shaft by hand in both directions for a few minutes; then connect the air line and run the motor until there is not further trace of solvent in the exhaust. If the muffler is dirty, replace it. Relubricate the motor with a squirt of oil into the chamber and reassemble.
11. If servicing assistance is needed, contact Parr Instrument Company directly at the address shown on the back of these instructions.
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15
4540 High Pressure Reactor System

Periodic Pressure Tests

Each cylinder used in a Parr stirred reactor is tested under hydrostatic pressure to the higher of 1.43 times the rated working pressure at room tem­perature or 1.30 times the rated working pressure corrected for temperature before it is released from the factory. Micrometer caliper measurements are taken during this test to check the deflection of the walls under pressure. Excessive deflection or failure of the metal to resume its original dimensions after pressure is released indicates that a cylinder is po­tentially unsafe and it will be rejected. Similar tests should be made at regular intervals during the life of each cylinder, and particularly whenever the user suspects that the equipment has been over-stressed or damaged.
Some laboratories maintain hydraulic test facilities and make it a rule that all pressure vessels must be tested at regular intervals. Records are kept of deflections at specific test pressures so that any increase in deflection becomes a warning that the metal has lost strength. Any cylinder that fails to return to its original dimensions after application of the prescribed hydrostatic test should be discarded as unsafe for further use.
Users who do not have pressure test facilities can return any Parr pressure vessel to the factory for hy­drostatic testing and overhaul. This should be done whenever the metal shows excessive damage from corrosion or whenever an over-pressure or other unusual occurrence raises any safety questions.
To return a vessel for repair, contact Parr Instrument Company for a return authorization number (RMA).

Technical Support

Parr Instrument Company strives to provide our customers with world class support. When contact­ing Parr for technical support, please provide the complete serial number etched on the side of the cylinder. Serial numbers are a long string of letters and numbers. See highlighted text in figure below for an example of a complete serial number.
PARR INSTRUMENT COMPANY
MOLINE, IL. USA
2430HC3 222315 T316 112409 4600-1003-14106
MAWP 1900 PSI AT 350C 2010
Each Parr operating instruction manual binder comes with a customized Parts Lists that contains a list of the parts in each major component of your Parr Reactor. Do not discard this Parts List. You should use this parts list for reordering consumable and replacement parts to ensure that you order the correct parts for your reactor system.
Apparatus returned for testing and overhaul should be shipped prepaid to the following address:
Ship repair to:
Parr Instrument Company Attn: Service Department RMA # XXXXXX 211 53rd Street Moline, Illinois 61265
An order or letter of instructions should be mailed to the same address, as no repair work will be started without specific instructions and a Health & Safety Assurance Certification form (FX004) signed by a responsible user.
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Parr Instrument Company
Customer Service
Questions concerning the installation or operation of this instrument can be answered by the Parr Customer Service Department:
1-309-762-7716 • 1-800-872-7720
Fax: 1-309-762-9453
E-mail: parr@parrinst.com
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4540 SERIES REACTION VESSEL PARTS LIST

Standard Vessel Fittings

(5000 psig/ 350 °C)
4540 High Pressure Reactor System
Consult the itemized list for your reactor, provided along with this manual. For purpose of reactor iden­tification the following abbreviation codes are used:
RV - Removable Vessel FH - Fixed Head
FG - Flat Gasket Seal OR - O-ring Seal
MD - Magnetic Drive FMD - Footless Magnetic Drive
LD - Light Duty HD - Heavy Duty
Cylinders*
Part No. Description
2302HC Cylinder, 600 mL 2302HC2 Cylinder, 600 mL with BDV 2302HC10 Cylinder, 1200 mL 2302HC12 Cylinder, 1200 mL with BDV
Heads*
Part No. Description Code
2300HC14 Head RV 2300HC15 Head RV FMD 2301HC8 Head FH 2301HC7 Head FH FMD
* For parts made from alternate materials use the codes shown below as a suffix to the standard part number.
CM - Alloy 400 CC - Alloy 20Cb3
CT - Alloy 600 CA - Titanium G2 or G4
CG - Alloy b-2 CH - Alloy C-276
CX - Zirconium
Split Rings and Accessories
Part No. Description Code
A2305HC Split ring, 4140 alloy steel RV A2305HC-T Split ring, T316SS (PED Vessels) RV 2304HC Compression Ring RV A2315HC2 Split ring, with latches captive
compression ring, 4140 alloy steel
A2315HC2-T Split ring, with latches captive
compression ring, T316SS (PED Vessels)
1278HC6F Bolts, split ring 5/8”- 18-1/2” Hex 1368HC Torque Wrench 3/8” drive 1369HC2 Torque Adapter 3/8” drive x 1/2” hex
FH
FH
Gaskets & Seals
Part No. Description
48HC Gasket, silver, mag drive 48HCFG Gasket, gold plated, mag drive 2303HC Head Gasket, PTFE
Thermowell
Part No. Description
A2067HC Thermowell, 600 mL / 1200 mL
* For Special Fittings
Dip Tubes
Part No. Description
257HC39 Dip Tube with nut, 600 mL 257HC40 Dip Tube with nut, 1200 mL
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4540 High Pressure Reactor System
Shafts
Part No. Description Code
352HC10 Stub Shaft, mag drive RV 352HC11 Stub Shaft, mag drive FH 2141HC19 Shaft, 600 mL MV LD FMD 2141HC20 Shaft, 1200 mL MV LD FMD 2141HC21 Shaft, 600 mL FH LD FMD 2141HC22 Shaft, 1200 mL FH LD FMD
A449HC16 Shaft Assembly with coupling, 600 mL
387HC2 Coupling, T316 .50 OD 379HC Pin, shaft, coupling 448HC16 Shaft w/ bushing, 600 mL
A449HC17 Shaft Assembly with coupling, 1200 mL
387HC2 Coupling, .50 OD 379HC Pin, shaft, coupling 448HC17 Shaft w/ bushing, 1200 mL
447HC Shaft bushing, PTFE 448HC16 Shaft with 447HC bushing, 600 mL 448HC17 Shaft with 447HC bushing, 1200 mL A2308HC Impeller with screws, 1.75” dia. A2148HC4 FMD Impeller w/ screw, 1.75” diameter 358HC2F Screw for impeller
Stirrer Support Bracket
Part No. Description
A2307HC3 Stirrer Bracket with bushing 380HCF Cap Screw for bracket 299HC Bushing PTFE for bracket
External Fittings
Part No. Description
94CAAD Plug, ¼” NPTM A451VB Needle Valve, straight regulating 1/4”
NPTM-M (Liquid Sample)
A455VB2 Valve, angle regulating 1/4” NPTF-F
(Gas Inlet & Gas Release) 1446HC Adapter, 1/4” NPTM 491HCAD Hex Nipple, 1/4” NPTM 491HC2AD Hex long nipple, 1/4” NPTM 208HC6 Valve Adapter, two 1/4” NPTF 208HC15 Gage Adapter, angled, two 1/4” NPTF 209HC4 Bushing 288VBAD Male Connector, 3/8” T-1/4” NPTM 396HC3 Stirrer Plug 35HC Compression Nut, for plug A1357E2 Thermocouple, grounded, 600 mL, Type J A1357E A888HC2 Safety Rupture Disc assembly w/o disc
A2685HC Cooling Sleeve Assembly
Thermocouple, grounded, 1200 mL, Type J
(see 231M)
Magnetic Stirrer
Part No. Description
A1120HC Magnetic Drive Assembly
(rubber coupling)
A1120HC6 Magnetic Drive Assembly
(universal coupling)
See manual 234M for a full list of magnetic stirrers & parts.
Cooling Coils*
Part No. Description
3227HC6 Serpentine Cooling Coil, 600 mL 3227HC7 Serpentine Cooling Coil, 1200 mL
Cooling Loops
Part No. Description
3763HC Cooling Loop, 600 mL 3763HC2 Cooling Loop, 1200 mL
Cooling Loop Fittings
Part No. Description
A92HWAD Male Connector 217VB Nut for A92HWAD ¼T 218VB Ferrule for A92HWAD ¼” T 79HW Plug, Hex Head 1/8” NPTM
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Parr Instrument Company
Gages
Part No. Description
56HCPA Pressure gage, 4-1/2”, 0-100 psi 56HCPB Pressure gage, 4-1/2”, 0-200 psi 56HCPC Pressure gage, 4-1/2”, 0-600 psi 56HCPD Pressure gage, 4-1/2”, 0-1000 psi 56HCPF Pressure gage, 4-1/2”, 0-2000 psi 56HCPH Pressure gage, 4-1/2”, 0-5000 psi 56HCPK Pressure gage, 4-1/2”, 0-10,000 psi
* For Special Fittings

Heaters Parts List

4540 High Pressure Reactor System
Heaters for Bench Top and Floor Stand Vessels
Part No. Description
A2256HC12EB
A2256HC12EE
A2256HC22EB
A2256HC32EE
Heater Assembly w/ thermowell 1000W 115V 600 mL
Heater Assembly w/ thermowell 1500W 230V 600 mL
Heater Assembly w/ thermowell 1500W 115V 1200 mL
Heater Assembly w/ thermowell 2000W 230V 1200 mL
Heaters for Moveable Cart Model
Part No. Description
A735HCEB*
A735HCEE*
A735HC8EE
A735HC3EB
A735HC3EE
* 600 mL without Bottom Drain Valve
1200 mL with or without Bottom Drain Valve
Heater Assembly 1500W 115V 600 mL
Heater Assembly 1500W 230V 600 & 1200 mL
Heater Assembly 2000W 230V 1200 mL w/o Bottom Drain Valve
Heater Assembly 1000W 115V 600 mL w/ Bottom Drain Valve
Heater Assembly 1000W 230V 600 mL w/ Bottom Drain Valve
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4540 High Pressure Reactor System

Overarm Parts List

Motor
Part No. Description Code
1355EES Motor, VS/PM 130VDC 1/8HP
A1554EES
A1393HC Air Motor LD A388E6 Air Motor HD A388EES Motor 1/4 HP VS 90 VDC LD HD A388E2ES Motor 1/2 HP VS 90VDC HD A388EEQ Motor 1/4 HP EXP VS 90 VDC LD HD A388E2ET Motor 1/2 HP VS 180 VDC HD A388EER Motor 1/4 HP EXP VS 180 VDC LD HD A388EET Motor 1/4 HP VS 180 VDC LD HD
Motor, VS/PM 130VDC 1/8HP with EMC filter
Driven Pulley Assembly
Part No. Description Code
A2179HC Driven Pulley Assembly LD 839HC Ball Bearing LD 841HC Snap Ring, External .693” LD 842HC Snap Ring, 1.804” LD 858HC2 Pulley, Driven LD 862HC Support Hub LD 299HC2 Bushing, PTFE LD
Shaft Couplings
Part No. Description Code
A722HC2 Shaft Coupling .38 rubber RV A722HC Shaft Coupling .50 rubber RV 2075HC2 Shaft Coupling .38 universal FH 2352HC Shaft Coupling .50 universal FH
Release Knobs
Part No. Description Code
845HC2 Release Knob, .38 Shaft LD 726HC Release Knob, .50 Shaft HD
Drive Pulleys (Motor)
Part No. Description Code
857HC Pulley 600 RPM LD 857HC3 Pulley 800 RPM LD 857HC4 Pulley 1000 RPM LD 857HC5 Pulley 1700 RPM LD 695HC5 Pulley 600 RPM .62 HD 695HC3 Pulley 1000 RPM .62 HD 695HC2 Pulley 1700 RPM .62 HD
Pulley Belt Combinations
A2519HC Driven Pulley Assembly HD 706HC2 Pulley, Driven HD 725HC Support Hub HD 730HC Ball Bearing HD 731HC Snap Ring Internal 2” HD 732HC Snap Ring External 1” HD 2429HC Bushing PTFE HD
Upper Drive Shafts
Part No. Description Code
A860HC Upper Drive Shaft RV
A742HC13
A2562HC Upper Drive Shaft FH A2564HC Upper Drive Shaft 11.27” FH
* For Special Fittings
* For Special Fittings
Upper Drive Shaft, standard Calrod heater only
RV
LD Drive RV-Belt FH-Belt
857HC 847HC6 847HC9 857HC3 847HC6 847HC9 857HC4 847HC6 847HC9 857HC5 847HC4 847HC10
HD Drive RV-Belt FH-Belt
695HC5 728HC 728HC5 695HC3 728HC 728HC5 695HC2 728HC3 728HC6
Optional Tach Parts
Part No. Description
1564HC Optical Wheel A10 01E Tach Sensor Assembly (9.0”L)
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Parr Instrument Company
4540 High Pressure Reactor System
BELT GUARD
DRIVE PULLEY
OVERARM PLATE
ISOLATOR
ENCASEMENT
MOTOR
BACK PLATE
BELT
TACH SENSOR
ASSEMBLY
RELEASE KNOB
OPTICAL WHEEL
DRIVEN PULLEY
HUB ASSEMBLY
SNAP RING
UPPER DRIVE SHAFT
UNIVERSAL COUPLING
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21
4540 High Pressure Reactor System

4540 SERIES DRAWINGS

4540 Series Vessel with Fittings

Shown with Standard Magnec Drive
A92HWAD MALE CONNECTOR
A888HC2 RUPTURE DISC HOLDER
366VBAA HEX COUPLING
288VBAD MALE CONNECTOR
A1120HC6 MAG DRIVE
352HC10 STUB SHAFT
299HC BUSHING (UNDERSIDE)
208HC15 GAGE ADAPTER
209HC4 ADAPTER BUSHING
2300HC14 HEAD
94CAAD PLUG
A1357E2 THERMOCOUPLE, 600mL A1357E THERMOCOUPLE, 1200mL A138CA MALE CONNECTOR
REMOVABLE VESSEL
A92HWAD MALE CONNECTOR
A1120HC6 MAG DRIVE REF
352HC11 STUB SHAFT
299HC BUSHING (UNDERSIDE) REF
56HC SERIES GAGE
A455VB2 VALVE
GAS INLET VALVE
2301HC8 HEAD
1446HC ADAPTER
GAS HOSE CONNECTION
FIXED HEAD VESSEL
A455VB2 VALVE
491HC2AD NIPPLE
GAS RELEASE VALVE
A2305HC SPLIT RING ASS'Y
2304HC COMPRESSION RING
A449HC16 SHAFT ASS'Y, 600mL
A449HC17 SHAFT ASS'Y, 1200mL
3227HC6 COOLING COIL, 600mL
3227HC7 COOLING COIL, 1200mL
2X A92HWAD MALE CONNECTOR
2X A2308HC IMPELLER
491HCAD NIPPLE
A451VB VALVE
LIQUID SAMPLING VALVE
208HC6 ADAPTER 209HC4 ADAPTER
A2067HC THERMOWELL CUT TO LENGTH
257HC39 DIP TUBE, 600mL 257HC40 DIP TUBE, 1200mL
A2315HC2 SPLIT RING ASS'Y
A2307HC3 STR BRACKET
2302HC CYLINDER, 600mL 2302HC10 CYLINDER, 1200mL 2303HC GASKET
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Parr Instrument Company
4540 Series Vessel with Fittings
Shown with Footless Magnec Drive
4540 High Pressure Reactor System
A2140HC2 MAG DRIVE
1133HC BUSHING (UNDERSIDE)
2996HC COLLAR (UNDERSIDE)
2300HC15 HEAD
A2140HC2 MAG DRIVE REF
1133HC BUSHING (UNDERSIDE) REF
2996HC COLLAR (UNDERSIDE) REF
2301HC7 HEAD
FIXED HEAD VESSELREMOVABLE VESSEL
2141HC19 SHAFT, 600mL
2141HC20 SHAFT, 1200mL
2X A2148HC4 IMPELLER
2141HC21 SHAFT, 600mL
2141HC22 SHAFT, 1200mL
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4540 High Pressure Reactor System

1/4 HP Light Duty FH/RH Overarm and Motor

Diagram of Overarm for: 4544A, 4545A, 4546A & 4547A
24
RPM
600 RPM 695HC5 Ø1.75 728HC5 1000 RPM 695HC3 Ø3.00 728HC5 1700 RPM 695HC2 Ø4.00 728HC6
Parr Instrument Company
RPM Table
Pulley Diameter Belt

1/8 HP Light Duty FH/RH Vessel Overarm and Motor

Diagram of Overarm for: 4544A, 4545A, 4546A, & 4547A
4540 High Pressure Reactor System
RPM Table
RPM
600 RPM 857HC Ø1.19 847HC9 1000 RPM 857HC4 Ø1.85 847HC9 1700 RPM 857HC5 Ø3.00 847HC10
Pulley Diameter Belt
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25
4540 High Pressure Reactor System

4544 600 mL Removable Head Reactor

Without Bottom Drain Valve
26
Parr Instrument Company

4545 600 mL Fixed Head Reactor

Without Bottom Drain Valve
4540 High Pressure Reactor System
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27
4540 High Pressure Reactor System

4544/4544A 600 mL Removable Head Reactor

With or Without Bottom Drain Valve
28
Parr Instrument Company

4545/4545A 600 mL Fixed Head Reactor

With or Without Bottom Drain Valve
4540 High Pressure Reactor System
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4540 High Pressure Reactor System

4546 1200 mL Removable Head Reactor

Without Bottom Drain Valve
30
Parr Instrument Company

4547 1200 mL Fixed Head Reactor

Without Bottom Drain Valve
4540 High Pressure Reactor System
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31
394M R02 12/30/14
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