Parr Instrument 4558 User Manual
4555-4558
5G & 10L Pressure Reactors
Operating Instruction Manual
403M
TABLE OF CONTENTS
TABLE OF CONTENTS............................ 2
Related Instructions...........................3
Customer Service.............................. 3
PREFACE ................................................. 4
Scope ................................................ 4
Safety Information ............................. 4
Provisions for Lifting and Carrying.....4
General Specifications....................... 5
Explanation of Symbols..................... 6
Environmental Conditions .................. 6
Intended Usage.................................7
User’s Responsibility.........................7
Unpack Carefully...............................7
INSTALLATION ........................................ 8
Pressure, Temperature Limits ........... 8
Slave Box Control A1761HC3 ........... 8
ASSEMBLE THE REACTOR....................9
Removable Head Vessel................... 9
Fixed Head Vessel .......................... 10
Cylinder Slide Adjustment................ 12
IDENTIFY THE VALVES......................... 13
Gas Inlet Valve................................ 13
Gas Release Valve.......................... 13
Liquid Sampling Valve..................... 13
OTHER VESSEL HEAD FITTINGS ........ 14
Safety Rupture Disc......................... 14
Type J Thermocouple...................... 14
Pressure Gage ................................ 14
Gage and Valve Adapters................14
HOW TO USE THE VESSEL..................15
Flat Gasket or O-ring Seal............... 15
To Open the Vessel......................... 15
Before Closing the Vessel ............... 15
Close the Vessel.............................. 16
Gas Connections............................. 16
Pressurizing the Vessel................... 16
Do Not Overfill.................................17
Releasing Pressure......................... 17
- 2 -
4555 - 58 Series
5G & 10L Pressure Reactors
Withdrawing Liquid Samples............17
The Shaft Seal.................................17
REACTORS WITH SLAVE BOX CONTROLS 18
3-Zone Slave Box A1761HCEE........ 18
3-Zone Slave Box A1761HC3........... 18
Initial Operating Test......................... 18
ACCESSORIES........................................ 19
Internal Cooling Coils........................ 19
Stirrer Drive Systems........................ 19
Quick Disconnect Drive Coupler....... 19
Air Motor...........................................20
Variable Speed Electric Motor ..........20
Spare Parts Kit .................................. 20
EXPLOSION PROOF OPERATION......... 21
The Motor ......................................... 21
The Temperature Controller.............. 21
Slave Box Control............................. 21
The Heater........................................ 21
The Wiring ........................................21
PERIODIC PRESSURE TESTS ............... 22
GENERAL MAINTENANCE NOTES........ 23
Fuses................................................ 24
PARTS LISTS........................................... 25
Vessel Parts List............................... 25
Internal Fittings ................................. 25
External Fittings................................ 26
Internal Parts Identification ............... 27
External Parts Identification..............28
Cooling Coils & Fittings..................... 29
Drive Parts List.................................. 30
Stands............................................... 31
Slave Boxes...................................... 31
Heaters.............................................32
APPENDIX A – REMOVABLE VESSEL
REACTOR DRAWINGS ........................... 33
APPENDIX B – FIXED HEAD VESSEL
REACTOR DRAWINGS ........................... 36
4555 - 58 Series
5G & 10L Pressure Reactors
_________________________________
Related Instructions
The following Parr publications are also available 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 Discs
548M Operating Instructions for 4848 Reactor Controllers
234M Operating and Maintenance Instructions for Parr Magnetic Drives
323M Operating Instructions for Parr Pressure Relief Valves
F0042 Health & Safety Assurance Certification
_________________________________
Customer Service
Questions concerning the installation or operation of this instrument can be answered by the
Parr Customer Service Department:
309-762-7716
800-872-7720
Fax: 309-762-9453
www.parrinst.com
parr@parrinst.com
- 3 -
5G & 10L Pressure Reactors
4555 - 58 Series
PREFACE
Scope
These instructions include information for the installation and operation of standard Parr
Models 4555, 4556, 4557, 4558, 4667, and 4668 (5G and 10L volume) Reactors. It should be
noted that these reactors can be custom designed to accommodate a customer’s specific
operating parameters. This may impact certain areas of these instructions or related instructions
mentioned within this manual.
These instructions cover the basic steps to be followed in installing these reactors and
describe the function of all principal components. They are intended to be used in conjunction
with several related instruction sheets listed on the previous page which provide information
describing several components which are common to most Parr pressure reaction apparatus.
These instructions also include safety precautions and other information applicable to all
pressure equipment.
The user should study all of these instructions carefully before starting to use these reactors
to fully understand the capabilities and limitations of the equipment, and to be well aware of the
precautions to be observed in the operation.
Safety Information
To avoid electrical shock, always:
1. Use a properly grounded electrical outlet of correct voltage and current handling capacity.
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.
Provisions for Lifting and Carrying
The 4555, 4556, 4557, 4559, 4667 and 4668 (five gallon and ten liter volume) reactors and
their components are very heavy. Before moving ensure all cables are disconnected. Use
proper and safe lifting techniques when installing or moving the reactor and/or its components.
Caution
Do not use in hazardous atmospheres.
- 4 -
5G & 10L Pressure Reactors
4555 - 58 Series
General Specifications
Electrical Ratings
Controller ratings are found in the Operating Instructions for the controller supplied with your
reactor.
Before connecting any Series A1761HC Slave Control Box 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.
Slave Boxes
A1761HCEE rated 230VAC, 50/60 Hz, 50.0 Amp
A1761HC3 rated 400/415V 3-P “Y”, 50/60 Hz, 20.0/ Leg Amp
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
slave control box by more than 10 percent.
Thermocouple: Unless otherwise specified, all Parr controllers operate with a Type J (ironconstantan) thermocouple. The total resistance of the thermocouple and the lead wires should
not exceed 20 ohms. If the resistance of the thermocouple circuit is higher, it will reduce the
sensitivity of the control system.
- 5 -
Explanation of Symbols
4555 - 58 Series
5G & 10L Pressure Reactors
I
O
~
3 ~
On position
Off position
Alternating current (AC)
Three–phase alternating current
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 apparatus is to be used indoors. It should be secured to the floor in a well-ventilated
area with convenient access to an electric outlet, running water and a drain.
Operating: 15 °C to 35 °C; maximum relative humidity of 80% non-condensing.
Installation Category II (overvoltage) 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.
- 6 -
5G & 10L Pressure Reactors
4555 - 58 Series
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. Ho wever, it is the user's
responsibility to install and operate it in conformance with local pr essure and electrical codes.
If this equipment is used in a manner beyond its intended usage, the protection provided by
the equipment may be impaired.
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 which 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 under-designed equipme nt. The ha zards
introduced by under-designed pressure vessels are readily app arent, 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 m ade 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 a 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 destructiv e high
pressures. If you need more information or need help in selecting a proper re lief 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 procedu res for periodic testing to
be sure the vessel remains structurally sound.
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 c arriers. 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 lo ose 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.
- 7 -
5G & 10L Pressure Reactors
4555 - 58 Series
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 Customer Service. No attempt should be made to increase these limits by
making alterations or by substituting components which 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.
Limits for vessels will be determined by the physical characteristics of the vessel material
and will be prescribed on an individual basis.
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.
The working pressure and temperature in these five gallon and ten liter reactors must not
exceed the following maximum limits:
Pressure and Temperature Limits
Vessel Material Maximum Pressure Maximum Temperature
T316SS 1900 psig 350° C PTFE Flat Gasket
T316SS 1900 psig 225° C FKM O-ring
T316SS 1900 psig 275° C FFKM O-ring
A1761HC3 400/415V 3-Phase "Y" Slave Box Control
Installation of a 3-phase slave box requires a switch or circuit breaker installed in the
building.
1. It shall be in close proximity to equipment and within easy reach of the operator.
2. It shall be marked as disconnecting device for the equipment.
- 8 -
5G & 10L Pressure Reactors
4555 - 58 Series
ASSEMBLE THE REACTOR
These reactors require a work area 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.
Use the associated assembly reference drawings
included in this manual to help identify parts to
assemble the reactor.
Removable Head Vessel
1. Take the lift tube assembly with the top
bushings/housings on it and lower the tube through
the work surface and center stand section. Place
the end of the tube over the bottom bushing.
2. If applicable, mount the hoist by hooking it to
the lift tube assembly. If it is an electric hoist, plug it
into receptacle provided in the arm of lift tube
assembly.
3. The wiring for the electric hoist, motor, and tachometer is routed through the lift tube and
out through the bottom bearing support. Route this wiring through the conduit ducts
underneath the center stand bottom shelf and up through the conduit duct on the left rear
leg of the center stand. Connect these wires to the appropriate connectors.
4. Install two Lift Rings (1593HC) in cylinder flange. Attach one Lift Ring (1593HC) into the
Lift Plate (1594HC). Attach two Lift Cables (A1595HC) to the lift plate in the holes that are
180° apart. Attach Lift Cables to the Lift Rings in cylinder. Attach this assembly to the lift
hoist hook. Lift the cylinder and carefully lower into the heater. Remove the two Lift
Rings from the cylinder flange after it is in the heater.
5. If applicable, install the Bottom Drain Valve into bottom of cylinder, through the bottom
of the heater.
6. Lift the head with three Lift Cables (A1595HC) attached to the lift plate in the holes that
are 120° apart. Attach the cables to the three 1571HC Lift Eyes on the head. Lift the head
and place carefully on the cylinder to avoid damage to the sealing surfaces.
7. Install the Split Rings per instructions in section, "How to Use the Vessel".
8. If the drive coupler needs to be adjusted to center the coupler halves, loosen the
mounting bolts of the motor and move the motor assembly as required to center the drive
couplers. Tighten the bolts while holding the motor assembly in position.
- 9 -
5G & 10L Pressure Reactors
4555 - 58 Series
Fixed Head Vessel
Caution Symbols:
1. For the apparatus to be fully stable in all
configurations, the base of this unit must be securely
fastened to the floor before operation. Four 3-hole inside
corner brackets are provided (3159HC). Brackets will
accommodate 5/16” diameter anchoring hardware (not
provided). See drawing A3130HC Basic Main Support
Frame Pkg. shown in Appendix B.
2. See drawing A3140HC Pneumatic Vertical Lift Pkg in
the appendix. Moving parts, potential pinch-point. Keep
hands clear.
3. See drawing A3170HC 2 Hinged Split Ring Pkg in the appendix. Moving parts, potential
pinch-point. Keep hands clear.
Setting up the stand.
1. If the motor has been removed for shipping purposes, reinstall the motor. Refer to
drawings A3160HC and A3160HC2 (pages 43-45).
2. Unpack vessel assembly, remove the split rings, and lift the head assembly from the
cylinder.
3. If furnished with band heaters, install prior to mounting the cylinder.
4. Set cylinder mounting pad on the cylinder support plate. Refer to drawing A3150HC in
the appendix.
5. Handles are provided to assist in lifting the cylinder. Lift the cylinder and place it on the
cylinder support plate, lining up the holes for the retaining bolts. Install retaining bolts. Refer
to drawing A3150HC in the appendix.
6. Set the head assembly on the cylinder carefully to avoid damage to the sealing
surfaces.
7. Push in the cylinder support plate. Install 3 fixed head support rods (3156HC). Refer
to drawing 4557 Sheet 2 in the appendix.
- 10 -
8. Remove the front drive guard shield if applicable. Refer to drawing 4557 Sheet 2 in
the appendix.
9. Connect pneumatics. A quick disconnect fitting has been provided on the back of the
unit for airline connection. User is responsible for providing air source.
10. Lift “up” on joystick to raise cylinder, push “down” to lower. The joystick can provide
speed control up to the maximum preset speed. Lift up slowly to raise the head and
cylinder into position for attaching the fixed head support rods to the upper motor
platform. Refer to drawing 4557 Sheet 2 in the appendix.
11. The lift pressure regulator pressure may need to be increased to raise the additional
weight of the head assembly and cylinder. After the head has been fixed, readjust the
pressure for cylinder weight. The maximum lifting capacity can be adjusted using the
pressure regulator pressure setting. Adjust by lifting up on the top cap and turning clockwise
to increase the amount of pressure being sent to the pneumatic cylinder. Turn
counterclockwise to decrease the amount of pressure. After adjusting, press the cap down
to lock. Depending on vessel size, type, and weight, regulator will be preset at factory for 60
to 80 psi.
12. Ensure the motor coupling and the drive coupler are aligned. If adjustment is
required, loosen the motor bolts to realign and then retighten bolts.
13. Install the front drive guard shield if applicable.
14. Lower the cylinder.
15. If furnished with a flexible mantle heater and/or a bottom drain valve, install at this
time.
5G & 10L Pressure Reactors
4555 - 58 Series
- 11 -
5G & 10L Pressure Reactors
4555 - 58 Series
Cylinder Slide Adjustment
Minimal, if any, adjustments
are required for binding or sagging
of the cylinder slide support.
Note: To adjust for sagging, the
cylinder must be removed from the
Slide Support. This can be done
by leaving the closure intact with
the head and cylinder and
removing the (3) 3/8” nuts from the
bottom of the cylinder standoffs.
Lower the support stand
accordingly. This may require
removal of any plumbing devices
or accessories located on the
bottom of the cylinder.
Caution: The
cylinder is very
heavy and caution
should be
observed when the
cylinder is
disconnected from
the Slide Support.
1. Any adjustments to the Slide Support must be made with the Slider Support in the “IN”
position. Adjustments in the “OUT” position can cause unwanted binding to occur.
2. Once the (3) nuts have been removed from the bottom of the Slide Support, the Slide
Support can be lowered. It can then be leveled by loosening the Angle Support Brackets
detailed in the figure F1. Gently loosen the (8) horizontally mounted 5/16 x ¾” fasteners on
the Angle Support Brackets and adjust the Cylinder Support until it is level. Then tighten the
(8) 5/16 x ¾” fasteners accordingly.
3. Loosen the (4) 5/16 x ½” vertically mounted fasteners on the Angle Support brackets
until the support bracket moves freely. Center (left to right) the Slide Support and ensure
that there is no excessive force being applied against or away from the slide rails. Then
tighten the (4) fasteners accordingly.
4. Raise the Slide Support to the bottom of the cylinder until the standoffs are inserted into
the holes provided on the Slide Support. Attach the Slide Support to the cylinder using the
3/8” nuts previously removed.
Slotted holes for
center adjustment
(Left/Right)
(4) 5/16 x 1/2”
Oversized holes for
level adjustment
(Sagging)
(4) 5/16 x 3/4” Bolts
Holes for
cylinder
mounting
(3) 3/8” Nuts and
Flat Washers
- 12 -
5G & 10L Pressure Reactors
4555 - 58 Series
IDENTIFY THE VALVES
Gas Inlet Valve
The gas inlet valve is easily identified when the vessel is open by noting that it is
connected to a dip tube which extends to a point near the bottom of the cylinder. Typically,
this is an angle valve with an attached fitting which provides a socket for attaching the
A495HC pressure hose furnished with the reactor.
Gas Release Valve
The gas release valve is connected to a plain opening on the underside of the head. Gas
released from this valve will be drawn from the top of the reactor.
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 sample taken during a run will be representative of the charge. This
can be done by opening the gas valve momentarily to force any liquid in the dip tube back
into the reactor before withdrawing a sample from the sampling valve.
- 13 -
5G & 10L Pressure Reactors
4555 - 58 Series
OTHER VESSEL HEAD FITTINGS
Safety Rupture Disc
There is a safety rupture disc attached to the head which 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.
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 reactor.
Pressure Gage
A pressure gage, typically a 0-2000 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, and 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.
- 14 -
Loading...