Parr Instrument 4838 User Manual
4838
Reactor Controller
Operating Instruction Manual
551M
Table of Contents
Table of Contents
Preface
Related Instructions — 3
Scope — 3
Applications — 3
Explanation of Symbols — 4
Safety Information — 4
Provisions for Lifting and Carrying — 4
Intended Usage — 4
Cleaning & Maintenance — 4
General Specifi cations — 5
Environmental Conditions — 5
4838 Reactor Controller Specifi cations — 5
User’s Responsibility — 6
Unpack Carefully — 6
Installation
General Instructions — 7
Connections — 7
Component Summary
Switches and Indicators — 8
Protective Fuses and Relays — 8
High Limit Reset — 9
Access to the Controller Cabinet — 9
Fuses — 9
Instructions for the 4838 Reactor Controller
Temperature Control Module — 10
Communication with PC — 16
4838 Factory Defaults
Navigating the Menu System / Factory Default Settings — 18
Primary Temperature Module — 18
Pressure Module — 19
HTM / ETLM Module — 20
Appendix A: Controller Parameters
Initial Setting Mode — 21
Operation Mode — 22
Regulation Mode — 23
Parts List
Fuses — 24
Primary Temperature Module — 24
Pressure Display Module (PDM) — 25
Hi-Temp Cut-Off Module (HTM) — 26
or External Temperature Limit Module (ETLM) — 26
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Parr Instrument Company
4838 Reactor Controller
Preface
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
552M CD for 4838 Controller
Scope
These instructions cover the installation and operation of Parr Model 4838 Reactor Controller as used
with Parr Laboratory Reactors and Pressure Vessels.
They cover the basic functions provided in each of
these controllers and describe the several optional
control modules which can be added to these expandable units. The users should study the instructions carefully before using any of these controllers
so that they will fully understand the capabilities
of this equipment and the safety precautions to be
observed in its operation.
Applications
Each 4838 Reactor Controller consists of a packaged
temperature control unit completely wired and assembled with appropriate power and safety relays,
switches and pilot lights.
These units are designed specifi cally for use with
Parr pressure vessels and are to be used only with
Parr equipment.
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 • http://www.parrinst.com
Visit our website to fi nd our Controller FAQ
http://www.parrinst.com/support/48384838-controller-support/controller-faq/
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4838 Reactor Controller
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.
Protective Earth (PE) terminal. Provided for connection of the protective earth (green or green/yellow) supply system conductor.
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 fi re 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:
5. Do not use in the presence of fl ammable or combustible materials; fi re or explosion may result.
This device contains components which may
ignite such material.
6. Refer servicing to qualifi ed personnel.
Caution!
Do not use in hazardous atmospheres.
Provisions for Lifting and Carrying
Intended Usage
This controller has been designed for use with Parr
pressure vessels and reactors. 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 the instrument is used in a manner not specifi ed
by Parr Instrument Company, the protection provided by the equipment may be impaired.
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 4838 Controller.
There are no user serviceable parts inside the product other than what is specifi cally 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 be replaced or
serviced.
Before moving the instrument, disconnect all connections from the rear of the apparatus. Lift the
instrument by grabbing underneath each corner.
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Parr Instrument Company
Ensure that any hot surfaces have had adequate time to cool before cleaning or maintaining the reactor and/or its components.
4838 Reactor Controller
General Specifi cations
Electrical Ratings
115VAC, 15.0 Amps, 50/60 Hz
230VAC, 15.0 Amps, 50/60 Hz
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 specifi ed, all 4838
Controllers operate with a Type-J (Iron-Constantan)
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 not function properly.
Environmental Conditions
This instrument is intended to be used indoors.
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 ºC and 65 ºC; 10% to 85% relative hu-
midity.
4838 Reactor Controller Specifi cations
General Specifi cations
Input Thermocouple type Type-J
Operating Range 0-800 °C
Readout and Setpoint
Resolution
System Accuracy +/- 2 °C
Control action three-term PID plus limit
Control output 1 115VAC or 230VAC
Operating voltages 115VAC or 230VAC
1 °C
control
Heater Loop
Proportional Band: 12 °C
Integral time: 375 seconds
Derivative: 93 °C/second
Cycle time: 20 seconds
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4838 Reactor Controller
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 fi nal 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 the choice between over or
under-designed 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 specifi ed 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.
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. 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.
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Parr Instrument Company
Installation
General Instructions
Set the controller on a sturdy bench or table where
there is convenient access to an electrical outlet
with the appropriate supply voltage and current ratings in accordance with national and local electrical
code requirements. Leave a space of at least twelve
inches between the controller and the heater of the
reactor so that the controller will not be affected by
radiant heat.
Connections
4838 Reactor Controller
Labeled connections are provided on the rear panel
of the controller.
Parr Heating Only
The heating output connector is to be used only
with Parr Instrument Company heater assemblies
supplied with the appropriate heater power cord.
The Primary Temp Input connection is for the Pri-
mary Temperature Module sensor input.
The Temperature Input connection is for the Tem-
perature Module or ETLM sensor input.
The Pressure Input connection is for the Pressure
Module sensor input.
The Comm connector is for Communication output.
4838 Rear Panel 115V
4838 Rear Panel 230V
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4838 Reactor Controller
Component Summary
Switches and Indicators
Front side
4838 Reactor Controller
The Heater Switch is a manual, three-position, illu-
minated switch which controls the amount of power
sent to the heater. In the HIGH (II) position, full
power is developed by the heater. In the middle (0)
position the heater is off. In the LOW (I) position, a
diode is switched into the system to allow only onehalf of the rated voltage to be supplied to the heater.
This low setting will be most useful when operating
the reactor at temperatures below 175 °C. Power
for the heater is supplied through a solid state relay
controlled by the temperature control module. The
light in the heater switch will glow only when current is fl owing to the heater.
The high limit indicator light will glow if the controller receives an indication from any of its sensors
that a high temperature or high pressure limit has
been reached and the High Limit Reset has opened.
When the light comes on, the user must fi nd the
source of the problem, correct it, and then manually
reset the system using the high limit reset button on
the front of the controller.
The Main Power Switch will cut off power to the
controller. Take care to position the controller such
that the main power switch may be accessed easily
when the controller needs to be disconnected.
Back side
4838 Reactor Controller 115V
Protective Fuses and Relays
An instrument fuse is mounted on the back panel.
This is a Fast-acting, 250VAC, 1.0 amp fuse, intended
to protect the temperature control module and any
installed display modules.
A load fuse is mounted on the back panel on 115V
systems. This fast-acting, 250VAC, 20 amp fuse is intended to protect the controller and prevent electric
shock hazard from fault from occurring.
Two load fuses are mounted on the back panel
on 230V systems. These are fast-acting, 20 Amp,
250VAC and are intended to protect the controller
and to prevent electric shock hazard from fault from
occurring.
Caution!
Unplug unit before servicing. For continued
protection against possible hazard, replace
fuses with same type and rating of fuse.
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Parr Instrument Company
Back side
4838 Reactor Controller 230V
4838 Reactor Controller
On Model 4838 Controllers the high temperature
limit is preset at the factory to 375 °C for most systems. On these controllers an alarm condition is
indicated by an illuminated red indicator labeled as
"ALM". If the temperature exceeds the limit, the controller alarm condition will appear, the High Limit
Reset will be tripped, and power to the heater will
be shut off.
Access to the Controller Cabinet
To open the controller cabinet, unplug the power
cord and remove the two screws in the upper
corners of the back panel. Then lift the top plate
upwards, allowing the hinged top and front panel to
swing forward, providing full access to all internal
components.
Thermocouple burnout protection is included in
each of these controllers. If the thermocouple
should burn out, or if there is a break in the thermocouple circuit, power to the heater will be shut off.
In most cases this will cause the controller to show
a “NO CONN” reading. A similar high reading will
be displayed if the controller is turned on without an
attached thermocouple. In either of these situations,
the high limit reset will activate. The thermocouple
break must then be corrected and the High Limit Reset must be reset in order to activate the system.
High Limit Reset
Each Series 4838 Controller has a high temperature
limit control which will trip the High Limit Relay
and shut off the heater if the temperature reaches
a preset level. If tripped, the lockout relay will pop
out, thereby preventing the system from reheating
the reaction when the temperature falls back below
the limit setting. This must be manually reset before
heating can occur again.
Caution!
Inside of controller cabinet should be accessed by qualifi ed personnel only.
Fuses
The 4838 Controller has a number of fuses which
are intended to be fi eld serviceable.
Fuse Rating Part number
Instrument
Fuse
Line Fuse(s) Fast acting, 20
Fast acting, 1
Amp, 250VAC
Amp, 250VAC
Caution!
Unplug unit before servicing. For continued
protection against possible hazard, replace
fuses with same type and rating of fuse.
139E6
2074E
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