Parr Instrument 4838 User Manual

4838
Reactor Controller
Operating Instruction Manual
551M
Table of Contents
Table of Contents
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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