Page 1
4838
Reactor Controller
Operating Instruction Manual
551M
Page 2
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
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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.
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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
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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
Page 9
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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4838 Reactor Controller
Instructions for the 4838 Reactor Controller
Caution!
Check that controller settings are set to
factory defaults before operating for the fi rst
time. The default settings are listed at the
back of this manual.
Note: Controller parameters can be found in
Appendix A on page 21 of this manual.
Temperature Control Module
Temperature Control
The easiest way to control temperature with the
4838 Controller is to use setpoint control. With setpoint control, the controller will attempt to bring the
temperature to the value of the setpoint by adjusting the heater output.
The setpoint may be adjusted by doing the following:
1. Press the up or down arrow until the lower
display shows the desired setpoint. The lower
display will blink, showing the value has not
been set yet.
2. Press the set button. The lower display will stop
blinking, showing the new value has been set.
High Temperature Alarm Setpoint
The 4838 Reactor Controller also has a High Temperature Alarm built into it. When the temperature
exceeds this limit, it will pop the High Limit Reset,
preventing power from going to the heater. The
High Temperature Alarm setpoint may be adjusted
by doing the following:
PRIMARY
TEMPERATURE
The 4838 Reactor Controllers have a microprocessor
based control module that provides full three-term
PID control with adjustable tuning parameters. The
temperature control interface is labeled as Primary
Temperature on front panel.
To facilitate start up with reasonably good PID control, parameters for both heating and cooling are
pre programmed at the factory.
Output 1 on these controllers drives the heater. Output 2 is not used on the 4838 Controller. The control
parameter can be set independently for this output.
Two lines of information, labeled PV and SV, are
shown on the display during normal operations.
The upper line (PV) shows the actual temperature
as read by the control thermocouple. The lower
line (SV) shows the set point. When the controller
is heating, the Out1 light will illuminate or blink.
When an alarm condition has been reached, the
ALM light will illuminate and trip the High Limit
Reset, cutting power to the heater.
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Parr Instrument Company
1. Press the circular arrow key three times. The upper display will read AL1H and the lower display
will read the High Temperature Alarm setpoint
(usually 375 °C).
2. Use the up or down arrow to adjust this to the
desired setpoint.
3. Press the up or down arrow until the lower
display shows the desired setpoint. The lower
display will blink, showing the value has not
been set yet.
4. Press the set button. The lower display will stop
blinking, showing the new value has been set.
5. Pressing the set button again will return the display to the main screen.
PID groups
a. The primary temperature controller contains
4 groups of PID parameters (PID0, PID1, PID2
and PID3), which can be used to store up to four
different sets of PID parameters. Each group is
identifi ed by the SV used during the autotuning
cycle.
b. The parameter displayed is the group in use
with exception of PID4. When PID4 is set, the PID
parameters will automatically switch between
PID groups 0, 1, 2 and PID group 3, depending
on which group’s SV best matches the current
temperature (PV).
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4838 Reactor Controller
c. All of PID parameters in the group can be ob-
tained from auto-tuning or they can be set
manually. When manually entering PID values
into a particular group, the SV for that group can
be manually entered as well.
Autotuning
1. Fill the vessel with an amount of liquid which
well represents the intended process.
Caution!
Refer to Manual 230M for safety information
on the heating of liquids in Parr Reactors
and Pressure Vessels.
2. If you wish to autotune at different temperatures
using the four available PID groups proceed with
step 3, otherwise skip to step 4.
3. Press the set key once followed by the return key
(circular arrow) twice. [
PID0
] will be displayed
on the screen in the top display. Use the up and
down arrow keys to change between PID groups
0, 1, 2 and 3. Press the set key to solidify the
change. Press the set key again to return to the
main screen.
4. Heat the system to the desired temperature using set point control on the primary temperature
controller. Let the temperature come to steady
state which will typically occur 15 to 30 minutes
after reaching the desired set point depending
on the size of the reactor.
5. On the main screen of the controller, press the
set key. The screen will show [
display and [
OFF
] on the bottom display. Press
AT
] on the top
the up arrow to change the lower display to
[ON]. The display will blink, press set to solidify
the change. Press set again to return to the main
screen.
6. As the Autotune starts, the LED indicator under
AT will blink, and Out 1 will fully engage attempting to heat the reactor 100% power. This
will continue for a while, and the controller
will go through a few cycles where it turns the
power on at 100% and turns it off to see how the
temperature responds.
7. A typical Autotune time is half an hour for liquid
water systems, but it may take longer depending
on the process. When the process is complete,
the AT light will stop fl ashing, and the temperature will settle on the set point.
Temperature Profi les - Ramp and Soak
The 4838 Controller has a programming feature
which allows more fl exibility when compared to set
point control. Rather than controlling temperature
to a single set point, a ramp and soak program may
be entered to control various soak times, ramp rates
and set points. Within the programming mode there
are eight patterns available with each pattern having up to eight steps which can be programmed.
Patterns can be set to repeat and they can be linked
to other patterns (or the same pattern which allows
for infi nite program cycles). This allows for up to 64
unique steps and thousands of possible program
confi gurations.
To input a ramp and soak:
1. First set the controller’s Run/Stop [
rameter to Stop [
STOP
]. This will prevent the
R-S
] pa-
program from automatically starting after the
program has been entered. You can do this by
pressing the return key once and use the arrow
keys to change the setting to “stop” and press
the set key to solidify the change.
2. To enable the ramp and soak control mode, hold
the set key for approximately three seconds. The
upper display will change to indicate the Input
INPT
[
] parameter, and the lower display will
indicate the temperature sensor type.
3. Press the return key until the upper display
indicates the control mode parameter [
CRTL
]
and the lower display indicates the control
method (default is PID [
to change this value to the program [
PID
]). Use the arrows
PROG
]
setting. The display will blink, and pressing the
set key will solidify the change.
4. Press the return key once. The upper display will
indicate the pattern [
PATN
] parameter and the
lower display will show the pattern number. The
pattern parameter defi nes which pattern parameters are being viewed in steps 5 - 10. Setting the
pattern parameter to off [
OFF
] allows you to
skip the proceeding ramp/soak parameters. Use
the arrow keys to change the pattern number
and press the set key to solidify the change.
5. Press the return key once. The upper display will
SP00
read [
], where the “00” represents the
pattern and step number, respectively. The lower
display will indicate the set point for indicated
step. The set point can be adjusted using the
arrow keys then press the set key to solidify the
change.
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4838 Reactor Controller
Note: The fi rst SP_O used must be a higher
temperature than the current temperature
(PV) or the program will not execute properly.
6. Press the return key once. The upper display will
TI00
read [
], where the “00” represents the
pattern number and the step number, respectively. The lower display will show the time to
execute the current set point in “hh:mm” format.
The time setting can be changed by using the
arrow keys then press the set key to solidify the
change.
7. Repeat steps 4 and 5 for “SP01” through “SP07”
and “tI01” through “tI07” as required. Once you
have entered all the steps you want, you can
leave the remaining “SP” and “tI” variables at
zero and press the return key to advance.
8. Press the return key to display [
PSY0
] on the
upper display, where “0” represents the current
pattern number. This parameter determines the
last step to execute in the pattern. For example,
if PSy0 has a value of 3, Steps SP00 through
SP03 will execute. Use the arrow keys to change
the setting and press the set key to solidify the
change.
9. Press the return key to display [
CYC0
], where
“0” represents the pattern number. This parameter defi nes how many times you want the
indicated pattern to repeat. If you would like the
pattern to only execute once, set this value to
zero. Use the arrow keys to change the setting
and press the set key to solidify the change.
10. Press the return key to display [
LIN0
], where
“0” represents the pattern number. This parameter allows you to link the indicated pattern another. If you would like more than seven
separate steps in the process, set this to the next
pattern number you wish to link to. Use the arrow keys to change the setting and press the set
key to solidify the change.
11. Press set to return to the main screen. Note
that the lower display of the main screen has
changed to show the program step.
Note: The program will attempt to hold the
temperature at the set point determined by
the last step executed. So, if you wish for the
reactor cool to room temperature once the
program has fi nished, the last executed step
must have a set point consistent with room
temperature and the time for the last step
can be set to 00:00.
Engaging a Program
1. From the main screen, press the return key two
times to display [
PTRN
] on the upper display.
The lower display will indicate the pattern at
which you wish to execute.
2. Press the return key until the run/stop parameter
R-S
[
] is on the upper display. The lower display
will indicate the setting of the run/stop parameter. Change this value to [
RUN
] in order to start
the program determined in step 1. Press set to
return to the main screen.
If you wish to stop the program completely, you
may change this value to [
STOP
]. Changing
the run/stop mode back to stop will restart the
program from the beginning.
If you wish to stop the program and continue
controlling the temperature at the current set
point, you may change this value to program
PSTP
stop [
]. Changing back to run mode from
a program stop will restart the program from the
beginning.
If you wish to hold the program at the current
temperature, you may change this to program
PHOD
hold [
]. Changing back to run mode from
a program hold will continue the program from
its current step.
3. The main screen will now show the current set
point on the lower display. Pressing the arrows
will allow you to change between: [
display the current pattern and step, [
P-ST
R-TC
] to
] to
display the remaining time in the current pattern step, or [SP] to display the set point for the
current pattern step. Press set will solidify this
display change.
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4838 Reactor Controller
Appendix: sample programs
A sample program to ramp from 25 °C to 250 °C in
2-hrs:
Variable Value Meaning
ptrn 00 Pattern 0
SP00 25 Setpoint of 25 ºC (first step is a
soak by default)
tI00 00:01 Hold for 1-min
SP01 250 Setpoint of 250 °C
tI01 02:00 Ramp to setpoint in 2 hrs
SP02 250 Setpoint of 250 °C
tI02 00:40 Ramp to setpoint in 40-min*
SP03 25 Setpoint of 250 °C
tI03 00:00 Ramp to setpoint immediately**
SP04 25 Setpoint of 25 °C
tI04 00:00
SP05 25 Setpoint of 25 °C
tI05 00:00
SP06 25 Setpoint of 25 °C
tI06 00:00
SP07 25 Setpoint of 25 °C
tI07 00:00
PSy0 3 Execute steps 0-3 only***
CyC0 0 Do not re-cycle program
Lin0 off Do not execute another program
upon completion
* The beginning and fi nal setpoint are equal, making
this a soak step.
** The time is zero, making this a step function instead of a ramp.
*** Steps 4-7 are not executed here.
**** The SP_0 vaue must be higher than the initial
temperature (PV) of the reactor or the program will
not initiate correctly.
A sample program to heat to 200 °C as fast a possible, hold for 2-hrs, and come back down as quickly
as possible:
Variable Value Meaning
ptrn 00 Pattern 0
SP00 200 Setpoint of 200 °C (first step is
a soak by default)
tI00 00:00 Move setpoint to 200 °C im-
mediately
SP01 200 Setpoint of 200 °C
tI01 01:00 Ramp from 200°C to 200 °C
over 1-hrs *
SP02 200 Setpoint of 200 °C
tI02 02:00 Ramp from 200C to 200 °C over
2-hrs **
SP03 25 Setpoint of 25 °C
tI03 00:00 Ramp to setpoint immediate-
ly***
SP04 25 Setpoint of 25 °C
tI04 00:00
SP05 25 Setpoint of 25 °C
tI05 00:00
SP06 25 Setpoint of 25 °C
tI06 00:00
SP07 25 Setpoint of 25 °C
tI07 00:00
PSy0 3 Execute steps 0-3 only****
CyC0 0 Do not re-cycle program
Lin0 off Do not execute another pro-
gram upon completion of this
program
* The physical system will take some time to go from
room temp to 200 °C. Step 01 is presented as a “heat
up” step. The time value in this step should be adjusted after the fi rst run is complete and the operator
knows the expected heat up time.
** It is useful to keep this step 02 separate from step
01 so you can adjust step 01 to match the heat up
time.
*** The time is zero, making this a step function instead of a ramp.
**** Steps 4-7 are not executed here.
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4838 Reactor Controller
Pressure Display Module (PDM)
PRESSURE
When this optional module is present, the left display in red shows the pressure, and the right hand
display in green shows the Pressure Alarm setpoint.
If the reactor pressure exceeds this setpoint, the
pressure module will trip the High Limit Alarm, cutting power to the heater.
This module provides a digital read out for continuously monitoring the pressure within the reactor,
plus a backup safety feature which will terminate
power to the heater if a preset maximum is reached.
Pressure is displayed with a 1 psi resolution and a
1% FS accuracy. The safety cut-out feature offers
excellent protection against accidental over-pressure
by allowing the user to set a maximum pressure
which, if reached, will activate the high limit relay
and turn off the heater immediately.
The Pressure Alarm setpoint may be adjusted by doing the following:
1. Press the up or down arrow until the lower
display shows the desired setpoint. The lower
display will blink, showing the value has not
been set yet.
2. Press the set button. The lower display will stop
blinking, showing the new value has been set.
When ordering a pressure display module separately or installed in any Parr controller, always
specify the reactor on which the transducer will be
installed so that the proper mounting hardware can
be furnished.
Note: if the pressure transducer is not attached
to the 4838 Controller, the High Limit Reset
may trip or show a fi xed but incorrect value.
We recommend always operating with the
transducer attached.
High-Temp Cut-Off Module (HTM)
The signal for the pressure display is generated by
a transducer in a stainless steel housing mounted
on the reactor. The transducer must not be heated
above 120 °C; an elevated temperature can caused
the accuracy of the transducer to suffer. A water
cooling sleeve attached to the transducer mounting
body can be used to keep the transducer below this
limit when operating the reactor at higher temperatures.
For applications involving reactants corrosive to
stainless steel, the transducer body can be replaced
with an isolator of special alloys which will keep the
reactants away from the transducer. Users should
consult with the Parr Technical Support before purchasing one of these.
TEMPERATURE
This module provides a redundant high temperature safety cut-off which will shut down the reactor
heater if an unusual malfunction should develop in
the primary control system. It is a completely independent safety backup system, operating in addition
to the high-limit control built into each Parr temperature controller. It has its own thermocouple, digital
display and wiring, and can be preset to shut down
the heater at any desired temperature.
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4838 Reactor Controller
If the secondary temperature (PV) exceeds the alarm
setpoint (SV), the alarm indicator on this display will
illuminate and the High Limit breaker will trip, interrupting power to the heater.
The High Temp Cut-Off Alarm setpoint may be adjusted by doing the following:
1. Press the up or down arrow until the lower
display shows the desired setpoint. The lower
display will blink, showing the value has not
been set yet.
2. Press the set button. The lower display will stop
blinking, showing the new value has been set.
This secondary temperature module does not control the heater. It is used as an alarm only.
When ordering this option separately or installed in
the 4838 Parr Controller, always specify the reactor
with which it will be used so that a thermocouple of
the proper style and length can be furnished.
External Heater Temperature Limit Control
Module (ETLM)
setpoint. This non-latching setpoint will establish a
maximum wall temperature, and combined with the
main temperature control module will help suppress
overshoot in diffi cult to control processes.
As an added safety feature, there is also a secondary alarm which will trip the High Limit Reset when
breached. This secondary alarm provides a redundant high temperature safety cut-off which will shut
down the reactor heater if an unusual malfunction
should develop in the primary control system. It is
a completely independent safety backup system,
operating in addition to the high limit control built
into each Parr temperature controller. It has its own
thermocouple, digital display and wiring, and can be
preset to shut down the heater at any desired temperature.
To set the primary (non-latching) temperature limit,
press the up or down arrow on the display. The setpoint value on the right will fl ash. Press the set button to solidify this display and complete the change.
If the heater temperature exceeds the ETLM setpoint
(non-latching), the output to the heater will be interrupted. This will not trip the High Limit Reset, and
when the heater temperature falls back below the
primary setpoint, it will allow power to fl ow to the
heater again.
TEMPERATURE
ETLM
This module should be considered in systems with
large thermal lags or long dead times such as gas
phase reactions or other systems where temperature control is diffi cult.
This confi guration is similar to the High Temperature Cut Off Module (HTM), but the display will now
turn off the heater if it exceeds a pre-set adjustable
To set the secondary (latching) temperature limit,
press the circular arrow key three times. The lefthand display will read ALIH and the right-hand
display will read the secondary temperature limit
setpoint (usually 375 °C). Press the up or down arrow on the display. The setpoint value on the right
will fl ash. Press the set button to solidify this display and complete the change.
When ordering this option separately or installed in
the 4838 Parr Controller, always specify the reactor
with which it will be used so that a thermocouple of
the proper style and length can be furnished.
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4838 Reactor Controller
Communication with PC
The 4838 Controller is provided with RS-485 port
(labeled comm) and may be connected to a USB
port on a PC with optional A1925E4 communication
cable.
Quick Start Instructions for Connecting with PC
1. Put the 552M CD into the CD-ROM.
2. Connect the A1925E4 communication cable
between the comm port on the back of the 4838
Controller and an open USB slot on the PC.
3. The PC should open an "Install Hardware" wizard
automatically when the cable is connected to the
USB slot. If it does not, go to the Control Panel
and select "Add Hardware" to start the wizard.
4. When prompted, check the box to search removable media for the proper driver. The wizard should fi nd the driver on the 552M CD and
install the USB driver. It may prompt that the
driver has not been validated; select "continue
anyway" to continue the installation. After this
it may repeat the installation process for the RS485 converter.
5. Copy the controller software to the PC. The software is located on the CD at: "software\ParrCom.
exe”.
6. Once copied to the PC, open the ParrCom.exe
fi le. No installation is necessary.
7. At the main ParrCom program screen, select
"protocol >> set PC". Ensure that the following
values are set:
Baud: 9600
Data length: 8
Parity: even
Stop bit: 1
ASCII: RTU
Click OK to return to the main screen.
8. At the main screen, select "Program >> Monitor".
The Monitor screen will come up. There will be
a generic icon on the left, and four mini screens
on the right. Each mini screen can be used to
connect to a different module on the 4838 Controller.
9. In the fi rst mini screen, select 1 for the Address,
and click Connect. It should connect to the
Primary Temperature module on the 4838 Controller, and the bottom half of the screen should
show parameters for the controller. These may
be modifi ed here. Of most interest will be the
"Input >> SV" value, which is the setpoint for
temperature. Also, the "Alarm >> Alarm 3" value
will show the High Limit alarm for this module.
10. Any other modules on the 4838 Controller may
be accessed through the remaining available
mini screens. A pressure display module will
typically be address 3 and an HTM/ETLM will be
adress 4.
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4838 Reactor Controller
Datalogging and Charting
The 4838 Controller comes equipped with a charting
and datalogging program. This program cannot be
run simultaneously with the control program, but
once the user is satisfi ed that the controller is set,
the control program may be closed, allowing the
charting and datalogging program to run. The modules on the 4838 may still be modifi ed manually at
the physical panel during datalogging and charting.
1. Open the ParrCom.exe fi le. No installation is
necessary.
2. At the main program screen, select "protocol >>
set PC" (if you have already done previously, you
may skip this step). Ensure that the following
values are set:
Baud: 9600
Data length: 8
Parity: even
Stop bit: 1
ASCII: RTU
Click OK to return to the main screen.
3. At the main screen, select "Program >> Recorder". The Recorder screen will come up.
4. Select the proper address for the Devices you
wish to chart. The primary temperature has address 1. A pressure display module will typically
use address 3 and an HTM/ETLM will use address 4.
7. The chart will show the process values of each
module represented. As the values change, the
chart will automatically scale to show the values.
8. When you wish to stop recording, click the stop
button. The chart has already been
saved in the REC fi le created in step 5.
You may view the chart by clicking the
recorder button.
9. You can convert the fi le to a TXT fi le for export to
a spreadsheet as well.
Converting a Chart File to TXT
Once a chart REC fi le has been created, you can convert it to a TXT fi le for export into a spreadsheet.
1. Insert the 552M CD into the CD-ROM. Locate the
conversion fi le at “ \software\convert.exe”. Copy
it to the PC.
2. Open the convert.exe fi le. No installation is
necessary.
3. Click the "CONVERT" button. Locate the REC fi le
to be converted, and click "Open".
4. The conversion program will create a new TXT
fi le in the same location as the REC fi le with the
name "CONVFILE.TXT".
5. Click the Save button and save a REC
fi le to an appropriate place on the PC.
When the chart is generated, it will
write to this fi le.
6. When you return to the main Recorder screen, notice that the Save button
is depressed. Hit the Start button to
begin recording.
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4838 Reactor Controller
4838 Factory Defaults
Navigating the Menu System / Factory Default Settings
There are three broad categories of functions in the
4838 Controller modules. They are Regulation, Operation, and Initial Settings. From the main screen,
Regulation mode is accessed by pressing the set
button. The Initial Setting mode is accessed by
holding the set button for three seconds. Operation
mode is accessed by pressing the circular arrow.
In each mode, you can cycle through the variables
by pressing the circular arrow. To change a value,
use the up or down arrow, which causes the value
to fl ash. Then press the set button to solidify the
choice. Return to the main screen by pressing set
again.
Keys command:
1. Press “SET” to select
2. Press return key move to next operation mode
3. Up/Down arrow keys to adjust value or select
type
Primary Temperature Module
Press return key and release
Operation
Mode
r-S Run Run/Stop
SP 0** Decimal point position
AL1H 375 Upper alarm setting
LoC OFF Lock mode (lock all keys
Out1 - (read-only) Heater output %
** If using a type-J or type-K thermocouple, SP = 0
If using an RTD, SP = 1
Select
type/value
Comment
or only up/down arrow
able to use)
Press and hold down “SET” for 5-sec
Operation
Mode
InPt J** Input type
tPUn C Temperature unit
tP-H 800** Upper-limit range
tP-L 0 Lower-limit temperature
CTRL PID Control mode (ON/OFF,
S-HC HEAT Output 1 is Heating
ALA1 6 Alarm operates when PV
ALA2 0 Alarm 2 is disabled
ALA3 0 Alarm 3 is disabled
SALA OFF System alarm
CoSH ON Communication write
C-Sl RTU Format type
C-no 1 Communication address
bPS 9600 Communication baud
Len 8 Data length setting
PrtY Even Parity bit setting
StoP 1 Stop bit setting
Select
type/value
Comment
range
MANUAL, PID and PID
PROG)
value is higher than AL1H
setting or PV value is
lower than AL1L setting
function that able to use
set point from software
rate
** If using a type-J thermocouple, InPt = J, tP-H = 800
If using a type-K thermocouple, InPt = K, tP-H = 800
If using an RTD, InPt = Pt, tP-H = 600
Press “SET” and release
Operation
Mode
At OFF Auto Tuning ON/OFF
PID0 0 The 0th PID Parameter
SV 0 The 0th SV
P0 11. 8 Proportional control
I0 375 Integral control
D0 93 Derivative control
IoF0 0 Integral value offset
HtPd 5 Heat cycle control
CoEF 1 1 & 2 value output group
tPoF 0 Inaccuracy adjustment
Select
type/value
Comment
during dual loop output
control
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4838 Reactor Controller
Pressure Module
Press return key and release
Operation
Mode
r-S Run Run/Stop
SP To be deter-
AL1H 0 Upper-limit alarm 1
LoC OFF Lock mode (lock all keys or
Select
type/value
mined**
Comment
Decimal point position
only up/down arrow able
to use)
** If units are psi, SP = 0
If units are Bar, SP = 1
If units are MPa, SP = 2
Press and hold down “SET” for 5-sec
Operation
Mode
InPt V5 Input type (V5 = 0-5V, V10
tP-H Determined
tP-L 0 Lower-limit pressure range
CTRL ON/OFF Control mode (ON/OFF,
S-HC Heat Heat/Cool control
ALA1 2 Alarm operates when PV
SALA OFF System alarm
CoSH ON Communication write
C-Sl RTU Format type
C-no 3 Communication address
bPS 9600 Communication baud rate
Len 8 Data length setting
PrtY Even Parity bit setting
StoP 1 Stop bit setting
Select
type/value
by transducer**
Comment
= 0-10V, nA0 = 0-20mA,
nA4 = 4-20mA, nV =050mV)
Upper-limit pressure range
MANUAL, PID and PIDPROG)
value is higher than SV
Value + ALH setting
function that able to use
set point from software
** Set according to the following:
Transducer
range - psi
200 200 13.79 1.38
300 300 20.68 2.07
500 500 34.47 3.45
1000 1000 68.95 6.89
2000 2000 137.9 13.79
3000 3000 206.8 20.68
5000 5000 344.7 34.47
7500 7500 517.1 51.71
tP-H for
psi
tP-H for
Bar
tP-H for
MPa
Press “SET” and release
Operation
Mode
HtS 0 Heating hysteresis setting
tPoF 0 Temperature correction
Select
type/value
Comment
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4838 Reactor Controller
HTM / ETLM Module
Press return key and release
Operation
Mode
r-S Run Run/Stop
SP 0** Decimal point position
AL1H 375*** Upper-limit alarm 1
LoC OFF Lock mode (lock all keys or
Out1 - (read-only) Heater Output %
Select
type/value
Comment
only up/down arrow able
to use)
** If using a type-J or type-K thermocouple, SP = 0
If using an RTD, SP = 1
*** If using an HTM, AL1H = 0
If using an ETLM, AL1H = 375
Press and hold down “SET” for 5-sec
Operation
Mode
InPt J** Input type
tPUn C Temperature unit
tP-H 800** Upper-limit temperature
tP-L 0 Lower-limit temperature
CTRL ON/OFF Control mode (ON/OFF,
S-HC Heat Heat/Cool control
ALA1 6*** Alarm operates when PV
SALA OFF System alarm
CoSH ON Communication write
C-Sl RTU Format type
C-no 4 Communication address
bPS 9600 Communication baud rate
LEn 8 Data length setting
PrtY Even Parity bit setting
StoP 1 Stop bit setting
Select
type/value
Comment
range
range
MANUAL, PID and PID
PROG)
value is higher than AL1H
value
function that able to use
set point from software
** If using a type-J thermocouple, InPt = J, tP-H = 800
If using a type-K thermocouple, InPt = K, tP-H = 800
If using an RTD, InPt = Pt, tP-H = 600
*** If using an HTM, ALA1 = 2
If using an ETLM, ALA1 = 6
Press “SET” and release
Operation
Mode
HtS 0 Heating hysteresis setting
tPoF 0 Inaccuracy adjustment
Select
type/value
Comment
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Appendix A: Controller Parameters
Initial Setting Mode
Press to advance
Set input type
Set temperature unit
(Does not display when analog input)
Set upper-limit of temperature range
Set lower-limit of temperature range
Select control mode
Select heating/cooling control or dual loop output control
Alarm 1 mode setting
Alarm 2 mode setting
(Only available on Primary Temperature Controller)
Alarm 3 mode setting
(Only available on Primary Temperature Controller)
4838 Reactor Controller
Set system alarm
Communication write function enable/disable
ASCII, RTU communication format selection
Communication address setting
Communication baud rate setting
Data length setting
Parity bit setting
Stop bit setting
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4838 Reactor Controller
Operation Mode
Press to advance
Use key to set temperature set point
Control setting RUN or STOP
Start pattern setting
(PID program control and
Decimal point position selection
(except for B, S, R type inputs, all the other types can be set)
Upper-limit alarm 1
(This parameter is available only when ALA1 function is enabled)
Lower-limit alarm 1
(This parameter is available only when ALA1 function is enabled)
Upper-limit alarm 2
(This parameter is available only when ALA2 function is enabled)
Lower-limit alarm 2
(This parameter is available only when ALA2 function is enabled)
Upper-limit alarm 3
(This parameter is available only when ALA3 function is enabled)
Lower-limit alarm 3
(This parameter is available only when ALA3 function is enabled)
Time setting)
Setting lock mode
Display output value of 1st output group
Display output value of 2nd output group
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Regulation Mode
Press to advance
Auto-tuning
(Available in PID control and RUN mode)
4 groups PID modes (n=0~3). When n=4, PID control is auto regulated.
PD control offset setting
(Available when PID control is ON and Ti=0, set the value of PdoF)
Heating hystereisis setting
(Available in ON/OFF control mode)
Cooling hystereisis setting
(Available in ON/OFF control mode)
or
Heating and Cooling control cycle
(Available in PID control mode)
4838 Reactor Controller
Control cycle setting of 2nd output group
(Available in PID control and Dual Loop output control mode)
P value of 1st & 2nd output group during dual loop output control
P value of 2nd output group = (P value of 1st output group) x
Dead Band (Available in Dual Loop output control mode)
Regulate temperature deviation value
Regulate upper-limit of analog output value
(Display when equipped with an analog output)
Regulate lower-limit of analog output value
(Display when equipped with an analog output)
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4838 Reactor Controller
Parts List
Fuse Rating Part Number
Instrument Fuse Fast acting, 1 Amp, 250VAC 139E6
Line Fuse(s) Fast acting, 20 Amp, 250VAC 2074E
Warning:
For continued protection against possible hazard, replace fuses with same type and rating of fuse.
Part number Description
A470E2 Thermocouple extension wire, type-J, 5-ft
A470E4 Thermocouple extension wire, type-J, 10-ft
A470E7 Thermocouple extension wire, type-J, 15-ft
A470E5 Thermocouple extension wire, type-J, 20-ft
A470E8 Thermocouple extension wire, type-J, 25-ft
A470E6 Thermocouple extension wire, type-J, 30-ft
A470E9 Thermocouple extension wire, type-J, 35-ft
A470E10 Thermocouple extension wire, type-J, 40-ft
Fuses
Primary Temperature Module
A472E4 Thermocouple, type-J, 5-1/2" length
A472E2 Thermocouple, type-J, 9-1/2" length
A472E3 Thermocouple, type-J, 11-1/2" length
A472E Thermocouple, type-J, 7-1/2" length
A472E5 Thermocouple, type-J, 21-1/2" length
A472E6 Thermocouple, type-J, 15-1/2" length
A490E4 Dual T/C, type-J, 5-1/2” length
A490E Dual T/C, type-J, 7-1/2" length
A490E2 Dual T/C, type-J, 9-1/2" length
A490E3 Dual T/C, type-J, 11-1/2" length
A490E6 Dual T/C, type-J, 15-1/2" length
A490E2 Dual T/C, type-J, 21-1/2” length
A511E2 Heater thermocouple, type-J, bayonet style
A511E4 Heater thermocouple, dual, type-J, bayonet style
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Pressure Display Module (PDM)
Part number Description
A1905E5 Pressure harness, 5-ft, covered
A1905E Pressure harness, 10-ft, covered
A1905E8 Pressure harness, 15-ft, covered
A1905E3 Pressure harness, 20-ft, covered
A1905E9 Pressure harness, 25-ft, covered
A1905E7 Pressure harness, 30-ft, covered
A1905E10 Pressure harness, 35-ft, covered
A1905E11 Pressure harness, 40-ft, covered
A1906EP02 Transducer, 200 psi
A1906EP05 Transducer, 500 psi
A1906EP10 Transducer, 1000 psi
A1906EP20 Transducer, 2000 psi
A1906EP30 Transducer, 3000 psi
A1906EP50 Transducer, 5000 psi
A2599HC2 Transducer cooling body assembly
A2685HC Cooling sleeve assembly
2683HC Cooling sleeve for A2599HC2
827HC O-rings for cooling sleeve
2714HC Hose nipple
4838 Reactor Controller
Note: Additional Pressure Ranges are available upon request.
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4838 Reactor Controller
Part number Description
A470E2 Thermocouple extension wire, 5-ft
A470E4 Thermocouple extension wire, 10-ft
A470E7 Thermocouple extension wire, 15-ft
A470E5 Thermocouple extension wire, 20-ft
A470E8 Thermocouple extension wire, 25-ft
A470E6 Thermocouple extension wire, 30-ft
A470E9 Thermocouple extension wire, 35-ft
A470E10 Thermocouple extension wire, 40-ft
A472E Thermocouple, type-J, 7-1/2" length
A472E2 Thermocouple, type-J, 9-1/2" length
A472E3 Thermocouple, type-J, 11-1/2" length
A472E4 Thermocouple, type-J, 5-1/2" length
A472E5 Thermocouple, type-J, 21-1/2" length
A472E6 Thermocouple, type-J, 15-1/2" length
Hi-Temp Cut-Off Module (HTM)
or External Temperature Limit Module (ETLM)
A490E Dual T/C, type-J, 7-1/2" length
A490E2 Dual T/C, type-J, 9-1/2" length
A490E3 Dual T/C, type-J, 11-1/2" length
A490E4 Dual T/C, type-J, 5-1/2" length
A490E5 Dual T/C, type-J, 21-1/2" length
A490E6 Dual T/C, type-J, 15-1/2" length
A511E2 Heater thermocouple, type-J, bayonet style
A511E4 Heater thermocouple, dual, type-J, bayonet style
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Notes
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Revision 05/20/13
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