Parr Instrument 4848 User Manual
4848
Reactor Controller
Operating Instruction Manual
548M
Table of Contents
Preface
Related Instructions — 2
Scope — 2
Applications — 2
Explanation of Symbols — 3
Safety Information — 3
Intended Usage — 3
Cleaning & Maintenance — 3
Provisions for Lifting and Carrying — 3
General Specifications — 4
Environmental Conditions — 4
4848 Reactor Controller Specifications — 4
User’s Responsibility — 5
Unpack Carefully — 5
Installation
General Instructions — 6
Connections — 6
Component Summary
Switches and Indicators — 7
Protective Fuses and Relays — 8
High Limit Reset— 9
Access to the Controller Cabinet— 9
Fuses— 9
4848 Factory Defaults
Navigating the Menu System/Factory Default Settings
— 20
Primary Temperature Module — 20
TDM / MCM Module — 21
Pressure Module — 21
HTM/ETLM Module — 22
MTM Module — 23
Appendix A: Controller Parameters
Initial Setting Mode — 24
Operation Mode — 25
Regulation Mode — 26
Parts List
Fuses — 27
Communication — 27
Cooling Solenoids — 27
Primary Temperature Module — 28
Pressure Display Module (PDM) — 28
Tachometer Module (TDM) — 29
or Motor Control Module (MCM) — 29
Hi-Temp Cut-Off Module (HTM) — 29
or External Temperature Limit Module (ETLM) — 29
Instructions for the 4848 Reactor
Controller
Temperature Control Module — 10
Temperature Control— 10
High Temperature Alarm Setpoint— 10
PID groups— 10
Autotuning— 11
Temperature Profiles - Ramp and Soak— 11
Engaging a Program— 12
Adjustments To Speed Control Board— 17
Solenoid Valve Module — 17
Communication with PC — 18
Quick Start Instructions for Connecting with PC— 18
Datalogging and Charting— 19
Converting a Chart File to TXT— 19
Visit our website to find our Controller FAQ
http://www.parrinst.com/support/48484838-controller-support/controller-faq/
2
Parr Instrument Company
4848 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
576M 4848 Controller CD
Scope
These instructions cover the installation, operation and maintenance of Parr Model 4848 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 and limitations of this equipment
and the safety precautions to be observed in its
operation.
Applications
Each 4848 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 specifically for use with
Parr reactors and pressure vessels and are to be
used only with Parr equipment.
Controllers furnished with Parr reactors equipped
with variable speed, DC motors have a motor switch
and a speed control knob on the front panel. Controllers to be used with AC equipment or an air motor do not have a speed control knob.
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
www.parrinst.com
3
4848 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 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:
5. 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.
6. Refer servicing to qualified personnel.
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.
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 4848 Controller.
There are no user serviceable parts inside the product other than what is specifically called out and
discussed in this manual. Advanced troubleshooting
instructions beyond the scope of this manual can
be obtained by calling Parr Instrument Company in
order to determine which part(s) may be replaced or
serviced.
Ensure that any hot surfaces have had adequate time to cool before cleaning or maintaining the reactor and/or its components.
Provisions for Lifting and Carrying
Before moving the instrument, disconnect all connections from the rear of the apparatus. Lift the
instrument by grabbing underneath each corner.
Caution!
Do not use in hazardous atmospheres.
If the instrument is used in a manner not specified
by Parr Instrument Company, the protection provided by the equipment may be impaired.
4
Parr Instrument Company
4848 Reactor Controller
General Specifications
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 specified, all 4848
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.
4848 Reactor Controller Specifications
Input Thermocouple
type
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
Control output 2 .2 amp max
Operating voltages 115VAC or 230 VAC
Heater Loop
Proportional Band: 12 C
Integral time: 375 sec
Derivative: 93 C/sec
Cycle time: 20 sec
Type-J
1 °C
control
115VAC or 230VAC
Cooling Loop
Proportional Band: 5 C
Cycle time: 5 sec
www.parrinst.com
5
4848 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 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 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 specified for that design.
But in order to preserve the validity of these designs, all temperature and pressure limits must
be observed, and no attempt should be made to
increase these limits by making alterations or by
substituting components which are not recommended by Parr Instrument Company.
2. Install and operate the equipment within a
suitable barricade, if required, with appropriate
safety accessories and in full compliance with
local safety codes and rules.
All standard Parr pressure vessels are provided
with either suitable relief device or a means to
attach one (typically in the form of a plugged
opening). When a pressure vessel is delivered
without a pressure venting device, it is the customer’s responsibility to provide pressure relief
in order to protect the operator and the equipment from destructive high pressures. If you
need more information or need help in selecting
a proper relief device, please contact Parr Instrument Company.
3. Establish training procedures to ensure that any
person handling the equipment knows how to
use it properly.
4. Maintain the equipment in good condition and
establish procedures for periodic testing to be
sure the vessel remains structurally sound.
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.
6
Parr Instrument Company
4848 Reactor Controller
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
Labeled connections are provided on the rear panel
of the controller.
Parr Cooling Only:
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 RPM Input connection is for the RPM Module
sensor input.
The Comm connector is for Communication output.
The Auxiliary 1 and Auxiliary 2 input connections
are for additional connections and may be used on a
number of devices. The 4848 Reactor Controller can
be purchased with Auxiliary 1 and/or 2 configured as
a Temperature Module Input or a Pressure Module
Input.
The cooling output connector is to be used only
with Parr Instrument Company cooling solenoid
valve assemblies supplied with the appropriate
cooling power cord.
Parr Heating Only:
The heating output connector is to be used only
with Parr Instrument Company heater assemblies
supplied with the appropriate heater power cord.
Motor:
Secure the clamp on motor cord to the controller with the provided screw next to the
motor socket for safety purposes.
The motor output connector is to be used only with
Parr Instrument Company motor assemblies supplied with the appropriate motor power cord.
Other appropriate connectors are provided on the
rear panel of the controller.
4848 Rear Panel 115V
The Primary Temp Input connection is for the Pri-
mary Temperature Module sensor input.
4848 Rear Panel 230V
www.parrinst.com
7
4848 Reactor Controller
Component Summary
Switches and Indicators
Front Side
4848 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 flowing 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 find 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 Motor Controls consist of an on-off switch
and a speed control knob. The speed control knob
should be turned down to a minimum setting before
turning on the motor switch to minimize electrical surges within the speed control unit. A speed
control know is not included when the reactor is
equipped with an air motor for stirring or when the
controller is created for use with a non-stirred vessel.
If equipped with a motor control module, there will
also be a remote/local switch. When the remote/
local switch is in local mode, the speed control
knob will adjust the motor stirring speed. When the
remote/local switch is in remote mode, the RPM
module will adjust the motor stirring speed. If there
is no motor control module installed, the remote/local port will be plugged and the speed control knob
is the sole control for the stirring speed.
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.
8
Parr Instrument Company
Back Side
4848 Reactor Controller
4848 Reactor Controller
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.
The motor reset/motor fuse provides overload
protection for 0-90VDC motors. This is a re-settable
breaker designed to protect the motor if it becomes
overloaded. The breaker will have a rating selected
to match the motor on the apparatus.
A lighted fuse holder provides protection for 0-180
VDC motors. A light will come on if the motor becomes overloaded and the fuse burns out. The fuse
rating will be selected to match the motor on the
apparatus.
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 Amps,
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.
www.parrinst.com
9
4848 Reactor Controller
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 CONT” 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 4848 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 heating
the reaction when the temperature falls back below
the limit setting. This must be manually reset before
heating can occur again.
On Model 4848 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.
Caution!
Inside of controller cabinet should be accessed by qualified personnel only.
Fuses
The 4848 Controller has a number of fuses which
are intended to be field serviceable.
Fuse Rating Part No.
Instrument
Fuse
Cooling Fuse Fast acting, .25 Amp,
Line Fuse(s) Fast acting, 20 Amp,
Motor Board
Fuse (A+)
Motor Board
Fuse (L)
Motor fuse/
reset
Fast acting, 1 Amp,
250VAC
250VAC
250VAC
Very Fast acting, 8
Amp, 250VAC
Fast acting, 10 Amp,
250VAC
Check back panel for
specifications
139E6
139E10
2074E
959E5
185E2
Check part
list
10
Caution!
Unplug unit before servicing. For continued
protection against possible hazard, replace
fuses with same type and rating of fuse.
Parr Instrument Company
4848 Reactor Controller
Instructions for the 4848 Reactor
Controller
Caution!
Check that controller settings are set to
factory defaults before operating for the first
time. The default settings are listed at the
back of this manual.
Note: Controller parameters can be found in
Appendix A on page 24 of this manual.
Temperature Control Module
power to the heater, and the ALM light will illuminate indicating a High Limit was activated.
Temperature Control
The easiest way to control temperature with the
4848 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 4848 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 4848 Reactor Controllers are available with 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 can be used to activate a cooling system.
The control parameters can be set independently for
each of these outputs.
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 the controller is cooling, the Out2 light will
illuminate or blink. When an alarm condition has
been reached, the High Limit Reset will trip, cutting
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 375C).
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
identified by the SV used during the autotuning
cycle.
www.parrinst.com
11
4848 Reactor Controller
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).
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
PID0
(circular arrow) twice. [
] 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 [AT] on the top
display and [
OFF
] on the bottom display. Press
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 flashing, and the temperature will settle on the set point.
Temperature Profiles - Ramp and Soak
The 4848 Controller has a programming feature
which allows more flexibility 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 infinite program cycles). This allows for up to 64
unique steps and thousands of possible program
configurations.
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 [
PAT N
] parameter and the
lower display will show the pattern number. The
pattern parameter defines 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
12
Parr Instrument Company
Loading...