Parr Instrument 4857 User Manual
No. 519M
r
Parr Instrument Company
4857
Process Controlle
Operating Instruction Manual
4857 Reactor Controllers
TABLE OF CONTENTS
Related Instructions .............................2
Customer Service.................................2
Preface 3
Scope...................................................3
Applications..........................................3
Explanation of Symbols........................4
Safety Information................................4
Intended Usage....................................4
General Specifications.........................5
Environmental Conditions....................5
User’s Responsibility............................6
Unpack Carefully..................................6
Installation 7
General Instructions.............................7
Connections.........................................7
Switches and Indicators 8
4857 Switches and Indicators..............8
Protective Fuses 8
4857 Fuses ..........................................8
Model 4857 Process Controller
Specifications 9
Temperature Control Parameters.......9
Software Installation 10
Before Software Installation.................10
Minimum PC Requirements.................10
CalGrafix Installation Instructions.........10
Install USB Drivers...............................10
Single Reactor......................................11
Two Reactors.......................................12
Operation of the 4857 Controller 13
Running CalGrafix................................13
Restoring Factory Defaults...................15
Finding the Active COM Port................16
Setting the Active COM Port................16
Changing the Name of a Module .........17
Autotuning............................................18
Module 1: Temperature Control Module
Setpoint Adjustment.............................19
High Temperature Alarm Adjustment...20
Changing PID Settings.........................21
Temperature Programmer....................22
Module 2: Pressure Display and
High Pressure Alarm
Alarm Adjustment.................................25
Module 3: Tachometer
Stirring Speed Adjustment...................26
Module 4: Optional Module
Optional Module...................................27
Data Logging 28
Creating a Chart ..................................28
Exporting Data from a Chart................30
Solenoid Valve Module 30
Cleaning and Maintenance 31
Fuses...................................................31
Access to Controller Cabinet...............31
Controller and Circuit Diagrams 32
Parts for the 4857 Controller 35
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
521M 4857 Process Controller CD
547M 4857 CalGrafix CD
567M 4875 Power Controller Operating
Instructions
Customer Service
Questions concerning the installation or
operation of this instrument can be answered
by the Parr Customer Service Department:
309-762-7716
800-872-7720
Fax: 309-762-9453
www.parrinst.com
parr@parrinst.com
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4857 Reactor Controllers
PREFACE
Scope
These instructions cover the installation and
operation of Parr Model 4857 Process Controller
as used with Parr Laboratory Reactors and
Pressure Vessels. They cover the basic
functions provided in each of these controllers.
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 Series 4857 Process 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 of the power controller. Controllers to
be used with AC equipment or an air motor do
not have a speed control knob.
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Explanation of Symbols
4857 Reactor Controllers
I
O
This CAUTION symbol may be present on the Product Instrumentation
Safety Information
To avoid electrical shock, always:
1. Use a properly grounded electrical outlet of
correct voltage and current handling capacity.
2. Ensure that the equipment is connected to
electrical service according to local national
electrical codes. Failure to properly connect may
create a fire or shock hazard.
3. For continued protection against possible
hazard, replace fuses with same type and rating
of fuse.
4. Disconnect from the power supply before
maintenance or servicing. The power supply
cord of the equipment is the main disconnect
device.
To avoid personal injury:
1. Do not use in the presence of flammable or
combustible materials where fire or explosion
may result. This device contains components
which may ignite such materials.
2. Refer servicing to qualified personnel.
On position
Off position
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.
Intended Usage
This controller has been designed for use with
Parr Pressure Vessels, Reactors and Power
Controllers. 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
specified by Parr Instrument Company, the
protection provided by the equipment may be
impaired.
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4857 Reactor Controllers
General Specifications
Electrical Ratings:
115VAC 50/60 Hz 3.0 Amps
230VAC 50/60 Hz 3.0 Amps
Before connecting to a reactor or heating device,
the user must be sure 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 supply
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
Series 4857 Process 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 to be used indoors and
requires 3 square feet of space below the
controller in a well-ventilated area with
convenient access to an electric outlet.
Operating: 15°C to 30°C; maximum relative
humidity of 80% non-condensing.
Installation Category II
(overvoltage) in accordance with
IEC 664. Pollution degree 2 in
accordance with IEC 664.
Altitude Limit: 2,000 meters.
Storage: -25°C and 65°C; 10% to 85%
relative humidity.
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.
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4857 Reactor Controllers
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 a suitable relief device or a means to
attach one (typically in the form of a plugged
opening). When a pressure vessel is delivered
without a pressure venting device, it is the
customer’s responsibility to provide pressure
relief in order to protect the operator and the
equipment from 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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4857 Reactor Controllers
INSTALLATION
General Instructions
Set the controller near the reactor on a sturdy
bench or table where there is convenient access
to an electrical outlet capable of carrying up to
20 amperes. 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 each controller.
The Control Temp connection is for the internal
reactor thermocouple or RTD harness.
The Auxiliary Temp connection is for a
secondary thermocouple or RTD harness.
The Tachometer connection is for the optical
sensor harness.
The Pressure connection is for the reactor
pressure sensor harness.
The Auxiliary connection is for an optional
input.
The Power Control connection is for connection
to the 4875 Power Controller.
The RS-485 PORT connection is for
communication to PC.
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4857 Reactor Controllers
SWITCHES AND INDICATORS
4857 Switches and Indicators
The Main Switch is a manual, two-position,
illuminated switch which will cut off power to the
controller. The light indicates power the power is
on. Take care to position the controller such that
the main power switch may be accessed easily
when the controller needs to be disconnected.
PROTECTIVE FUSES
4857 Fuses
Two instrument fuses are mounted on the
back panel. These are Fast-acting, 250VAC, 3.0
amp fuses, intended to protect the internal
circuitry of the controller.
4857 Process Controller Front Panel
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4857 Reactor Controllers
MODEL 4857 PROCESS CONTROLLER SPECIFICATIONS
Temperature Control Parameters
To facilitate start up with reasonably
good PID control parameters for heating
and cooling, all 4857 Process
Controllers are programmed at the
factory with the temperature control
settings shown on the right.
Output 1 on these controllers drives the
heater. Output 2 can be used to
activate a cooling system. Control
parameters can be set independently for
each of these outputs.
Module 1: Temperature Control
Cycle time 2 seconds
Proportional Band
Integral Time 5 min
Derivative Time 25 sec
Input thermocouple
Operating range
Display resolution
Setpoint resolution
System accuracy
Control action
Control output 1
Control output 2
Operating voltages
Maximum switching
load
25 °C
Type J
0 to 800 °C
.1 °C
.1 °C
+/- 0.1% FS
+/- 1°C typical
Three term PID control
plus limit control
15 amp @ 115V,
15 amp @ 230V
0.25 amp
115 and 230 VAC
15 amp @ 115 VAC
15 amp @ 230 VAC
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4857 Reactor Controllers
SOFTWARE INSTALLATION OF THE 4857 PROCESS CONTROLLER
Before Software Installation
The CalGrafix software should be installed on a
PC which has not previously been used to run
software for Cal applications. The PC should
meet at least the minimum system requirements.
Minimum PC Requirements
As a general requirement, we would
recommend a minimum of Pentium 450MHz
with 256MB RAM, Windows
screen resolution, 1024 x 768. 100MB of
free hard drive space is more than
sufficient.
TM
2000/XP and
Installation Instructions:
Note: Temperature control modules have been set to park mode as a precaution against
heating before connection to a PC. Following these installation instructions will reset the
parameters for these modules to allow heating and stirring.
Do not connect the 4857 to the PC until the following installation has been completed.
CalGrafix Installation Instructions:
1. Locate the 547M CalGrafix CD and insert it into the CD drive.
2. From the CD, open the setup.exe file to run the installation program.
3. Follow on screen instructions to complete installation.
Install USB Drivers (for USB cables only)
Note: If using serial port communication, no driver installation is required.
1. Insert the 521M CD.
2. Attach USB Cable to PC. Do not connect cable to 4857 Process Controller yet.
3. The "Add new hardware" wizard should appear. Click "Next."
4. Select "Search for the best driver for your device." Click "Next."
5. The wizard will then ask the location of the driver. With the Parr 521M CD in the CD-
drive, select "CD-ROM drive" and click "Next."
6. The wizard should find the "\FTDIBUS.INF" file. If it does not find the driver, select
“specify driver location” and find the driver at: ”/installation/USB-SerialPortAdapter/BBElec/USOTL4/VISTA_XP or WIN98_ME”. Click "Next."
7. The wizard should install the driver. Click "Next."
8. The wizard will also find the USB Serial Port. This should be installed in the same
manner as the previous driver. When it is finished, click "Finish."
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4857 Reactor Controllers
Connections between single Reactor,
4857 Process Controller, and single 4875 Power Controller
Diagram 1: Schematic Diagram of Connections to
4857 Process Controller for control of
a single reactor with 4875 Power Controller
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4857 Reactor Controllers
Connections between two Reactors,
4857 Process Controller, and dual 4875 Power Controllers
Diagram 2: Schematic Diagram of Connections to
4857 Process Controller for control of
two reactors with two 4875 Power Controllers
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