551M 4838 Reactor Controller Operating Instruction Manual
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 Specifications — 5 Environmental Conditions — 5 4838 Reactor Controller Specifications — 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 Hi
4838 Reactor Controller Preface Applications Related Instructions 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. The following Parr publications are also included to further your understanding of this instrument and its component parts: No.
838 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.
4838 Reactor Controller General Specifications Environmental Conditions Electrical Ratings 115VAC, 15.0 Amps, 50/60 Hz This instrument is intended to be used indoors. 230VAC, 15.
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.
4838 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.
4838 Reactor Controller Component Summary Switches and Indicators Front side Back side 4838 Reactor Controller 4838 Reactor Controller 115V The Heater Switch is a manual, three-position, illuminated 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.
4838 Reactor Controller Back side 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.
4838 Reactor Controller Instructions for the 4838 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 21 of this manual. Temperature Control Module Temperature Control The easiest way to control temperature with the 4838 Controller is to use setpoint control.
4838 Reactor Controller c. All of PID parameters in the group can be obtained 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.
4838 Reactor Controller Note: The first 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 read [TI00], 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.
4838 Reactor Controller Appendix: sample programs A sample program to ramp from 25 °C to 250 °C in 2-hrs: 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 Variable Value Meaning ptrn 00 Pattern 0 ptrn 00 Pattern 0 SP00 25 Setpoint of 25 ºC (first step is a soak by default) SP00 200 Setpoint of 200 °C (first step is a soak by default) tI00 00:01 Hold for 1-min tI00 00:00 SP01 250 Setpoint of 250
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.
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. setpoint. This non-latching setpoint will establish a maximum wall temperature, and combined with the main temperature control module will help suppress overshoot in difficult to control processes.
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.
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 satisfied 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 modified manually at the physical panel during datalogging and charting. 7. 1. Open the ParrCom.exe file. No installation is necessary.
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.
4838 Reactor Controller Pressure Module Press return key and release Operation Mode r-S SP AL1H LoC Select type/value Run To be determined** 0 OFF Comment Run/Stop Decimal point position Upper-limit alarm 1 Lock mode (lock all keys or 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 Select type/value InPt V5 tP-H tP-L CTRL Determined by transducer** 0 ON/OFF S-HC ALA1 Heat 2 SALA CoSH OFF ON C-Sl C-no bPS Len PrtY StoP RTU 3 9600 8
4838 Reactor Controller HTM / ETLM Module Press return key and release Operation Select Comment Mode type/value J** Input type tPUn C Temperature unit 800** Upper-limit temperature range Upper-limit alarm 1 tP-L 0 Lock mode (lock all keys or only up/down arrow able to use) Lower-limit temperature range CTRL ON/OFF Control mode (ON/OFF, MANUAL, PID and PID PROG) S-HC Heat Heat/Cool control ALA1 6*** Alarm operates when PV value is higher than AL1H value SALA OFF System alarm CoSH ON
4838 Reactor Controller 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) Set system alarm Communi
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 Time setting) 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 whe
4838 Reactor Controller 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.
4838 Reactor Controller Parts List Fuses 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.
4838 Reactor Controller Part number Pressure Display Module (PDM) 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, 1
4838 Reactor Controller Hi-Temp Cut-Off Module (HTM) or External Temperature Limit Module (ETLM) Part number Description 26 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
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Revision 05/20/13
