"user manual"
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1. 15 PARR INSTRUMENT COMPANY 211 Fifty third Street Moline Illinois 61265 USA 309 762 7716 800 872 7720 Fax 309 762 9453 http www parrinst com e E Mail parr parrinst com Revision 3 25 04 162. 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 an air motor or with no motor do not have a speed control knob Electrical Ratings Before connecting any 4836 Controller to a reactor or heating device the user must be sure that the line load and Revision 3 25 04 4836 Temperature Controllers other characteristics of the installation do not exceed the following limits Voltage The line voltage should not differ from the rated voltage shown on the nameplate by more than 10 percent Frequency This controller can be operated from either a 50 or 60 Hertz power supply without affecting its operation or calibration Current The solid state switching relay in these controllers will handle non inductive loads up to 25 amps maximum but loads drawn from the PARR HEATING ONLY outlet on the back panel must not exceed 15 amperes All supply and accessory wiring to this controller shall have a minimum insulation rating of 105 C type SJT or better Inductive Loads Inductive loads must be limited to 750 watts 1 hp at 115 volts or to 1100 watts 1 1 2 hp at 230 volts Do not connect these controllers to the primary input side of an auto transformer Variac Powerstat or the like The heavy inductive load on the primary side of such transformers will destroy the relay The secondary output side of an
3. auto transformer can be carried through the relay if this circuit is isolated from the controller A separate full voltage connection must then be made to operate the temperature controller and to actuate the relay Thermocouple Unless otherwise specified all 4836 Controllers operate with a Type J iron constantan thermocouple The total resistance of the thermocouple and the lead wires should not exceed 20 ohms If the resistance of the thermocouple circuit is higher it will reduce the sensitivity of the control system 4836 Temperature Controllers Connections CONNECTIONS TO A PARR REACTOR 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 15 amperes Leave a space of at least twelve inches between the controller and the reactor so that the controller will not be unduly affected by radiant heat from the reactor This controller is intended to be used indoors at an ambient temperature between 10 C and 30 C with a relative humidity of less than 80 percent Labeled plug in sockets are provided on the rear panel for the reactor heater cord and for a Type J thermocouple There is also a special polarized socket for the stirrer drive motor An additional socket labeled PARR COOLING ONLY is energized at full line voltage whenever cooling is called for by the controller This circuit provides a means for activating an optional c
4. performed by the user There are no user serviceable parts inside the Series 4840 Controller Advanced troubleshooting instructions can be obtained by calling the Parr Instrument Company to determine which parts may need to be replaced or serviced Revision 3 25 04 14 4836 Temperature Controllers 11110 Parts for all Series 4836 Controllers 139E8 Fuse So blo 2 5 amp 1 2hp 180VDC Motor 139E23 Fuse fast act 15 Amp 139E19 Fuse slo blo 1 5 Amp 1 4 hp 180 VDC Motor 1129E Thermocouple socket A410E8EB Speed Control Module 120 VAC 90VDC 1 4 hp A410E8EE Speed Control Module 230 VAC 90VDC 1 4 hp A410E9EB Speed Control Module 120 VAC 90VDC 1 2 hp A410E8EE Speed Control Module 230 VAC 90VDC 1 2 hp A1252bEEE Speed Control Module 230 VAC 180VDC 1 2 hp A1252E2EE Speed Control Module 230 VAC 180VDC 1 4 hp 585E2EE Switch inst motor 1119E Relay 25 amp 801E Circuit breaker 0 5 amp 1 12hp 90VDC motor 801E2 Circuit breaker 2 5 amp 1 4hp 90VDC motor 801E3 Circuit breaker 1 5 amp 1 8hp 90VDC motor 801E4 Circuit breaker 5 amp 1 2hp 90VDC motor A1845E Temperature control module 4836 876E Resistor 0 05 ohm 1 4hp 90VDC 1 2hp 180VDC motors 876E2 Resistor 0 025 ohm 1 2hp 90VDC motor 876E3 Resistor 0 10 ohm 1 4hp 180VDC motor 876E4 Resistor 0 18 ohm 1 8hp 90 VDC motor 876E5 Resistor 0 035 ohm 3 4hp 180VDC motor 876E6 Resistor 0 25 ohm 1 17hp 90VDC motor Revision 3 25 04
5. No 446M A Parr Instrument Company Operating Instruction Manual for 4836 Temperature Controllers 4836 Temperature Controllers TABLE OF CONTENTS Related Instructions 2 Customer Service 2 iocus 3 rs MERE 3 Applications ape 200 3 Electrical Ratings cai nus 3 Connections 4 Connections 1 4 Instructions for 4836 Controllers 5 Switches and Indicators 6 Protective Fuses and Relays 7 Access to the Controller Cabinet 7 MOOUL BS iris cities cubi asi sasinan 8 Digital RPM Display 8 Digital Pressure Display 9 Digital Temperature Display 10 Digital Ammeter Display 11 Solenoid Valve Module 12 Speed Control and Adjustments 12 Motor Speed Control 12 Adjustments sss 13 Cleaning and Maintenance 14 Parts List 15 Revision 3 25 04 Related Instructions The following Parr publications are also included to further your understanding of this instrument and its component parts No Description 230M Safety Precautions to be observed when operating Pressure Reaction Equipment 201M L
6. bly 6 feet display will show the stirring speed over a A1002E3 Cable Assembly 10 feet range from 0 to 2000 rpm with a 1 rpm A1002E4 Cable Assembly 20 feet resolution and 10 rpm accuracy Revision 3 25 04 8 Digital Pressure Display TRANSDUCER PSI Digital Pressure Display This module provides a digital readout for continuously monitoring the pressure within the reactor Pressure is displayed with 1 psi resolution and 10 psi accuracy on a digital readout normally calibrated from 0 to 2000 psig The signal for the pressure display is generated by a transducer in a stainless steel housing mounted on the reactor near the Bourdon tube pressure gage The transducer must not be heated above 120 C A water cooling sleeve attached to the transducer fitting can be used to keep the transducer below this limit when operating the reactor in a higher range For applications involving reactants corrosive to stainless steel the stainless steel transducer fitting can be replaced with an isolator which will keep the reactants away from the transducer Users should consult with the Parr engineering staff regarding possible corrosion protection arrangements When ordering a pressure display module separately or installed in any Series 4836 Controller always specify the reactor in which the transducer will be installed so that the proper mounting hardware can be furnished Revision 3 25 04 4836 Temperature Controllers Pa
7. constant stirring speed at any given setting changes in the current drawn by the motor will correspond to changes in the viscosity of the reactants in the vessel This will be a useful option for users who want to monitor the progress of a polymerization reaction in which there is a viscosity change as the reaction proceeds Revision 3 25 04 11 Solenoid Valve Module Solenoid Valve Module This module provides a solenoid valve a metering valve and all parts needed to assemble an automatic system for controlling the flow of coolant through a cooling coil in any reactor It usually is installed in a cold water line with a flow connection to the cooling coil and an electrical connection to the cooling socket on the back of the temperature controller Coolant will then be admitted to the coil whenever cooling is called for by the controller thereby minimizing any temperature overshoot This system is particularly advantageous when holding fixed temperatures below 150 C or for controlling exothermic reactions Compressed air can be used as a coolant if the amount of heat to be removed is not large Revision 3 25 04 12 4836 Temperature Controllers Speed Control and Adjustments Motor Speed Control 4836 Controllers are equipped with a solid state speed control module for use with the variable speed DC motors installed on Parr stirred reactors The module itself approximately 4 inches square is mounted inside
8. couple 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 maximum temperature reading A similar high reading will be displayed if the controller is turned on without an attached thermocouple The thermocouple break must be corrected in order to activate the system Revision 3 25 04 7 4836 Temperature Controllers Digital RPM Display Module Parts for Optical Tachometer Module TDM A1001E Optical sensor for cart reactor A1001E2 Optical Sensor for bench TACHOMETER top reactor A1001E3 Optical Sensor for compact reactors 1564HC Optical wheel for cart and bench top reactors Digital RPM Display Module 3056HC Optical wheel for compact This optional feature can be included reactors in any Series 4840 Controller to provide a A1005EEB EE Tachometer display means for continuously monitoring the A1005E2EB EE Tachometer display stirring speed in a Parr reactor It consists w 4 20ma analog out of a digital readout mounted in the controller A1005E3EB EE Tachometer display cabinet connected to an optical sensor w 0 5vdc analog out installed in the overarm drive on the reactor A1005E4EB EE Tachometer display The connecting cable has a microphone w 0 10vdc analog out plug which fits into a marked socket on the A1002E Cable Assembly 3 feet back panel of the controller The digital A1002E2 Cable Assem
9. d on current Parr stirred reactors 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 There is no speed control knob Revision 3 25 04 6 4836 Temperature Controllers Switches and Indicators Continued PROTECTIVE FUSES AND RELAYS Access to the Controller Cabinet An instrument fuse is mounted on To open the controller cabinet unplug the power cord and remove the two screws in the upper corners of the back panel This will allow the hinged top and front panel to swing forward providing full access to all internal components the back panel This is a Type 3AG 15 amp fuse intended to protect the temperature control module any installed display modules and the connected heater from short or overloads in the circuitry Protection for 0 90 volt motors is provided by a circuit breaker mounted on the back panel This is a resetable breaker designed to protect the motor if it becomes over loaded The breaker will have a rating selected to match the motor on the apparatus Protection for 0 180 volt motors is provided by a lighted fuse holder mounted on the back panel 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 Thermocouple burnout protection is included in each of these controllers If the thermo
10. e 0 minutes For cooling Cycle time 5 seconds Proportional band 25 C Output 1 on these controllers drives the heater Output 2 can be used to activate a cooling system Control parameters can be set independertly for each of these outputs Revision 3 25 04 4836 Temperature Controllers Model 4836 specifications Input thermocouple Operating range Readout resolution Setpoint resolution System accuracy Control action Control output 1 Control output 2 Operating voltages Type J 0 to 750 C 1 C 1 C 2 C Three term PID control plus limit control 15 amp 9 115V 15 amp 230V 0 5 amp 115 and 230 VAC Maximum switching load 15 amp 115 VAC 15 amp 230 VAC 126 Programmable ramp and soak segments RS232 Communications 4836 Temperature Controllers Switches and Indicators switenessnodndisators on any Series 4836 Controller furnished with a Parr reactor equipped with an air motor These controllers will have only an onoff motor switch The speed control function will also be omitted from any controller furnished for use with an earlier Parr reactor equipped with a variable speed motor having its own free standing speed control unit There are three illuminated switches on the front panel along with a speed control potentiometer The instrument switch controls power to the temperature control module and to the cooling circuit mentioned above It also energizes any optiona
11. e set at the factory for optimum performance and should not be changed unless customized settings are required to match a particular set of operating conditions The instructions below should be followed carefully if these controls are to be readjusted The CL current limiting torque adjustment with an orange knob is set at the factory to 1 5 times the motor rating It is intended to protect both the module and the motor against overloads and heavy surge currents during startup It can also serve as a torque limiting device by reducing the maximum power output of the system The IR compensation adjustment with an orange knob is used to improve motor control under varying load conditions If the loads do not fluctuate this control can remain at approximately one fourth of full setting But if the motor speed drops more than 296 under load this adjustment should be increased If it is set too high the motor speed will fluctuate in a cyclical manner The MAX maximum speed adjustment with a white knob controls the maximum speed of the motor To increase the motor speed turn the control knob on the front panel to its maximum setting then use the MAX trimpot to raise the speed to the desired level Note however that the motor may become unstable if the speed is raised above the motor s rated rpm Revision 3 25 04 13 4836 Temperature Controllers The MIN minimum speed adjustment with a red knob can be used to ra
12. imited Warranty 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 Preface Scope These instructions cover the installation and operation of the Parr Model 4836 Temperature Controller as used with Parr Laboratory Reactors and Pressure Vessels They cover the basic functions for this controller and describe the several optional control modules which can be added to this expandable unit The users should study the instructions carefully before using this controller so that they will fully understand the capabilities of this equipment and the safety precautions to be observed in its operation Applications Each 4836 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 They are wired for plug in attachment to current Parr models but they can be modified for use with older Parr equipment if changes are required Four additional control and display modules are available for use with these controllers These are described later in this manual Any one of these optional modules can be installed in a 4836 Controller
13. ise the minimum motor speed above zero To change this setting turn the control knob on the front panel to its minimum setting then adjust the MIN trimpot to obtain the desired minimum speed This adjustment will also affect the maximum setting making it necessary to adjust both MAX and MIN trimpots to obtain the desired spread The ACCEL acceleration adjustment with a yellow knob is normally set to provide controlled acceleration from zero to full speed in 2 seconds It can be adjusted to higher or lower acceleration times anywhere between 0 5 and 4 seconds but changing this setting will affect the MAX speed and the IR compensation which will have to be readjusted If the acceleration time is reduced to 0 5 seconds 6 o clock trimpot position increase the IR trimpot one quarter turn clockwise and decrease the MAX trimpot one fifth turn counterclockwise If the acceleration time is increased to the maximum time of 4 seconds full rotation the IR trimpot must be decreased and the MAX increased in the same rotation amounts mentioned above MOTOR RESISTOR 4836 Temperature Controllers Cleaning and Maintenance Periodic cleaning may be performed on the exterior surfaces of the controller with a damp cloth All power should be disconnected when cleaning Series 4840 Controller The replacement of protective fuses for the heater and motor circuits are the only internal maintenance procedures that should be
14. l display or control modules installed in the controller The high limit indicator light will glow if the controller receives an indication from any of its sensors that a high temperature or pressure limit has been reached and the lockout relay has opened When this 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 back of the controller Main Power Switch 230 Volt only The back panel of the 230 Volt models contains a power switch This switch will cut off power to both lines of a 230 volt system Polarity Indicator Light 230 Volt only The light will illuminate when the unit is properly plugged in In countries with un polarized electrical plugs the polarity indicator light will only illuminate when the plug is correctly inserted into its socket The heater switch is a manual two position illuminated switch which controls whether or not power is sent to the heater Both the instrument switch and the heater switch must be turned on to activate the heater because 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 Turning off the instrument switch will also turn off the heater The motor controls consist of an on off switch and a potentiometer to control the speed of the DC motor furnishe
15. ndependent extension wire 5 ft temperature display It has its own A470E4 Thermocouple thermocouple digital display and wiring extension wire 10 ft When used with a Parr Mini or Micro A470E5 Thermocouple Reactor this module requires a dual extension wire 20 ft thermocouple consisting of two A460E Duabelement thermocouples sealed within a single sheath thermocouple series and installed in the single thermocouple A472E Single element fitting in the reactor head In all other Parr thermocouple series reactors this module operates from a second thermocouple inserted into the thermowell together with the basic control thermocouple When ordering this option separately or installed in a Series 4836 Controller always specify the reactor with which it will be used so that a thermocouple of the proper style and length can be furnished Revision 3 25 04 10 4836 Temperature Controllers uv Digital Ammeter Display Module Parts For Ammeter Display Module A1191EEB EE Ammeter 1 8 hp motor A1191E2EB EE Ammeter 1 4 1 2 3 4 hp motors A1191E3EB EE Ammeter 1 8 hp motor 5 vdc analog A1191E4EB EE Ammeter 1 4 1 2 3 4 hp motors 5 vdc analog A1191E5EB EE Ammeter 1 4 1 2 3 4 hp motors 4 20 ma analog 1193E Shunt resistor 0 1 ohm Digital Ammeter Display Module This module provides a means for continuously monitoring the current being drawn by the stirrer motor Since the motor speed control will provide a
16. ooling system by using a solenoid valve to control the flow of cold water through an internal cooling coil of the reactor Appropriate connectors are also provided for a pressure sensor for a high limit Type J thermocouple and for an optical tachometer when these options are specified If the connectors provided on the controller are not compatible with earlier Parr equipment conversion kits can be supplied to make the necessary modifications Revision 3 25 04 4 Instructions For 4836 Controllers Instructions for 4836 Controllers The Model 4836 Controllers have a micro processor based control module that provides full three term control with adjustable tuning parameters Detailed operating instructions are provided in the manufacturer s User s Manual which is furnished as a supplement to these instructions Users should study these instructions carefully to ensure that they take full advantage of the sophisticated capabilities provided by these control modules That portion of the instructions which deals with installation can be overlooked since all of the described steps and connections were accomplished when the module was installed in the Parr chassis To facilitate start up with reasonably good PID control parameters for both heating and cooling all 4836 Controllers are programmed at the factory with the following settings For heating Cycle time 5 seconds Proportional band 25 C Reset 10 minutes reset Rat
17. rts for Pressure Transducer Module A818EEB EE A818E4EB EE A818E6EB EE A818E7EB EE A818E8EB EE A818E9EB EE A818E10EB EE A818E11EB EE A818E12EB EE A818E13EB EE A818E14EB EE A818E15EB EE A818E17EB EE A821E A821E3 A821E3 825HC 827HC 828HC A836EP25 A836EP50 1394HC Pressure display 2000 psi Pressure display 20 000 psi Pressure display 2000 psi 5 vdc analog Pressure display 2000 psi 10 vdc analog Pressure display 2000 psi 4 20 ma analog Pressure display 345 bar Pressure display 20 000 psi 5 vdc analog Pressure display 172 bar Pressure display 172 bar 5 vdc analog Pressure display 172 bar 4 20 ma analog Pressure display 345 bar 5 vdc analog Pressure display 5000 psi 10 vdc analog Pressure display 5000 psi 4 20 ma analog Pressure harness external 5 ft Pressure harness external 10 ft Pressure harness external 20 ft Snap ring for cooling sleeve O ring for cooling sleeve Cooling sleeve Pressure transducer 2500 psi Pressure transducer 5000 psi Adapter body 4836 Temperature Controllers 1110 Digital Temperature Display Parts for Temperature Module 1129E Thermocouple socket A819EEB EE Temperature display A819E3EB EE Temperature display 5 vdc analog NC BEP LIMIT A819E4EB EE Temperature display 4 20 ma analog A819E5EB EE Temperature display 10 vdc analog Digital Temperature Display A470E2 Thermocouple This module provides an i
18. the chassis on the bottom plate A motor switch and a speed adjustment potentiometer are mounted on the front panel A transient protector fuse is included with each module to prevent damage to the power bridge from voltage spikes in the AC line Each module also requires a resistor matched to the horsepower of the motor with which it will be used as listed in the table below Motor Motor Resistor Parr Rating Voltage Required Number 117HP 90VDC 0 25ohm 876E6 1 8HP 90 VDC 0 18ohm 876E4 1 4HP 90 VDC 0 05ohm 876E 1 4HP 180 VDC 0 10 ohm 876E3 1 2HP 90 VDC 0 025 ohm 876E2 1 2HP 180 VDC 0 05 ohm 876E 3 AHP 180 VDC 0 035 ohm 876E5 Controllers furnished as part of a complete Parr stirred reactor system will have the proper resistor installed at the factory Any controller sold separately will require a motor specification so that the proper resistor may be provided Always turn the speed control knob fully counterclockwise to the off position before turning on the motor switch then advance the knob clockwise slowly to develop the desired speed Do not overload the motor Any high speed or high viscosity load which trips the circuit breaker is too heavy Use the reset button on the rear panel to restart the motor and reduce the speed to avoid overloading Speed Control and Adjustments Continued Adjustments There are five trimpots in the speed control module that can be used to adjust the performance of the motor These ar
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