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4838 Reactor Controller

14

Pressure Display Module (PDM)

PRESSURE

When this optional module is present, the left dis-
play 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, cut-
ting power to the heater.

This module provides a digital read out for continu-
ously 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 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 tempera-
tures.

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  Technical  Support  before  pur-
chasing one of these.

The Pressure Alarm setpoint may be adjusted by do-
ing 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 sepa-
rately  or  installed  in  any  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)

TEMPERATURE

This module provides a redundant high tempera-
ture 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 inde-
pendent safety backup system, operating in addition 
to  the  high-limit  control  built  into  each  tempera-
ture controller.  It has its own thermocouple, digital 
display and wiring, and can be preset to shut down 
the heater at any desired temperature.

Summary of Contents for 4838

Page 1: ...4838 Reactor Controller Operating Instruction Manual...

Page 2: ...ry 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 Comm...

Page 3: ...h of these controllers and describe the several optional control modules which can be added to these ex pandable units The users should study the instruc tions carefully before using any of these cont...

Page 4: ...4838 Controller There are no user serviceable parts inside the prod uct other than what is speci cally called out and discussed in this manual Advanced troubleshooting instructions beyond the scope of...

Page 5: ...l 4838 Controllers operate with aType J Iron Constantan thermocouple The total resistance of the thermo couple and the lead wires should not exceed 100 ohms If the resistance of the thermocouple circu...

Page 6: ...pera tion within the limits speci ed for that design But in order to preserve the validity of these de signs all temperature and pressure limits must be observed and no attempt should be made to incre...

Page 7: ...troller will not be affected by radiant heat Connections Labeled connections are provided on the rear panel of the controller Heating Only The heating output connector is to be used only with Company...

Page 8: ...When the light comes on the user must 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...

Page 9: ...imit setting This must be manually reset before heating can occur again On Model 4838 Controllers the high temperature limit is preset at the factory to 375 C for most sys tems On these controllers an...

Page 10: ...the value of the setpoint by adjust ing 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...

Page 11: ...p and Soak The 4838 Controller has a programming feature which allows more exibility when compared to set point control Rather than controlling temperature to a single set point a ramp and soak progra...

Page 12: ...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...

Page 13: ...r 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 in stead of a...

Page 14: ...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 wit...

Page 15: ...As an added safety feature there is also a second ary alarm which will trip the High Limit Reset when breached This secondary alarm provides a redun dant high temperature safety cut off which will sh...

Page 16: ...The soft ware is located on the CD at software _ _ _ Com exe 6 Once copied to the PC open the _ _ _ Com exe le No installation is necessary 7 At the main _ _ _ Com program screen select protocol set P...

Page 17: ...se address 3 and an HTM ETLM will use ad dress 4 5 Click the Save button and save a REC le to an appropriate place on the PC When the chart is generated it will write to this le 6 When you return to t...

Page 18: ...Out1 read only Heater output If using a type J or type K thermocouple SP 0 If using an RTD SP 1 Press and hold down SET for 5 sec Operation Mode Select type value Comment InPt J Input type tPUn C Temp...

Page 19: ...ol mode ON OFF MANUAL PID and PID PROG S HC Heat Heat Cool control ALA1 2 Alarm operates when PV value is higher than SV Value ALH setting SALA OFF System alarm CoSH ON Communication write function th...

Page 20: ...nge tP L 0 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 Syst...

Page 21: ...ontrol mode Select heating cooling control or dual loop output control Alarm 1 mode setting Alarm 2 mode setting Only available on PrimaryTemperature Controller Alarm 3 mode setting Only available on...

Page 22: ...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 a...

Page 23: ...control mode or Heating and Cooling control cycle Available in PID control mode Control cycle setting of 2nd output group Available in PID control and Dual Loop output control mode P value of 1st 2nd...

Page 24: ...tension 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 A472E4 Thermocouple type J 5...

Page 25: ...s 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 Transd...

Page 26: ...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 le...

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