Koehler K244 Sereis Guide

Operation and Instruction Manual
REV A
Koehler Instrument Company, Inc.
1595 Sycamore Avenue • Bohemia, New York 11716-1796 • USA
Toll Free: 1-800-878-9070 (US only) • Tel: [phone] • Fax: [phone]
http://www.koehlerinstrument.com • e-mail: [e-mail]
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
K244XX
Programmable Muffle Furnace

CERTIFICATE OF CONFORMANCE
Programmable Ashing Furnace
K24410, K24419, K24420, K24429, K24430, K24439
This certificate verifies that part number K244XX, Programmable Ashing Furnace,
was manufactured in conformance with the applicable standards set forth in this
certification.
Specifications: ASTM D482
ASTM D874
ASTM D3174
ASTM D4422
ASTM D5184
IP 4
IP 163
ISO 3987
ISO 6245
NF M 07-045
DIN 51352
DIN 51575
This unit is tested before it leaves the factory, to ensure total functionality and
compliance to the above specifications and ASTM standards. Test and inspection
records are on file for verification.
Jesse Kelly
Application Engineer
Koehler Instrument Company

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Operation and Instruction Manual
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Table of Contents
1Introduction ...................................................................................................................2
1.1 Koehler’s Commitment to Our Customers .............................................................................................2
1.2 Recommended Resources and Publications.........................................................................................2
1.3 Instrument Specifications.......................................................................................................................2
2Safety Information and Warnings ................................................................................3
3Getting Started...............................................................................................................3
3.1 Unpacking ..............................................................................................................................................3
3.2 Setup......................................................................................................................................................3
4Temperature Controller.................................................................................................4
4.1 Description of Controller.........................................................................................................................4
4.2 Basic Controller Operation.....................................................................................................................5
Touch Screen Interface ................................................................................................................................5
5Operation .......................................................................................................................7
5.1 General Notes........................................................................................................................................7
5.2 Maintenance and fault clearance...........................................................................................................7
5.3 Display Menu Navigation .......................................................................................................................8
Notifications ................................................................................................................................................19
Control Loops (Single Set point Operation)................................................................................................20
Event Control..............................................................................................................................................22
Process Monitoring.....................................................................................................................................23
System Alarms............................................................................................................................................25
Automatic Ramp/Soak Program Operation....................................................................27
Program Settings........................................................................................................................................28
Entering a Ramp/Soak Program.................................................................................................................29
Starting an Automatic Ramp/Soak Program...............................................................................................34
Monitoring Automated Ramp/Soak Program Operation.............................................................................36
Common Questions About Ramp/Soak Program Operation......................................................................37
6Service Trouble Shooting...........................................................................................38
6.1 Replacing the heating plates or heating coil........................................................................................38
7Wiring Diagram............................................................................................................39
8Service..........................................................................................................................40
9Storage.........................................................................................................................40
10 Warranty......................................................................................................................40
10 Returned Goods Policy...............................................................................................40
Notes..................................................................................................................................41

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1 Introduction
The Koehler K244XX Ashing Furnace is the
latest design for performing Ashing of petroleum
products according to the ASTM test methods
listed in Section 1.2.
This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and operating
instructions for the Koehler Muffle Furnace. This
manual should also be used in conjunction with
applicable published laboratory procedures.
Information on these procedures is given in
section 1.2.
1.1 Koehler’s Commitment to Our
Customers
Providing quality testing instrumentation and
technical support services for research and testing
laboratories has been our specialty for more than
50 years. At Koehler, the primary focus of our
business is providing you with the full support of
your laboratory testing needs. Our products are
backed by our staff of technically knowledgeable,
trained specialists who are experienced in both
petroleum products testing and instrument service
to better understand your requirements and
provide you with the best solutions. You can
depend on Koehler for a full range of accurate and
reliable instrumentation as well as support for your
laboratory testing programs. Please do not
hesitate to contact us at any time with your
inquiries about equipment, tests, or technical
support.
Toll Free: 1-800-878-9070 (US only)
Tel: [phone]
Fax: [phone]
Email: [e-mail]
http://www.koehlerinstrument.com
1.2 Recommended Resources and
Publications
1. American Society for Testing and Materials
(ASTM)
100 Barr Harbor Drive
West Conshohocken, Pennsylvania 19428-
2959, USA
Tel: [phone]
Fax: [phone]
http://www.astm.org
email: [e-mail]
ASTM Publication:
•ASTM D482: Standard Test Method for
Ash from Petroleum Products
•ASTM D874: Standard Test Method for
Sulfated Ash from Lubricating Oils and
Additives
•ASTM D3174: Standard Test Method for
Ash in the Analysis Sample of Coal and
Coke from Coal
•ASTM D4422: Standard Test Method for
Ash Analysis in Petroleum Coke
•ASTM D5184: Standard Test Methods for
Determination of Aluminum and Silicon in
Fuel Oils by Ashing, Fusion, Inductively
Coupled Plasma Atomic Emission
Spectrometry, and Atomic Absorption
Spectrometry
1.3 Instrument Specifications
Models:
K24410,K24420,
K24420-18L, K24430
K24419,K24429,
K24429-18L, ,K24439
Electrical
Requirements: 115V 60Hz 1 ph
230V 50/60Hz 1 ph
Temperature Range:
Ambient to 1200°C
Temperature Control
Accuracy: ± 1 °C
Temperature Control
Uniformity: ± 3 °C
Temperature Control
Resolution: ± 0.1 °C
Oven Volume:
0.17 ft3. model: 5 L
0.52 ft3. model: 15 L
0.64 ft3. model: 18 L
1.41 ft3. model: 40 L
Power:
K2441X: 2700 W
K2442X: 5500 W
K2443X: 11,000 W
Chamber Internal
Dimensions:
(wxdxh,in.(cm)
K2441X:8x7x5
(20.32x17.78x12.70)
K2442X 9x13x7
(22.86x33.02x17.78)
K2443X: 13x19x10
(33.02x48.26x25.40)

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2 Safety Information and Warnings
Safety Considerations. The use of this
equipment may involve hazardous materials and
operations. This manual does not purport to
address all of the safety problems associated with
the use of this equipment. It is the responsibility of
any user of this equipment to investigate,
research, and establish appropriate safety and
health practices and determine the applicability of
regulatory limitations prior to use.
Equipment Modifications and Replacement
Parts. Any modification or alteration of this
equipment from that of factory specifications is not
recommended voids the manufacturer warranty,
product safety, performance specifications, and/or
certifications whether specified or implied, and
may result in personal injury and/or property loss.
Replacement parts must be O.E.M. exact
replacement equipment.
Unit Design. This equipment is specifically
designed for use in accordance with the applicable
standard test methods listed in section 1.2 of this
manual. The use of this equipment in accordance
with any other test procedures, or for any other
purpose, is not recommended and may be
extremely hazardous.
Chemical Reagents Information. Chemicals and
reagents used in performing the test may exhibit
potential hazards. Any user must be familiarized
with the possible dangers before use. We also
recommend consulting the Material Data and
Safety Sheet (MSDS) on each chemical reagent
for additional information. MSDS information can
be easily located on the internet at
http://siri.uvm.edu or http://www.sigma-
aldrich.com.
Disposal. Upon delivery the furnace does not
contain any material which is to be classified as
hazardous waste. However, process residues
may collect in the insulation during operation.
These may be dangerous to health and/or
dangerous to the environment.
Therefore we recommend proceeding as follows:
•Remove electrical components and dispose of
as electrical waste.
•Remove insulation and dispose of as special/
hazardous waste (wear a protective mask P2,
protective gloves and a protective suit).
•Dispose of the housing as scrap metal
3 Getting Started
The instructions for preparing the equipment
assume that the user is aware of the contents of
this document, which lists the warranty conditions
and important precautions.
3.1 Unpacking
Carefully unpack and place the instrument and
accessories in a secure location. Ensure that all
parts listed on the packing list are present. Inspect
the unit and all accessories for damage. If any
damage is found, keep all packing materials and
immediately report the damage to the carrier. We
will assist you with your claim, if requested. When
submitting a claim for shipping damage, request
that the carrier inspect the shipping container and
equipment. Do not return goods to Koehler without
written authorization.
3.2 Setup
3.2.1 Installation Site
Place the furnace on a non-flammable support
(stone, metal or similar). Keep a safe distance
from flammable components, 0.5 m from the
furnace sides and 1 m from the top. The minimum
distance between the furnace sides and non-
flammable materials can be reduced to 0.2 m.
Ventilation. Provide sufficient room ventilation to
carry off exhaust heat and gases which develop
during the process. Non-observance can result in
a fire risk and danger to health.

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3.2.2 Assembling the Ventilation Pipe
•The Ventilation Chimney must be attached to
the top of the furnace using the 3 supplied
screws.
•In all cases, we recommend connecting the
furnace to an exhaust ductwork, leading the
arising gasses out of the facility
•A standard ventilation pipe of metal with
NW80 – NW 210 can be used. It must be laid
at a constant slope and fastened to the wall or
ceiling.
•Caution: The exhaust gases can only be
carried off if the room is ventilated by a
corresponding fresh air opening.
3.2.3 Electrical Connection
•Attach the correct plug to the power supply
cord(s) and connect the main plug in a
corresponding receptacle which is protected
sufficiently depending on the rated power of
the furnace. If the furnace is ordered /
delivered without a plug, a qualified electrician
must connect the furnace.
•NOTE:Using extension cables and/or junction
boxes may lead to a reduced furnace output
due to the voltage drop in the lines. The
power is also reduced if the connection line to
the junction box is very long, and the furnace
will not reach its nominal temperature. Please
have the connection checked by an
electrician. The voltage may not drop below
the rated load by more than 10%.
WARNING:For safety, disconnect the power
when performing any maintenance and/or
cleaning.
3.2.4 Initial Heating Procedure
•To dry out the brick lining and to create an
oxide protection layer on the resistance wire,
an initial heat run must be performed prior to
testing. This may cause an unpleasant smell.
Provide sufficient ventilation.
•Heat the empty furnace up to 1050 ºC over the
course of six hours.At each change rise in
temperature, run the AUTO TUNE on the
tuning page. Once 1050 °C is reached,
maintain this temperature for one hour, and
then let the furnace cool down on its own.
•The furnace is now ready to operate.
4 Temperature Controller
4.1 Description of Controller
4.1.1 Main Breaker and Power Switch/
Control Current Switch
The main breaker is located on the right rear
bottom corner and the power switch / control
current switch is located on the right side of the
control panel. Stop running a heating program
before turning off the furnace with the power
switch.

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4.2 Basic Controller Operation
This section is designed to help guide you through the touch screen interface and menu structure, so that you
can navigate through the various operation, monitor and setup screens and learn how to use them.
Touch Screen Interface
The display is split into two sections; the icon bar and main display area.
Single Loop View Screen
Main Display
Icon Bar
The menu icon will open the main menu for navigating to the different control and
monitoring screens. Menu items will
dynamically appear providing available options
based on the system area the user is in, i.e., security, data logging, setup, etc.
The information (help) icon will display text based help associated with the current
screen. Help is available in 28 langua
ges based on the user selection in the offline
setup of section of
the display.
The home icon will return the user to the main view from anywhere in the
the display
application. The main view is set by the OEM in the
the display configuration and can
be
the single or dual loop, chart, alarm, alarm history, event or digital IO view.
The alarm icon will appear and flash when a new system alarm occurs. Pressing the
alarm icon will take the user directly to the alarm monitor screen in order to view and /or
reset the active alarm condition.
The left and right navigation arrows will appear on screens that provide additional
information that the user can scroll to such as the loop view screens, charts or program
entry screen in order to cycle through each
step of a ramp/soak program.

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NOTE:A single press of the left or right arrows will scroll program steps to the next step or screens
to the next available loop or chart. Pressing and holding the arrow keys will continue the item
scrolling until the last step of the program is reached or the button is released.
IMPORTANT: Do not use any sharp or metal objects on the touch screen as they may damage the surface.
Also be sure that hands and fingers are free from oils or chemicals which may mar the
surface of the touch screen.

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5 Operation
5.1 General Notes
•The insulation consists of high-quality
refractory material which is susceptible to
shock. Take care not to knock against the
refractory material when charging the furnace
to avoid damage.
•In order to achieve an even temperature
distribution the furnace should be charged in
such a way that products have a certain
distance to each other and also to the side
walls. Koehler offers shelves, etc. so that the
furnace chamber can be used in the most
efficient way possible.
•If the furnace is charged with a high quantity
of products the heating time may be prolonged
considerably.
•The furnace heating is stopped when the door
is opened and is switched on automatically
when the door is closed.
•Do not open the furnace when it is hot. If the
furnace must be opened at high temperatures
do this as quickly as possible. Wear personal
protective equipment and clothing and provide
sufficient room ventilation.
•Make sure that the door is properly closed
during heating.
•Discolorations may occur on the stainless
steel housing (especially when the hot furnace
is opened); these, however, do not affect the
functionality of the oven.
5.2 Maintenance and fault clearance
Regularly clean the ventilation holes/pipes so that
the ventilation cross-section remains unobstructed
and the suction functions well.
In the case of commercial use:
Please observe the safety regulations
applicable to your country.
When ordering replacement part(s), please
provide the model number, serial number, and
product shipment date of your equipment so that
we can ensure you will receive the proper
replacement part(s).

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5.3 Display Menu Navigation
The display provides the user with the ability to select text based menu navigation, much like the typical file
menu system of a PC, as well as an icon based navigation system like that of a “smart” device. The user can
switch back and forth between the two from the Setup menu.
Text Based Navigation
Icon Based/Slide Page Navigation
The available menu items are dependent upon the OEM configuration of the display. Not all of the menu
items shown may be available on your system. The following information is provided as an overview of the
full navigational menus for the display.
Home Menu
The home menu is the top level, default menu provided when the display first powers on. Pressing the menu
(monitor) icon will display the main menu offering the selections shown below.
Active Page
Indicator (1 of 3)
Touch and drag
finger across
screen to switch
between menu
pages.

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Text Based Home Menu
The View menu provides navigation to all standard view screens. These
include the Single and Overall loop views, real time Charts, Alarm monitor,
Alarm File and Events control screens.
The Program menu provides access to the automatic ramp/soak program
actions, Entry and Status views. The program Start, Hold and Halt menu items
allow quick access to these functions if a program is already downloaded to the
display loop controls.
The Device menu provides access to the display controller settings. These
include, loop set point entry limits, alarm set points, communication settings,
email setup as well as access to offline settings for date/time, etc.
The Security menu provides access for user login, security settings and audit
trail viewing if the security system is enabled.
The Data menu provides access to data log functions, file utilities, FTP\WAN
back-up settings as well as the historical data viewer.

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Icon/Slide Page Based Home Menu
Slide page 1 provides navigation to
all standard view screens. These
include the Single and Overall loop
views, Event control, trend Charts,
Alarm monitor, and Alarm File.
It also provides quick access to the
display Settings and Data file
functions which include file utilities,
FTP\WAN back-up settings as well
as the historical data viewer.
Slide page 2 provides access to
automatic ramp/soak program
actions, Entry and Status views.
Start, Hold and Halt program menu
items allow quick access to these
functions if a program is already
downloaded to the display loop
controls.
Slide page 3 provides access to
security settings, Audit trail viewing,
current User information, user
Password editing and user Login
and Log Off functions.

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Automatic Ramp/Soak Program Menu
The automatic ramp/soak program menu is provided when the user selects either “Entry” or “Status” from the
Program menu. The menu provides all functions related to the creation, editing and operation of programs.
See section 5 on Automatic Ramp/Soak Program Operation for detailed information on how to create and run
programs.
Text Based Program Menu
The View menu provides navigation to the program view screens. These
include the Status, Entry and Settings screens.
The File menu provides functions needed to create, open, save and delete
automatic ramp/soak programs.
The Step menu provides all of the functions needed to edit programs.
These include Insert, Remove, Copy and Paste step functions as well as
the Clone event function which allows the user to transfer the current step
event selections to all following program steps with a single click to simplify
and speed program entry.
The Program menu provides the program control selections for Start, Hold
and Stop.

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Icon/Slide Page Based Program Menu
Slide page 1 provides navigation to
the program Status, Entry and
Settings screens and also provides
access to the functions needed to
create, open, save and delete
automatic ramp/soak programs.
Slide page 2 provides all of the
functions needed to edit programs.
These include Copy, Paste, Insert
and Remove step as well as the
Clone event function which allows
the user to transfer the current step
event selections to all following
program steps to simplify and speed
program entry.
Slide page 3 provides the program
control selections for Start, Hold and
Halt.

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Device Settings Menu
The device settings menu is provided when the user selects “Settings” from the main “Device” menu. See
section 8 on Device Settings for detailed information on these settings and their use.
Text Based System Setup Menu
The View menu provides navigation to the manual loop Tuning screen.
The Set menu provides access to settings Alarm set points, control loop
set point Limits, Event tagnames, Navigation type selection and
Communications options.
The Email menu provides settings for the email server to send SMS text
messages and/or emails on alarm and allows the user to compose and
send a Message to any user configured in the system.
The Offline menu provides access to the display offline setup which
provides the user with the ability to adjust the date/time, calibrate the
touch screen, configure profile power recovery options, etc.

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Icon/Slide Page Based Device Settings Menu
The Setup slide page provides
access to the display controller
settings. These include options for
Navigation type, control loop set
point Limits, Alarm set points, loop
Tuning, Event tagname entry and
Email server settings and
Messaging.
It also includes access to the
communications settings for the
web page, VNC server and
Modbus user communications.

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Offline Menu
The offline menu is provided when the user selects “Offline” from the device settings “Offline” menu. See
section 9 on Offline Settings for information on these settings and their use.
NOTE: Offline settings can only be accessed when an automated ramp/soak program is not running and
data logging is turned off.
Text Based Offline Setup Menu
The View menu provides navigation back to the display device settings
menu.
The Set menu provides access to the profile power Recovery options,
temperature Units selection, NTS Clock, and Language settings.
The Calibrate menu provides access to the user input Offset calibration
for the control loop inputs.
The System menu provides access to the display settings, import/export
Configuration utility, About screen and Exit application screen.

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Icon/Slide Page Based Offline Menu
Slide page 1 provides navigation
back to the device Settings menu,
Clock, Display settings, About the
display and Exit application
screens, temperature Units
selection, Language, import/export
Configuration utility and input
Offset calibration.
Slide page 2 provides access to
the automated program power
Recovery options.