Koehler K430 5 Series Guide

Operation and Instruction Manual
REV C
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
K430X5
D892 and D6082 Dual Twin
Foaming Characteristics Test Apparatus

CERTIFICATE OF CONFORMANCE
Liquid Foaming Characteristics Apparatus
K430XX
This certificate verifies that part number K430XX, Liquid Foaming Characteristics
Apparatus, was manufactured in conformance with the applicable standards set
forth in this certification.
Specifications: ASTM D892
ASTM D6082
IP 146
DIN 51566
FTM 791-3211
FTM 791-3213
NF T 60-129
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

K430X5 D892/D6082 Dual Twin Foaming Characteristics Test Bath
Operation and Instruction Manual
K430X5-Manual -1-
Table of Contents
1Introduction ...................................................................................................................3
1.1 Koehler’s Commitment to Our Customers .............................................................................................3
1.2 Recommended Resources and Publications.........................................................................................3
1.3 Instrument Specifications.......................................................................................................................4
1.4 Software Specifications..........................................................................................................................4
2Safety Information and Warnings ................................................................................4
3Getting Started...............................................................................................................5
3.1 Packing List............................................................................................................................................5
3.2 Unpacking ..............................................................................................................................................5
3.3 Setup......................................................................................................................................................5
4Descriptions...................................................................................................................6
4.1 Main Instrument Controls.......................................................................................................................6
4.2 Cold Bath Top Plate...............................................................................................................................6
4.3 Hot Bath Top Plate.................................................................................................................................7
4.4 Flowmeter Setup and Operation............................................................................................................7
4.5 Flowmeter Calibration Data....................................................................................................................7
4.6 Temperature Controller Operation.........................................................................................................8
5Operation .......................................................................................................................9
5.1 Bath........................................................................................................................................................9
5.2 Power .....................................................................................................................................................9
5.3 Preparation of Glassware and Tubing ...................................................................................................9
6Safety Features............................................................................................................10
6.1 Over-Temperature Protection ..............................................................................................................10
6.2 Over-Power Protection.........................................................................................................................10
7Maintenance.................................................................................................................10
7.1 Routine Maintenance ...........................................................................................................................10
7.2 Replacement Parts...............................................................................................................................11
8Wiring Diagrams..........................................................................................................12
8.1 Unit Wiring............................................................................................................................................12
9Troubleshooting..........................................................................................................13
9.1 Unit does not power up ........................................................................................................................13
9.2 Unit is on and keeps resetting into start up routine..............................................................................13
9.3 Unit is on but bath does not heat up ....................................................................................................13
9.4 Bath heats up but temperature does not stabilize................................................................................13
10 Service..........................................................................................................................13
11 Storage.........................................................................................................................13

K430X5 D892/D6082 Dual Twin Foaming Characteristics Test Bath
Operation and Instruction Manual
K430X5-Manual -2-
12 Warranty.......................................................................................................................13
13 Returned Goods Policy...............................................................................................14
Notes..................................................................................................................................15

K430X5 D892/D6082 Dual Twin Foaming Characteristics Test Bath
Operation and Instruction Manual
K430X5-Manual -3-
1 Introduction
The Koehler K430X5 High Temperature Dual
Twin Foaming Characteristics Test Apparatus is
the latest design for determining foaming
characteristics of lubricating oils according to
ASTM D892 and D6082 test methods and related
test specifications.
This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and operating
instructions for the High Temperature Dual Twin
Foaming Characteristics Test Apparatus. 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 D892: Standard Test Method for
Foaming Characterisitics of Lubricating
Oils
•ASTM D6082: Standard Test Method for
High Temperature Foaming
Characterisitcs of Lubricating Oils
2. Energy Institute (IP)
61 New Cavendish Street
London, WIM 8AR, United Kingdom
Tel: [phone]
Fax: [phone]
http://www.energyinstpubs.org.uk/
IP Publication:
•IP 146: Foaming Characteristics of
Lubricating Oils
3. Deutsche International Norm (DIN)
http://www.din.de
DIN Publication:
•DIN 51566
4. Federal Test Method (FTM)
FTM Publication:
•FTM 791-3211
•FTM 791-3213: Aircraft Lubricants Test
5. Association Française de Normalisation
(AFNOR)
http://www.afnor.fr
AFNOR Publication:
•NF T 60-129

K430X5 D892/D6082 Dual Twin Foaming Characteristics Test Bath
Operation and Instruction Manual
K430X5-Manual -4-
1.3 Instrument Specifications
Models:
K43005, K43095
Electrical
Requirements: 115V, 60Hz, 15.6A
230V, 50/60Hz, 8.1A
Temperature
Range:
Left (Cold)Bath: 24 °C (75
°F)
External Chiller required to
perform Sequence I and III
at 24 °C
Right (Hot)Bath: Ambient
to 150 °C (302°F) for
Sequence II and IV
Temperature
Control Stability: Exceeds ASTM
requirements
Digital Setpoint and
Displays °C/°F
Built-in Over-temperature
Cut-off Protection
Capacity:
4 Test Cylinders
Bath Medium:
Water or suitable heat
transfer fluid
(see section 5.1)
Bath Medium
Capacity:
38.5L (9 gal) each
1.4 Software Specifications
PC System
Requirements:
Intel® Pentium II Processor
or similar (minimum)
Operating
System:
Windows® 98 SE, 2000, NT,
XP
Memory
Requirements:
256Mb RAM (512Mb RAM
recommended) 15 Mb Hard
Disk Space (minimum)
Other:
Two RS-232 communication
ports
Microsoft® Excel (97 or
above)
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.

K430X5 D892/D6082 Dual Twin Foaming Characteristics Test Bath
Operation and Instruction Manual
K430X5-Manual -5-
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 Packing List
•K430X5 Foaming Characteristics Test
Apparatus including:
- (4) 1000mL Test Cylinders (K43012)
- (4) S/S Mott Certified Diffuser Stones
(344-005-01C)
- (4) Air Delivery Tube Assemblies (K430-3A)
- (4) Air Outlet Tubes (K430-0-13)
- (4) Rubber Stoppers (K430-0-8)
- (2) 12 x 18 Pyrex Bath Jar (332-001-003)
- (2) 18” Safety Shield (K23425-00000)
- (1) Test Tube Rack (K43002-0-13)
•K430X5-Manual D892 and D6082 Dual Twin
Foaming Characteristics Test Apparatus
Operation and Instruction Manual
3.2 Unpacking
Carefully unpack and place the instrument and
accessories in a secure location. Use extra care
while unpacking the Pyrex bath jars. 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.
3.3 Setup
Equipment Placement. Place the base on a firm,
level table in an area with adequate ventilation or
in a hood. The unit may be leveled by making
minor turning adjustments to the feet located at
the base of the unit. Please note that Koehler does
not supply a level with this equipment.
Install the borosilicate test jars. Fill each jar with
appropriate bath medium as per ASTM D892 and
D6082. Please see section 5.1 for further details
on appropriate bath medium.
Install the bath top assemblies on the jars and
plug the control cables into the receptacles on the
base unit. Refer to section 4.2 and 4.3 for proper
location of tops. Left Bath = Cold Bath. Right Bath
= Hot Bath.
Install the RTD probes in each bath tops with the
corks / thermometer probe holders provided
Ventilation. A fume hood or exhaust system is
required when operating the unit. Flammable
vapors and/or steam are generated during
operation and must not be permitted to
accumulate. A canopy-style hood may be used if
the height from the top of the unit to the canopy is
5 feet or less. The exhaust blower should have a
rating of 1000 C.F.M. or greater.
Power. Connect the line cords to properly fused
and grounded receptacles with the correct voltage
as indicated in section 1.3 or on the back of the
unit.
WARNING: For safety, disconnect the power
when performing any maintenance and/or
cleaning. Do NOT turn the power on unless the
bath is filled with the proper medium; otherwise,
damage may occur to the unit and the warranty
will be void.

K430X5 D892/D6082 Dual Twin Foaming Characteristics Test Bath
Operation and Instruction Manual
K430X5-Manual -6-
4 Descriptions
4.1 Main Instrument Controls
Figure 1: Main Instrument Descriptions
1. Power Switch. This switch controls the power
to motor and heater / temperature controller of
its corresponding side. When the power switch
is in the ON position, the digital temperature
controller and the stirrer are powered on.
2. Temperature Controller. The temperature
controller regulates the bath temperature its
corresponding bath. Refer to Section 4.3 for
full operational details.
3. Flowmeters. To regulate the flow of air into
each air delivery tube assembly. The two
flowmeters on the left handed side (while
looking at the bath), labeled with a number
one (1) on the knob are for the low flow rate
required for sequence I, II and III. Conversely,
the two flowmeters located on the right hand
side, labeled with a number two (2) are for the
high flow rate required by sequence IV.
NOTE:Sequence II must be performed by
placing the sample in the right handed (hot)
bath while using the left handed, low flow rate
flowmeters.
4. Stirrer Motor. The stirrer constantly circulates
bath medium to prevent temperature gradients
and ensures temperature stability. When
cleaning and/or servicing, please be sure to
disconnect unit power to avoid possible injury.
5. Heat Shield. An 18” safety shield is provided
to protect the user from accidentally touching
the “Hot” Bath while operating the instrument.
6. Temperature Probe. Detects the bath
temperature and communicates with the
temperature controller to maintain desired
temperature for each bath.
7. Air Delivery Tube. Connect to air conditioning
coil and flowmeter for passing air through gas
diffuser located at the bottom of the Test
Cylinder.
8. Cold Bath. For performing Sequence I and III
test procedures.
9. Hot Bath. For performing Sequence II and IV
test procedures.
4.2 Cold Bath Top Plate
Figure 2: Cold Bath (Left) Top Plate Descriptions
10. Single Heater.Provides moderate heating to
maintain 24 °C as required by sequence I to
the cold bath.
11. Cooling Coil. Connect Cooling Source to this
inlet port. Outlet port located at corresponding
position on the opposite side of the plate.
12. Conditioning Coil for Sample 1. Connect to
low flow rate flowmeter. Air then flows through
coil located within bath set at test temperature.
Connect outlet, located at the corresponding
position on the opposite side of the plate, to
the air delivery tube for Sample 1.