Koehler K45 Series Guide

Operation and Instruction Manual
REV B
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
K45XXX
Front View Distillation Apparatus

CERTIFICATE OF CONFORMANCE
Manual Front View Distillation Apparatus
K45XXX
This certificate verifies that part number K45XXX, Manual Front View Distillation
Apparatus, was manufactured in conformance with the applicable standards set
forth in this certification.
Specifications: ASTM D86
ASTM D216
ASTM D233
ASTM D447
ASTM D850
ASTM D1078
ASTM E133
IP 123
IP 195
ISO 3405
DIN 51751
FTM 791-1001
FTM 791-1015
NF M 07-002
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....................................................................................................................... 3
2Safety Information and Warnings.................................................................................3
3Getting Started...............................................................................................................4
3.1 Packing List............................................................................................................................................4
3.2 Accessories for Running Tests .............................................................................................................. 4
3.3 Unpacking .............................................................................................................................................. 4
3.4 Setup......................................................................................................................................................4
4Descriptions...................................................................................................................5
4.1 Assembling Test Equipment .................................................................................................................. 6
5Operation........................................................................................................................6
6Maintenance...................................................................................................................6
6.1 Routine Maintenance.............................................................................................................................6
6.2 Spare Parts ............................................................................................................................................6
6.2.1 Spare Parts for K45000/ K45100/ K45090/ K45190 (Groups 1-3).......................................................................6
6.2.2 Spare Parts for all 8 Units (including Group 4)....................................................................................................6
7Troubleshooting.............................................................................................................7
8Service............................................................................................................................7
8.1 Heater Replacement Procedure ............................................................................................................7
8.2 Procedure for Removing Roll Pin on Pinion Shaft Assembly ................................................................7
9Heater Assembly Drawings...........................................................................................8
10 Wiring Diagrams ............................................................................................................9
10.1 K45000 (Group 1-3, 115V, Right Hand Model) ..................................................................................9
10.2 K45090 (Groups 1-3, 220-240V, Right Hand Model) ....................................................................... 10
10.3 K45200 (Group 4, 115V, Right Hand Model)....................................................................................11
10.4 K45290 (Group 4, 220-240V, Right Hand Model) ............................................................................12
11 Storage .........................................................................................................................13
12 Warranty .......................................................................................................................13
13 Returned Goods Policy ...............................................................................................13
Notes..................................................................................................................................14

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1 Introduction
The Koehler K45XXX Front View Distillation
Apparatus is the latest design for distillation of
petroleum products. The standard front view
distillation apparatus is used for distillation of
Groups 1, 2 and 3 category products including
motor and aviation gasolines, aviation turbine
fuels, naphthas, kerosenes, distillate fuels,
natural gasoline, hydrocarbon mixtures and
other petroleum products. The K45000 is the
right hand 115V model while the K45100 is the
left hand 115V model. In the same respect, the
K45090 is the right hand 220-240V model while
the K45190 is the left hand 220-240V model.
The Group 4 front view distillation apparatus
is used for testing of Grade No. 2 fuel oil, Grade
No 2-diesel fuel oil, gas oils and other distillates
requiring condenser bath temperatures of up to
140°F (60°C). It is also suitable for gasolines,
aviation turbine fuels, naphthas, kerosenes and
other liquid petroleum products. The Group 4
apparatus is available with a right or left hand
heater unit. It can also run distillations for
petroleum products characterized as Groups 1,
2 and 3. The K45200 is the right hand Group 4
115V model while the K45300 is the left hand
115V model. The K45290 is the right hand
Group 4 220-240V model while the K45390 is
the left hand 220-240V model.
The Koehler K45XXX conforms to the ASTM
D86 test method 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 Front View
Distillation 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 to provide 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 D86: Standard Test Method for
Distillation of Petroleum Products at
Atmospheric Pressure
ASTM D216: Method of Test for
Distillation of Natural Gasoline
ASTM D233: Standard Test Methods of
Sampling and Testing Turpentine
ASTM D447: Test method for Distillation
of Plant Spray Oils
ASTM D850: Standard Test Method for
Distillation of Industrial Aromatic
Hydrocarbons and Related Materials
ASTM D1078: Standard Test Method for
Distillation Range of Volatile Organic Liquids
ASTM E133: Standard Specification for
Distillation Equipment
2. International Organization for
Standardization (ISO)
1, rue de Varembé
Case postale 56
CH-1211 Geneva 20, Switzerland

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Tel: [phone]
Fax: [phone]
http://www.iso.org
ISO Publication:
ISO 3405: Petroleum Products-
Determination of Distillation
Characteristics at Atmospheric Pressure
3. Deutsche International Norm (DIN)
http://www.din.de
DIN Publication:
DIN 51751: Distillation of Petroleum
Products at Atmospheric Pressure
4. Federal Test Method (FTM)
FTM Publication:
FTM 791-1001: Distillation
FTM 791-1015: Distillation
5. Energy Institute (IP)
61 New Cavendish Street
London, WIM 8AR, United Kingdom
Tel: [phone]
Fax: [phone]
http://www.energyinstpubs.org.uk/
IP Publication:
IP 123: Petroleum Products- Determination
of Distillation Characteristics
IP 195: Determination of distillation
characteristics of volatile organic liquids
6. National Fuel Marketing (NFM)
7979 East Tufts Avenue Parkway Suite 815
Denver, Colorado 80237
Office: 303-796-0325
Fax: [phone]
NFM Publication:
NFM 07-002
1.3 Instrument Specifications
Models:
K45000, K45100,
K45090, K45190
K45200, K45300,
K45290, K45390
Electrical
Requirements:
115V 60Hz
220-240V 50/60Hz
115V 60Hz
220-240V 50/60Hz
Capacity:
One (1) Sample
Dimensions:
15 ¼ x18 ¼ x19 ½ “
(39 x 46 x 50 cm)
Gross Weight:
65 lbs (29.5kg)
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 because it 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. Repairs should only be
carried out by authorized personnel.
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

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http://www.sigma-aldrich.com. Dispose of all
chemicals according to local and national
regulations.
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
K45000/K45100/K45090/K45190 (Groups 1-3)
Front View Distillation Apparatus
OR:
K45200/K45300/K45290/K45390 (Group 4)
Front View Distillation Apparatus
K45410 Flask Support Board A
(see Figure 4)
K45430 Flask Support Board C
(see Figure 4)
Graduate Support Block (see #1 Figure 1)
3.2 Accessories for Running Tests
Catalog No.
Type
Capacity
332-003-006
Flask A
100mL
332-003-001
Flask B
125mL
332-003-002
Flask C
200mL
332-003-005
Flask D
250mL
332-002-013
Graduate A
25mL
332-002-003
Graduate B
100mL
332-002-014
Graduate C
200mL
K45410
Flask Support
Board A
1 ¼”
K45420
Flask Support
Board B
1 ½”
K45430
Flask Support
Board C
2”
K45440
Flask Support
Board D
2 ¾”
K45500
Centering
Stopper
For a 125mL
flask
K45520
Centering
Stopper
For a 200mL
flask
3.3 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.
This unit comes packed upright in a
corrugated carton. Lift the back unit condenser
from the carton first and place on a firm level
bench. Lift the heater section from the carton.
Position the heater unit on the condenser by
lifting the heater and placing the unit on the
protruding hangers welded on the condenser.
Remove all tie-downs and crumpled paper from
the condenser section. Unpack the styrofoam
wrappings from around the heater section and
generally clean all wrappings from the units.
Unpack the 1 ¼” and 2” secondary flask support
boards and the wooden graduated cylinder
support and place in a safe location.
3.4 Setup
Equipment Placement. Place the instrument 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.
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. The unit
location should also be prevented from drafts.
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

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Operation and Instruction Manual
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bath is filled with the proper medium; otherwise
damage may occur to the unit and the warranty
will be void.
4 Descriptions
Figure 1: Apparatus (Front)
1) Graduated Cylinder Base
2) Graduated Cylinder (Receiving)
3) Condenser Tube
4) Distillation Flask
5) Black Knob: used to adjust the height of the
elevator platform to fit the flask.
6) Temperature Dial
Figures 2 through 4 show additional parts used
with the instrument.
Figure 2: Distillation Flask
Figure 3: Centering Stopper
Figure 4: Flask Support Board

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4.1 Assembling Test Equipment
1. Position the heater plate to lay flat on the
adjustable elevator plate.
2. Plug the line cord into a properly fused and
grounded receptacle of the correct voltage,
as marked on the information plate.
3. Adjust the front leg on the heater unit to
level the apparatus if the table is uneven.
4. Fill the condenser unit in accordance with
the ASTM D86 or related test specifications
listed in Section 1.2.
5. For the Group 4 units, attach the small
connector cable coming from the heater unit
to the connector on the bottom of the
condenser unit.
5 Operation
1. Adjust the height of the elevator platform to
fit the flask by pushing in the black knob and
turning.
2. Turn the power switch to ON and adjust the
variable transformer to the desired
temperature. Allow the temperature to
stabilize.
3. For the Group 4 units, turn the switch to ON
in the condenser unit and adjust the
thermoregulator to the desired temperature
as per method.
4. Place the secondary flask support under the
flask and adjust the plate in accordance with
the ASTM D86 or one of the test
specifications listed in Section 1.2.
5. Proceed to test according to the method.
6 Maintenance
WARNING. Disconnect power to the unit before
servicing to avoid exposure to high voltages
and/or temperatures which may result in
personal injury or death. If you have any
questions about maintaining your equipment,
please do not hesitate to contact the Koehler
technical service department.
6.1 Routine Maintenance
The K45XXX Front View Distillation Apparatus
requires little routine maintenance to provide
many years of continuous service. However,
over the course of time, some instrument parts
may need to be replaced. 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).
6.2 Spare Parts
6.2.1 Spare Parts for K45000/ K45100/ K45090/
K45190 (Groups 1-3)
Part No.
Description
K450-0-3B
Window
K450-0-14
Heater Transite
K450-0-15
Platform Transite
K450-0-19
Blotting Paper Holder
K450-0-20
Graduated Cylinder Base
K45410
Flask Support Board, 1 ¼”
diameter hole
K45430
Flask Support Board, 2” diameter
hole
K450-0-29
Cover Gasket
K450-1-30A
Rack and Pinion Housing
Assembly
225-115-003
Heater, 1250W, 115V
225-230-003
Heater, 1250W, 230V
280-115-002
Variable Transformer
280-230-001
Variable Transformer
050-002-001
Switch
6.2.2 Spare Parts for all 8 Units (including
Group 4)
The following spare parts are used for
mechanical refrigeration to maintain condenser
temperature for all 8 units (Groups 1-4)

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Part No.
Description
RC 1/3 Refrigeration Unit
030-104-02B
¼ MPT x 3/8 Brass Hose Barb
020-308-00B
3/8 x ¼ Brass Pipe Bushing
020-104-00B
¼ Brass Pipe Coupling Hex
020-108-00B
1/8 x ¼ Brass Pipe Bushing 8 ft
3/8 ID Reinforced Rubber Hose
5/8 –7/8 Hose Clamps
Grainger #5X443
7 Troubleshooting
WARNING: Troubleshooting procedures involve
working with high voltages and/or temperatures
which may result in personal injury or death, and
should only be performed by trained personnel.
Please do not hesitate to contact Koehler for
assistance.
8 Service
Under normal operating conditions and with
routine maintenance, the K45XXX Front View
Distillation Apparatus does not require service.
Any service problem can be quickly resolved by
contacting Koehler’s technical service
department either by letter, phone, fax, or email.
In order to assure the fastest possible service,
please provide us with the following information.
Model Number:
Serial Number:
Date of Shipment:
8.1 Heater Replacement Procedure
(See Heater Assembly Drawing A and B)
1. Remove (2) #8-32 x 5/8 large screws (“B”
Assembly Drawing) from the top insulator (-
14) and (1) holder (-13) from the top
insulator.
2. Disconnect heater wires and remove heater,
install new heater to the wires using the
double nut arrangement.
3. Reinstall the (-13) holder and top insulator (-
14) with the (2) #8-32 x 5/8 large screws to
the standoffs, this completes the heater
installation procedure. Consult the
assembly drawing for added information.
8.2 Procedure for Removing Roll Pin on
Pinion Shaft Assembly
(See Assembly Drawing A and B)
1. Remove (2) #8-32 x 5/8 large screws from
top insulator (-14) as shown in assembly
drawing “B.”
2. Lift up heater assembly and remove (3) 8-32
screws holding platform (-34) to bottom
insulator (-15). Lift up bottom insulator (-15)
and using a 5/64 Allen wrench, loosen the
set screw on (-34) and remove from the
shaft.
3. Using a pair of diagonal cutters or pliers,
remove the roll pin from the shaft and
discard. See the assembly drawing for more
information.

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9 Heater Assembly Drawings
“Drawing A” Side View

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“Drawing B” Top View

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10 Wiring Diagrams
10.1 K45000 (Group 1-3, 115V, Right Hand Model)

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10.2 K45090 (Groups 1-3, 220-240V, Right Hand Model)

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10.3 K45200 (Group 4, 115V, Right Hand Model)

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10.4 K45290 (Group 4, 220-240V, Right Hand Model)

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11 Storage
This laboratory test instrument is equipped
with electrical components. Storage facilities
should be consistent with an indoor laboratory
environment. This testing equipment should not
be subjected to extremes of temperature and/or
moisture. This equipment was shipped from the
factory in a corrugated cardboard container. If
long term storage is anticipated, re-packing the
instrument in a water-resistant container is
recommended to ensure equipment safety and
longevity.
12 Warranty
We, at Koehler, would like to thank you for
your equipment purchase, which is protected by
the following warranty. If within one (1) year from
the date of receipt, but no longer than fifteen
(15) months from the date of shipment, Koehler
equipment fails to perform properly because of
defects in materials or workmanship, Koehler
Instrument Company, Inc. will repair or, at its
sole discretion, replace the equipment without
charge F.O.B. its plant, provided the equipment
has been properly installed, operated, and
maintained. Koehler Instrument Company must
be advised in writing of the malfunction and
authorize the return of the product to the factory.
The sole responsibility of Koehler Instrument
Company and the purchaser’s exclusive remedy
for any claim arising out of the purchase of any
product is the repair or replacement of the
product. In no event shall the cost of the
purchaser’s remedy exceed the purchase price,
nor shall Koehler Instrument Company be liable
for any special, indirect, incidental,
consequential, or exemplary damages.
KOEHLER INSTRUMENT COMPANY, INC.
DISCLAIMS ALL OTHER WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING ANY
IMPLIED WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE. Please save the
shipping carton in the event the equipment
needs to be returned to the factory for warranty
repair. If the carton is discarded, it will be the
purchaser’s responsibility to provide an
appropriate shipping carton.
13 Returned Goods Policy
To return products for credit or replacement,
please contact Koehler Customer Service with
your purchase order number, our packing
list/invoice number, the item(s) to be returned
and the reason for the return. You will be issued
a Returned Authorization (RA) number, which
must be prominently displayed on the shipping
container when you return the material to our
plant. Shipping containers without an RA
number prominently displayed will be returned to
the sender. Goods must be returned freight
prepaid. Returns will be subject to a restocking
charge, the application of which will depend
upon the circumstances necessitating the return.
Some returns cannot be authorized, including
certain products purchased from outside
vendors for the convenience of the customer,
products manufactured on special order,
products shipped from the factory past ninety
(90) days, and products which have been used
or modified in such a way that they cannot be
returned to stock for future sale.

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Notes

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Notes