Koehler SV3000 Guide

operation and instruction manual
K21410, K21420, K21414, K21424
SV3000 & SV4000 Saybolt Viscosity Bath
service | innovation | technology
REV K-A

SV3000, SV4000 Saybolt Viscosity Bath
Operation and Instruction Manual
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SV3000, SV4000 Saybolt Viscosity Bath
Operation and Instruction Manual
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CERTIFICATE OF CONFORMANCE
SV3000 & SV44000 Saybolt Viscosity Bath
K21410, K21420, K21414, K21424
This certificate verifies that part numbers K21410, K21420, K21414, K21424, Saybolt Viscosity Bath, was manufactured
in conformance with the applicable standards set forth in this certification.
Specifications: ASTM D88
ASTM D244
ASTM E102
AASHTO T72
FTM 791-304
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.
Vincent Colantuoni
Product Manager
Koehler Instrument Company, Inc.
1595 Sycamore Ave.
Bohemia, NY 11716
United States of America
Serial Number: ________________________
Date: ________________________________

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Operation and Instruction Manual
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SV3000, SV4000 Saybolt Viscosity Bath
Operation and Instruction Manual
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Operation and Instruction Manual
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SV3000, SV4000 Saybolt Viscosity Bath
Operation and Instruction Manual
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Table of Contents
1. Introduction 2
1.1. Koehler’s Commitment to Our Customers 2
1.2. Recommended Resources and Publications 2
1.3. Instrument Specifications 2
2. Safety Information and Warnings 3
3. Getting Started 3
3.1. Packing List 3
3.2. Unpacking Error! Bookmark not defined.
3.3.Setup 4
4. Descriptions 5
4.1.Instrument Controls 5
4.2.Temperature Controller Operation 7
4.3.Preparation of Apparatus (As Per ASTM D88) 8
5. Operation 9
6. Maintenance 10
6.1.Routine Maintenance 10
6.2.Bath Maintenance 10
6.3.Replacement Parts 10
7. Wiring Diagrams 11
7.1.K21410 (115V Model) 11
7.2.K21420 (230V Model) 12
7.3.Assembly Diagram 15
7.4.Temperature Controller Configuration 16
8. Troubleshooting 17
9. Service 17
10.Storage 17
11.Warranty 17
12.Returned Goods Policy 17

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1. Introduction
The Koehler SV3000 Saybolt Viscosity Bath and SV4000 Saybolt Viscosity Bath with Automatic Timing are the latest design for
determining viscosity using Saybolt viscometer tubes and orifices. The bath operates at temperatures from ambient to 240°C
(464°F). The instrument determines the time required for 60mL of sample to flow through a calibrated orifice under precisely
controlled conditions. Saybolt Universal Seconds (SUS) is the standard measurement for lubricants, insulating oils, and lighter
fuel grades, and Saybolt Furol Seconds (SFS) is used for heavier oils and bitumens. The instrument conforms to the ASTM D88
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 Saybolt Viscometer Bath. 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 almost 100 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: [email protected]
http://www.koehlerinstrument.com
1.2. Recommended Resources and
Publications
1. American Society for Testing and Materials (ASTM)
100 Barr Harbor Drive
WestConshohocken,Pennsylvania19428-2959, USA
Tel: [phone]
Fax: [phone]
http://www.astm.org
email: [email protected]
ASTM Publication:
•ASTM D88: Standard Test Method for Saybolt Viscosity
•ASTM D244: Standard Test Method for Emulsified
Asphalts
•ASTM E102: Standard Test Method for Saybolt Furol
Viscosity of Bituminous Materials at High
Temperatures
2. American Association of State Highway and
Transportation Officials (AASHTO)
444 North Capitol Street N.W., Suite 249
Washington, DC 20001
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
1.3. Instrument Specifications
115V 60Hz 12.3A
Models:
K21410 (SV3000)
K21414 (SV4000 with Timers)
Capacity:
Four viscometer tubes
Bath Capacity:
5 gal (19L)
220-240V 50/60Hz 6.4A
Models:
K21420 (SV3000)
K21424 (SV4000 with Timers)
Dimensions:
29x25x33, in. (74x64x84cm)
Temperature Range:
Ambient to 240°C (464°F)
Net Weight:
65 lbs (30kg)
Temperature Accuracy:
± 0.03°C (0.05°F)
Gross Weight:
82 lbs (39kg)

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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 and will void 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.
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
•SV4000 Saybolt Viscosity Bath (K21414 / K21424)
•K22011 Thermometer Support (4)
•K22060 Saybolt Oil Strainer
•K22050 Socket Wrench
•K214-7 Port Closure Plug (2)
•K22070 Cleaning Plunger
•K214-0-29 Chained Cork (4)
•K22090 Withdrawal Tube
•K22030 Orifice Wrench
•K214-0-27 Port Cover (4)
•Also Included with SV4000:
•K21404 or K21494 Saybolt Viscosity Timing Sensor
•K21410-0-10 Draft Shield (2)
Additional Accessories
Part Number
Description
Part Number
Description
K21410-SFW
Saybolt Viscosity Software Package
K22050
Socket Wrench
332-003-003
Pyrex™ receiving flask
K22060
Oil Strainer
K22090
Withdrawal Tube
K22070
Cleaning Plunger
K22011
Thermometer Support
K22039
Orifice Wrench for Kansas Road Oil Orifices
K22030
Orifice Wrench for Universal and Furol
Orifices
K22080
Displacement Ring
Insert in viscometer tube gallery for bituminous
materials testing.Meets ASTM E102 specs.
355-001-004
Silicone heat transfer fluid.
5 gallon container.
Order quantity 1 per bath
355-001-004
Silicone heat transfer fluid.
5 gallon container.
Order quantity 1 per bath
Orifices and Viscometer Tubes
Part Number
Description
Part Number
Description
K22009
Saybolt Viscometer Tube, Brass
K22309
Saybolt Viscometer Tube, Stainless Steel
K22010
Saybolt Universal Orifice
K22020
Saybolt Furol Orifice
K22010-C/F
Saybolt Universal Orifice with Calibration
Certificate
K22020-C/F
Saybolt Furol Orifice with Calibration
Certificate
K22029
Kansas Road Oil Orifice

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3.2. 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.
WARNING: Be sure two or more individuals are available for extracting and lifting instrument from box to cart and from cart
to bench. Individuals must lift in accordance to proper technique. See Figure below.
1. Lift instrument from cart and place on bench.
2. 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 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 bath is filled with the proper medium; otherwise, damage may occur to the unit and the warranty will be void. This
bath is equipped with a low fluid protection feature to prevent damage, but caution should always be exercised.
Auto Timer Feature (SV4000 only). For the auto timer feature, connect the liquid level sensor
to the neck of the receiver flask. The arrows on the sensor should align with the 60mL fill line on
the flask. Use standard plastic ties to secure the sensor to the flask. The pin cord to control the
auto timer should be attached to the back of the unit. See figure 1 below. Additional auto timer
boxes should be connected in series to the previous auto timer unit.

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4. Descriptions
4.1. Instrument Controls
Figure 1: Instrument Descriptions (Front)
Figure 2: Instrument Descriptions (Back) Figure 3: Timer Components (SV4000 only)
1. Power Switch. This switch controls the power to the entire unit. When the power switch is in the ON position, power is
supplied to the unit, turning on the digital temperature controller and stirrer motor.
2. Temperature Controller. The temperature controller regulates the bath temperature for the test procedure. Refer to
Section 4.3 for full operational details.
1
3
2
1
3
2
4
4
5
5
6
6
7
7
8
8
9
9
10
10
9
10
11

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3. Lamp Switch. This switch controls turning ON/OFF the lamp for illuminating the test samples.
4. Receiving Flask Holder. Properly positions the receiver flask under the bath reservoir in order to receive sample from
the viscometer tube and orifice.
5. Binding Post Knob. There are four knobs located on the top plate of the viscometer bath. These Knobs must be
unscrewed to remove the cover.
6. Temperature Probe. Senses bath temperature within the unit and relays the information to the temperature controller.
7. Stirring Motor. 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.
8. Thermometer/Thermocouple Port. This port allows for independent temperature measurement of the bath temperature
with a thermometer or a Pt-100 RTD probe for precise temperature measurements and digital temperature controller
calibration. If the controller needs to be calibrated, then please contact the Koehler technical service department.
9. Viscometer Tube Port. Viscometer Tubes mount vertically through these ports into the Saybolt Viscosity bath.
10. Sliding Draft Shield. To prevent drafts from disrupting transfer of sample from the viscometer tube and orifice to the
receiving flask.
11. Cooling Coil Inlet Valve. Connect suitable cold water or refrigerated coolant for operation at near-ambient temperatures.
12. Overflow Outlet. Connect tubing from overflow outlet to a waste receptacle in case of oil expansion.
13. Cooling Coil Outlet Valve. Exit valve for coolant.
14. Bath Oil Draining Valve. To drain the oil from the unit place waste receptacle under the drain valve. In the open position,
the draincock will be parallel to the valve. When the bath is finished draining, close the draincock. In the closed position,
the draincock will be perpendicular to the valve.
15. Accessory Plug. Powers Stirrer Motor and Heating Coils. Must be disconnected when removing top plate to fill bath.
16. RS232 Port. For communication with an external PC. Using the Communication Port Cable supplied for the Saybolt
Viscosity Unit, connect the RS-232 port to a communication port on the PC.
17. Automatic Timing Display (SV4000 only). Displays time in seconds with an accuracy of 0.1s. Time starts when Sensor
on switch is pressed and stops when sample passes optical sensor mark on the receiving flask.
18. Reset Button (SV4000 only). Resets time to display zero. Timer will then be ready to perform another test.
19. Timer ON/OFF Switch (SV4000 only). Pressing this button to the ON position will automatically open the orifice valve
and start the timer. Upon completion of the test, pressing the switch to the OFF position closes the valve so the user can
load a subsequent test sample in the viscometer.

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4.2. Temperature Controller Operation
Figure 4. Temperature Controller
Item descriptions
1. Process Temperature Display. The upper white display shows the process temperature as read from the instruments
thermal sensing probe.
2. Set Point Temperature Display. The lower green display shows the set point temperature of the controller. (In menu
mode, it will show menu selection information)
3. Activity display indicators These symbols illuminate when ramp function, timer, and manual mode operations are in
use.
4. Digital output indicators These indicators show output status (yellow = active)
5. Up Increase setpoint value. (In menu mode, select menu item or increase value)
6. Down Decrease setpoint value. (In menu mode, select menu item or decrease value)
7. Back exit editing mode without change (in menu mode, return to previous menu level)
8. Menu/OK Call up main menu, switch to submenu/level, switch to editing mode, exit editing mode confirming changes.
IMPORTANT NOTE: The digital temperature controller has been pre-programmed specifically for this instrument at the
Koehler factory. Please do NOT attempt to re-program the controller as this may cause undesired operation and will void
the product warranty. If assistance is required, please do not hesitate to contact the Koehler technical service department.
Setting the Temperature. Set the desired operating temperature by pressing the up or down keys. The set point is displayed in
the lower green display. The green display will flash when the setpoint value is adjusted. Wait 5 seconds or press the Menu/OK
to confirm the change. “OK” will display briefly on the lower green display to confirm the adjustment. (Press the Back key to
discard the setpoint change while still flashing. The control will return to normal operation)
The instrument will then automatically adjust the temperature to the set value. Please allow the instrument to fully equilibrate
before proceeding with any testing.
Temperature Calibration. The below procedure allows the digital temperature control to be calibrated to a certified reference
thermometer.
a. Use a certified calibrated measuring device to acquire the temperature. Calculate the difference between the measuring
device and the Process value displayed on the controller.

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b. Press the Menu/OK key two times until PCt is displayed in the upper white display. Press the DOWN key. CAL will display
on upper white display. If there is a value observed in the upper white display, add it to the calculated difference obtained
in the previous step. This is the offset value.
c. Press the Menu/OK Key. The lower green display will flash. Use the up or down keys to adjust to the new calibration
offset value on the lower green display calculated in the previous step. When the value has been entered, the controller
will display OK on the lower display and store the value. The lower green display will stop flashing. If further adjustments
are necessary, press the Menu/OK key, then the up or down Keys again. Resume regular operations by pressing the
Back key two times. Verify if the new calibration is correct by observing the upper white display and comparing the value
with the calibrated reference device.
Auto Tune. The below procedure allows the digital temperature control to automatically learn the optimal heating P-I-D parameters
needed at a specific setpoint temperature. This operation should be performed to provide optimal bath temperature stability
when initially installing a new unit, after replacing or changing the bath medium type, or utilizing a different temperature set
point that is 20% different from the previously used set point temperature.
a. Set the operating temperature to the desired setting.
Press the up and down arrow buttons simultaneously for about 5 seconds. When Auto Tune is active, the lower green display will
scroll “Autotuning Active”. Auto Tune will automatically terminate when the tuning process is complete. Auto tune can be
terminated by pressing the up & down buttons simultaneously again.
4.3. Preparation of Apparatus (As Per ASTM D88)
1. Use a Universal orifice or tip for lubricants and distillates with efflux times greater than 32 seconds to give the desired
accuracy. Liquids with efflux times greater than 1000 seconds are not conveniently tested with this orifice.
2. Use a Furol orifice or tip for residual materials with efflux times greater than 25 seconds to give the desired accuracy.
The Saybolt Furol viscosity is approximately one tenth the Saybolt Universal viscosity and is recommended for
characterization of petroleum products such as fuel oils and residual materials having Saybolt Universal viscosities greater
than 1000 seconds.
3. Clean the viscometer thoroughly with an appropriate solvent of low toxicity; then remove all solvent from the viscometer
and its gallery. Clean the receiving flask in the same manner.
NOTE: The plunger commonly supplied with the viscometer should never be used for cleaning; its use might damage the
overflow rim and walls of the viscometer.
4. Set up the viscometer and bath in an area where they will not be exposed to drafts or rapid changes in air temperature,
and dust or vapors that might contaminate a sample.
5. Place the receiving flask beneath the viscometer so that the graduation mark on the flask is from 100-130 mm (4 to 5
inches) below the bottom of the viscometer tube and so that the stream of oil will jus strike the neck of the flask.
6. Fill the bath to at least 6 mm (1/4 inch) above the overflow rim of the viscometer with an appropriate bath medium.
7. Provide adequate stirring and thermal control for the bath so that the temperature of a test sample in the viscometer will
not vary more than +/- 0.03°C (+/- 0.05°F) after reaching the selected test temperature.
8. Do not make viscosity measurements at temperatures below the dew point of the room’s atmosphere.
9. For calibration and referee tests, keep the room temperature between 20 and 30°C (68 and 86°F) and record the actual
temperature. However room temperatures up to 38°C (100°F) will not introduce errors in excess of 1%.

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5. Operation
1. Remove the four binding post knobs on top of the bath. Remove the plug from behind the bath which is connected to
the terminal box. Gently remove the cover, making sure not to damage the heaters or stirrer shaft and place it in a safe
location.
2. Choose an appropriate viscometer tube. Remove the nut provided from the viscometer tube to be used. Install an orifice
into the bottom of the viscometer tube and tighten with the provided orifice wrench.
3. Insert a viscometer tube into one of the holes inside the bath. Be sure to place the lead gaskets between the top and
bottom surfaces of the tank. Screw on the nut from underneath the tank and tighten with the provided socket wrench. Up
to four viscometer tubes may be used
NOTE: If only two viscometer tubes are to be used, close off the two remaining holes with the two provided port closures
and tighten with the socket wrench. Be sure to place the Teflon gaskets between the top and the bottom surfaces of the
tank.
4. Fill the bath with oil (recommended by the test method) 1.5” from the top of the bath. Never turn the power ON unless
there is bath medium present otherwise the heaters will burn out which will automatically void the warranty. Do not let
any “bath” oil fall into the viscometer tubes.
5. Reinstall the cover on top of the bath into the screws and replace the two binding posts.
6. Place the port covers over the port holes.
7. Connect the plug from the terminal box into the back of the unit.
8. Install the RTD probe into the holder located on the right side on top of the bath.
9. Install a calibrated thermometer into the holder (cork) located in the center at the top of the bath.
10. Connect tubing from the overflow outlet (middle valve) located in the rear of the unit to a waste receptacle in case of oil
expansion.
11. Connect tubing to the cooling coil valves, located in the back of the instrument, to a suitable cold water supply (only if
needed).
12. Turn the Line and Light switches to ON.
13. To set to the desired temperature, use the UP/DOWN keys to set the temperature. After a few seconds, the
microprocessor will start the heater.
14. Place the chained corks into the bottom of the viscometer tubes.
15. Place the 60mL Pyrex™ receiving flask underneath the bath in the spaces provided, making sure the graduation marks
on the flasks are visible.
16. When the test temperature is stabilized, proceed to test in accordance with any of the test methods specified in Section
1.2.
For SV4000 Models only
17. Reset the timer on the auto timer using the red reset button.
18. Press the start/stop button on the auto timer to start the test. When the button is switched to start, the sample will flow
through the orifice and the timer will begin timing. The timer will automatically stop when 60mL of the sample has been
collected in the receiver flask.
19. Allow the entire contents of the reservoir to empty before switching of the start/stop button.
20. Record the value in seconds of the test results. Then, prepare the viscometer for the next test.

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6. Maintenance
WARNING: Disconnect power to the unit before servicing and accessing any internal portion of the instrument 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, then please do not hesitate to contact the Koehler technical service department.
6.1. Routine Maintenance
The SV3000 and SV4000 Saybolt Viscometer Baths require 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. Bath Maintenance
Replace the oil in the bath when the color turns light to medium brown to avoid unwanted oil expansion. To drain the oil from the
unit, place a sufficient waste receptacle under the drain located in the back of the unit. In the open position, the draincock will be
parallel to the valve. When the bath is finished draining, close the draincock. In the closed position, the draincock will be
perpendicular to the valve.
SHOCK AND BURN HAZARD: Only clean inside the bath when equipment is de-energized and unplugged from the
mains power supply. Allow adequate time for heating coils to completely cool before cleaning.
6.3. Replacement Parts
115V Models (K21410, K21414 only)
220-240V Models (K21420, K21424 only)
Part Number
Replacement Part
Part Number
Replacement Part
240-115-008
Ballast, 120V, 60Hz
240-230-014
Ballast, 230V, 50/60Hz
K21410-0-15
Heater, 1200W, 115V
K21420-0-15
Heater, 1200W, 230V
All Models (K21410, K21414, K21420, & K21424)
Part Number
Replacement Part
Part Number
Replacement Part
K22060
Oil Strainer
265-600-001
RTD Probe, 0.25’’ x 4’’, 600F, Over
Temperature
K214-0-29
Chained Corks
K214-0-31
Port Closure
K22090
Withdrawing Tube with Rubber Bulb
K22050
Socket Wrench
K22011
Thermometer Holder
275-103-047
Temperature Controller
K215-3
Teflon Gasket
279-115-002
Fluorescent Lamp
K215-6
#5 Thermometer/Probe Holder (cork)
K70519
RTD Probe Assembly, Bath
Temperature
K00303-23001
Stirrer Motor, 115/230V

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7. Wiring Diagrams
7.1. K21410 (115V Model)

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7.2. K21420 (230V Model)

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7.3. K21414 (115V Timer Model)

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7.4. K21424 (230V Timer Model)