Koehler SV4000 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
SV4000
Saybolt Viscosity Bath
for Automatic Viscosity Timing

CERTIFICATE OF CONFORMANCE
Constant Temperature Saybolt Viscosity Bath, SV4000
K214X4
This certificate verifies that part number K214X4, Constant Temperature 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.
Jesse Kelly
Application Engineer
Koehler Instrument Company

SV4000 Saybolt Viscosity Bath for Automatic Viscosity Timing
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....................................................................................................................... 3
1.4 Software Specifications..........................................................................................................................3
2. Safety Information and Warnings.................................................................................3
3. Getting Started...............................................................................................................3
3.1 Packing List............................................................................................................................................ 3
3.2 Additional Accessories Required for Performing Tests ......................................................................... 4
3.3 Unpacking .............................................................................................................................................. 4
3.4 Setup......................................................................................................................................................4
4. Descriptions ..................................................................................................................5
4.1 Instrument Descriptions .........................................................................................................................5
4.2 Digital Temperature Control................................................................................................................... 6
4.3 Preparation of Apparatus.......................................................................................................................7
5. Operation .......................................................................................................................8
6. Maintenance...................................................................................................................8
6.1 Routine Maintenance.............................................................................................................................9
6.2 Bath Maintenance..................................................................................................................................9
6.3 Spare Parts ............................................................................................................................................9
7. Wiring Diagrams ..........................................................................................................10
7.1 K21414 (115V) Model..........................................................................................................................10
7.2 K21424 (220-240V) Model...................................................................................................................11
8. Flow Chart for K21404 (Timing Sensor 115V)............................................................12
9. Troubleshooting...........................................................................................................13
10.Service..........................................................................................................................13
11.Storage .........................................................................................................................13
12.Warranty .......................................................................................................................13
13.Returned Goods Policy ...............................................................................................13
Notes..................................................................................................................................14
Notes..................................................................................................................................15

SV4000 Saybolt Viscosity Bath for Automatic Viscosity Timing
Operation and Instruction Manual
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1. Introduction
The Koehler SV4000 Saybolt Viscosity Bath
for Automatic Viscosity Timing is the latest
design for determining viscosity using saybolt
viscometer tubes and orifices equipped with
automatic timing sensors. The bath can be set
for operating temperatures from ambient to
240°C (464°F). It is equipped with an internal
cooling coil that when connected to an external
cooling source, can be utilized for rapid cooling
of the bath medium and for operation at near-
ambient temperatures.
This 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 Viscosity
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
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
E-mail: [e-mail]
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: [e-mail]
AASHTO Publication:
AASHTO T72: Standard Method of Test for
Saybolt Viscosity
3. Federal Test Method (FTM)
FTM Publication:
FTM 791-304

SV4000 Saybolt Viscosity Bath for Automatic Viscosity Timing
Operation and Instruction Manual
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1.3 Instrument Specifications
Models:
K21414
K21424
Electrical
Requirements:
115V 60Hz 12.3A
220-240 V 50/60Hz 6.4A
Temperature
Range:
Ambient to 240°C (464°F)
Temperature
Accuracy:
+/- 0.03°C (0.05°F)
Capacity:
Four viscometer tubes
Bath Capacity:
5 gal (19L)
Dimensions:
29x25x33 in.
(74 x 63.5 x 84cm)
Net Weight:
65 lbs (30 kg)
Gross Weight:
82 lbs (37kg)
1.4 Software Specifications
PC System
Requirements:
Intel® Pentium II
Processor or similar
(minimum)
Operating System:
Windows® 98 SE,
2000, NT, XP
Memory
Requirements:
64Mb RAM (128Mb
RAM recommended)
Disk Space:
30Mb free space
(minimum)
Communication
Ports:
One RS 232 port for
temperature controller
Other Software:
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 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
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
SV4000 Saybolt Viscosity Bath
(K21414/K21424)
Automatic Saybolt Viscosity Timing Sensor,
K21404:115V 60Hz
K21494:220-240V 50/60Hz
NOTE: Each port can accommodate one sensor for
automatic timing operation on SV4000 Saybolt Viscosity
Bath. Number of Timing Sensors equipped based on
original sales order.
Saybolt Viscosity Software V 1.4 CD
NOTE: Must be purchased separately
K22011 Thermometer Supports (4)
K22060 Oil Strainer
K22050 Tube Nut (Socket) Wrench

SV4000 Saybolt Viscosity Bath for Automatic Viscosity Timing
Operation and Instruction Manual
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K214-7 Port Closures (2)
K22070 Cleaning Plunger
K214-0-29 Chained Corks (4)
K22090 Withdrawal Tube
K22030 Orifice Wrench
K214-0-27 Port Covers (4)
K21410-0-10 Draft Shield (2)
3.2 Additional Accessories Required
for Performing Tests
Part Number
Description
355-001-002
Silicone heat transfer fluid-
1 gallon container.
Order quantity 5 per bath
355-001-004
Silicone heat transfer fluid-
5 gallon container.
Order quantity 1 per bath
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.
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
bath is filled with the proper medium; otherwise
damage may occur to the unit and the warranty
will be void.
Auto Timer Feature. 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.
Figure 1: Optical Sensor Pin Cord Connection

SV4000 Saybolt Viscosity Bath for Automatic Viscosity Timing
Operation and Instruction Manual
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4. Descriptions
4.1 Instrument Descriptions
Figure 14: Instrument Descriptions_Front
1. Lamp: Operates the viewing lamp.
2. Digital Temperature Controller: See
Section 4.2 for full operation details.
3. Line Switch: Controls power for all the
components of the instrument.
4. Receiving Flask: Place under Saybolt
Orifice to collect test sample. 60mL
graduation mark on flask neck indicates end
of test. Align optical sensor with graduation
mark to automatic stop timing after 60mL of
sample is received.
5. Viscometer Port: Bath capacity allows for
up to four viscometer tubes to be installed
and run tests simultaneously.
6. Motor: Constantly stirs medium for bath
temperature uniformity.
7. Temperature Probe: Stainless Steel RTD
probe for temperature measurement of bath.
Communicates directly with temperature
controller.
8. Thermometer Port: Additional opening in
bath for temperature verification and
calibration using a certified thermometer or
temperature simulator.
9. Automatic Timing Display: 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.
10. Reset Button: Resets time to display zero.
Timer will then be ready to perform another
test.
11. Timer ON/OFF Switch: 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.
Figure 15: Instrument Descriptions_Back
12. Line Cord: Connect the line cord to a
properly fused and grounded receptacle with
the correct voltage as indicated in section
1.3 or on the serial plate on the back of the
unit.
13. RS232 Port: For connection to external PC
for data acquisition.
14. Motor Cord: Connects motor to control
panel. Motor powers on when the line switch
to the entire unit is turned on.

SV4000 Saybolt Viscosity Bath for Automatic Viscosity Timing
Operation and Instruction Manual
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15. RTD Temperature Probe Port: Connects
RTD Temperature probe to control panel.
Temperature probe plug is connected to this
port to ensure communication between the
temperature controller and the probe.
16. Optical Sensor Pin Cord: Connect cord to
port to provide power to the optical sensor
assemblies on the front of the unit.
17. Drain Valve: For draining the medium from
the viscometer bath to change or clean.
18. Cooling Coil Inlet: Connect to Cold Water
Supply or Refrigerated Recirculator for near
and sub-ambient testing or rapid cooling of
bath medium.
19. Overflow Port: Provides isolation point for
bath medium to overflow in the event it rises
above bath limit.
20. Cooling Coil Outlet: Connect to Laboratory
sink drain or refrigerated recirculator inlet.
4.2 Digital Temperature Control
Figure 4. Temperature Controller
1. Process Temperature Display. The
upper red LED display shows the
process temperature as read from the
RTD probe.
2. Set Point Temperature Display. The
lower green LED display shows the set
point temperature of the controller.
3. Programming Key. Permits scrolling
through controller menu parameters.
One Level Forward
4. Down Key. Used to decrease the set
point temperature and to decrease or
change parameter values when
programming the temperature controller.
5. Up Key. Used to increase the set point
temperature and to increase or change
parameter values when programming
the temperature controller.
6. Exit / Function Key. This key is used to
exit or leave a level. One level backward
IMPORTANT NOTE: The digital
temperature controller for the unit
comes pre-programmed from the
Koehler factory. Please do NOT attempt
to re-program the digital temperature
controller as this 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 adjusting the set
point with the up and down keys. The set
point will be displayed in the lower green Set
Point LED display and the actual
temperature will be displayed in the upper
red Process LED display. Please allow the
instrument to fully equilibrate before
proceeding with any testing.
Temperature Calibration. This routine allows
the digital temperature controller to be
calibrated to a certified 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.
b. Press the program key two times until
PCt is displayed in the lower green LED
display. Press the DOWN key. CAL will
display on the lower green display. If
there is a value observed in the upper