Koehler ADA5000 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: [email protected]
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
ADA5000
Automatic Distillation Analyzer

ADA5000 Automatic Distillation Analyzer
Operation and Instruction Manual
ADA5000-Manual - 1 -
Table of Contents
1Int roduction........................................................................................1
1.1 Koehler’s Commitment to Our Customers...........................................1
1.2 Recommended Resources and Publications.......................................1
1.3 Instrument Specifications .................................................................... 2
1.4 Software Specifications.......................................................................2
2Safety Information and Warnings......................................................2
3Unpacking & Installation ....................................................................3
3.1 Packing List.........................................................................................3
3.2 Unpacking............................................................................................ 3
3.3 Instrument Installation ......................................................................... 3
3.4 Software Installation............................................................................3
4Operation.............................................................................................7
4.1 Description of Instrument Controls......................................................7
4.2 Instrument Operation...........................................................................7
4.3 Communication Manager ....................................................................8
4.4 Distillation Control.............................................................................. 10
4.5 Current Program................................................................................12
4.6 Diskstat.exe.......................................................................................16
4.7 Config.exe .........................................................................................16
4.8 ComMgr.............................................................................................17
4.9 DistCntl..............................................................................................17
5Safety Features .................................................................................17
5.1 Flask Heater Compartment and Auto Fire Extinguisher....................17
6Maintenance ......................................................................................18
6.1 Routine Maintenance.........................................................................18
6.2 Replacement Parts............................................................................18
7Service ...............................................................................................19
8Storage...............................................................................................19
9Warranty.............................................................................................19
10 Returned Goods Policy.....................................................................19

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1 Introduction
The Koehler Automatic Distillation Analyzer is
designed to perform optimal distillation analysis
of gasolines, fuels, oils, solvents, aromatics,
napthas, kerosenes, hydrocarbons, and other
volatile products to ensure conformity to rigid
quality control standards. The analyzer
automatically performs tests, process results,
and produce standard reports according to
ASTM, ISO, and related specifications.
This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and
operating instructions for the Automatic
Distillation Analyzer. 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: [email protected]
ASTM Publication:
ASTM D86:
ASTM D285:
ASTM D850:
ASTM D1078:
ASTM D4737:
ASTM D189 Section 10:
2. International Organization for
Standardization (ISO)
1, rue de Varembé
Case postale 56
CH-1211 Geneva 20, Switzerland
Tel: [phone]
Fax: [phone]
http://www.iso.org
ISO Publication:
ISO 3405:
3. 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:
4. Deutsche International Norm (DIN)
http://www.din.de
DIN Publication:
DIN 51751:
5. Association Française de Normalisation
(AFNOR)
http://www.afnor.fr
AFNOR Publication:
NF M 07-002
6. Japanese Industrial Standards(JIS)
http://www.jisc.go.jp
JIS Publication:
JIS J2254I

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1.3 Instrument Specifications
Models: K45603, K45604
K45703-TS, K45704-TS
Electrical Requirements: 120VAC ± 5%, 50/60Hz
230VAC ± 5%, 50/60Hz
Distillation Range: 0 - 450°C (±0.1°C)
Condenser: -5 to 60°C (±0.1°C)
Receiver Chamber: 0 to 60 C (±0.1°C)
Distillation Rate: 2-15 mL/min in 0.01mL
increments
Receiver Volume: 0 to 100 mL
Barometric Pressure: 550 to 900 mm Hg (±1 mm Hg)
Dimensions (l x w x h) 21 x 21.5 x 27 in (53.3 x 54.6 x
70.5 cm)
Net Weight: 200 lbs (91kg)
Operational Conditions: 0-45°C (32 to 113°F)
1.4 Software Specifications
PC System
Requirements:
Intel Pentium III Processor or
similar (minimum)
Operating System: Windows 98/XP
Memory
Requirements:
128 Mb RAM
4Gb hard drive
Communication Ports: RS-232 (serial), USB, RJ45
(Ethernet)
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.
Internal Access. If internal access into the
instrument is necessary, the analyzer must be
disconnected from the main power supply
otherwise electrical hazards may be
experienced. Be extremely careful because of
electrical shock and danger of personal injury.
Unit Design. This equipment is specifically
designed for use in accordance with the
applicable standard test methods listed in
section 1.2 of the operator’s 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.
Fire Safety. This equipment is designed with
an automatic fire extinguishing system. The
system must be checked periodically for proper
operation.
Troubleshooting. In the case of
troubleshooting the instrument, it is important to
be careful with the electronic boards. They are
static sensitive and it is absolutely necessary
that the operator has to be grounded before
touching the boards.
Overtemperature Protection. This unit is
equipped with Overtemperature Protection
(OTP) circuitry to prevent overheating. The unit
will automatically interrupt power whether
equipment malfunction or operator error causes
the temperature to exceed the maximum
recommended temperature range. The power
can only then be restored by identifying and
correcting the problem, allowing the unit to
return to normal operating temperatures, and
resetting the power to the unit.
Heater Element. The heater element (heating
coil) of the distillation unit, installed in the
heating area within the flask support has to be
inspected at least every 3 months. If any short
circuits of the windings are observed, it is
necessary to use a new heater element. It is
important to do this exchange very carefully. The
windings must not have a short circuit and need
to be adjusted carefully before operation. Do
NOT touch the heater element after a distillation
run. The element could still be extremely hot and
one could experience personal injuries.

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Ice Formation. Selecting low temperatures in
the receiver chamber with level follower system
for distillation groups 0,1,2,3 may produce ice on
the pipes of the air-heat exchanger system. Ice
could decrease the efficiency of cooling and
could effect damages to the exchanger. In case
of ice, it is absolutely necessary to thaw out the
pipes.
3 Unpacking & Installation
The instruction for preparing this equipment
assumes that the user is aware of the contents
of this document, which lists the warranty
conditions and important precautions.
3.1 Packing List
Please refer to the shipping documents for the
Automatic Distillation Analyzer regarding items
included on the packing list.
3.2 Unpacking
Carefully unpack and place the instrument and
accessories in a secure location. Ensure that all
parts listed in the previous section are present.
Inspect the unit and all accessories for damage.
If you find any damage, 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 Instrument Installation
Equipment Placement: Unit must be set on a
firm and stable bench capable of supporting at
least 250 lbs. It is advisable to place the unit in a
location with sufficient ventilation, preferably an
exhaust hood. Locate the unit in a non-corrosive
atmosphere. Room temperature must be below
86°F.
Electrical: Determine the electrical
requirements of the model distillation unit to be
installed. Measure the voltage supply for the
unit’s location and determine if it is correct.
Requirements for the different models are:
K45603, K45703-TS: 120VAC +/- 5%
50/60Hz, 20A
K45604, K45704-TS: 230VAC +/- 5%
50/60Hz, 10A
Nitrogen: Nitrogen must be available in order
for the automatic fire extinguishing system to
work. Connect a ¼” line capable of withstanding
100psi to the valve located in the top/back of the
unit. Adjust the line pressure to 70psi.
PC: If an external PC is to be used, locate within
50 ft of the first distillation unit to be connected
(See figure below). Connect to the unit by
RS232 cable. If PC does not have a COM Port
available, use a USB to Serial adapter cable.
Connect cable from the PC to the 25 pin PC
Adapter Plug that connects to the 25 pin
connector at the distillation unit. This adapter
MUST be installed for communications to work.
If multiple units are being installed, the units
must have a RS232 cable connected in daisy
chain to each unit in series.
Set/verify the address of the unit if multiple units
are to be installed. See section in Descriptions
for setting Unit Address.
Connect printer and proceed to install software.
3.4 Software Installation
If the distillation software is not pre-installed,
then insert the CD-ROM into the CD tray of the
PC. The CD should automatically display the
setup screen. If this does not happen within 10
seconds, then browse the files on the CD-ROM
and double click on the setup file (setup.exe) to
start the installation. Follow the instructions on
the screen to setup the software. The setup
program will require the PC to be restarted at
the end of the installation. Please close any
open programs before installing. The next
several pages will guide you through the
software installation process. Once the
installation has been completed, then you are
ready to run the software.
Note that on the K457XX-TS models, the
software is preloaded and the touch screen has
been calibrated at the factory. If you need to
recalibrate the screen, the calibration utility can
be accessed by clicking on Start >> All
Programs >> Fujitsu Touch Panel >> Touch
Screen Calibration Utility, as shown in Figure

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Software installation screen prompts:
Click on the “Next” button.
Click on the “Next” button.
Please confirm acceptance of the licensing
agreement by clicking on the “Yes” button.
Confirm that the computer meets these
minimum requirements and click on the “Next”
button.
Enter the name and company information of the
user. To utilize the software as a registered
version, please type in the company information
exactly as written on the software CD. Continue
by clicking on the “Next” button.
Utilize the default directory C:\Program
Files\Koehler. Click on the “Next” button to
continue.

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Utilize the default data directory C:\Program
Files\Koehler\data. Click on the “Next” button to
continue. Then, select “Custom” to copy all
programs and a demo database. Click the “Next”
button to continue.
Verify that all each box of the four components
are checked and click on the “Next” button.
Select or create a folder the add program icons
to. Click “Next” to continue.
Review the program settings. Click “Next” to
continue.
Wait while the setup program installs the needed
program files.
The setup program will require the PC to be
restarted after installation. Please select the
radio button next to “Yes” and then click on the
“finish button to restart.

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Restarting the program will create a folder with
shortcuts for the various programs used to
operate the distillation unit. Also, upon restart,
the “Config” program will start automatically, and
you will be prompted to enter a username and
password.
The default username is “admin” and the default
password in “admin”.
From the “Config” program, you can configure
your system. After installation it is possible to
run this program and to change parameters as
necessary. Only use this program to change
parameters, and do not try to make changes in
the registry directly.
Select the “General” tab at the top of the screen.
It is not recommended to alter the various paths;
please consult with Koehler technical service.
To change the units for temperature (1) and
pressure (2), select the desired units by clicking
on the corresponding radio buttons.
Registration (3). For demonstration you can
input “DEMO” in the company and serial number
fields. Upon starting the program, it will display
“Demo Version”. To register the program,
please input the company name and the serial
number exactly as listed on the registration code
on the CD label. It is important to input the
company name and serial number exactly as
written; note that these inputs are case-
sensitive. If not, an error message will appear
when starting Commgr.exe that the software
isn’t correctly registered.
Click on the “ComMgr” tab. Select which
analyzer is connected to the PC (1). If the
“AutoSave” and “AutoPrint” features are desired,
select accordingly for each item (2). Also, select
the communication port where the first analyzer
is connected (3).

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Click on the “Adjust” tab. Set the “Adjust
Interval” to the desired interval for displaying a
reminder of when the system should be
calibrated.
Congratulations, the installation is finished.
4 Operation
The Koehler Automatic Distillation Analyzer is
designed for acquiring test data in accordance
with the ASTM D86 and related test
specifications. Please be sure to read the safety
and hazard warnings, the installation procedure,
and the standard test method before operating
the instrument and it’s software.
4.1 Description of Instrument
Controls
1. Centering Stopper with PT100 probe
2. Distillation Flask
3. Stage Height Adjustment Knob
4. Control Buttons:
Power
Status
Start
Stop
Coolant Level Warning Light
5. Fire Extinguisher
6. Built in Touch Screen (K457XX-TS
models only)
7. Receiver Chamber
4.2 Instrument Operation
1. Power. Turn on the main power switch to
the unit. Turn on the power switches on the
PC and printer, if applicable. Note, the
internal computer on the K457XX-TS
models has a separate power switch and
must be powered on and off independently
of the rest of the unit.
2. Software. After the PC has been properly
booted, start the distillation software
program by double clicking on the Koehler
icon located on the computer desktop and
set up the parameters as needed.
3. User Setup. In order to enter user accounts
in the distillation software, go to
C:\Programfiles\Koehler\bin\ConfigPW.exe.
The software will prompt for a username and
password to enter this function. The default
username is “admin’ and the default
password is “admin”. Use the “+” and “–“
buttons to add and delete users along with
their passwords and level access. Note, in
order to save a new user to the memory, the
“+” must be selected again.
Access Levels:
3 Highest Access
2 Modification of test parameters only
1 No changes possible to test parameters, only
operation of unit as already programmed.