Koehler K16175 User manual

K16175
Fully Automatic Liquid Dielectric Portable
Breakdown Analyzer for Oil
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

Copyright © 2008 Koehler Instrument Company, Inc. All rights reserved.
No part of this publication may be reproduced, transmitted, stored, or translated in hardcopy or
electronic form without the written consent of Koehler Instrument Company, Inc,.
NOTE:
The information presented in this instruction manual is believed to be accurate and correct for the
intended use of this product. Should this instrument be used for other applications and purposes not
covered herein, please contact Koehler Instrument Company, Inc to validate its suitability.
This manual, all of its contents and the instruments specifications are subject to change without notice.
Windows®, Windows 2000®, Windows XP® are registered trademarks of Microsoft Corporation.
Bluetooth® and the Bluetooth Label are owned by the Bluetooth SIG, Inc.
PDF and the Adobe Acrobat Family of Software are trademarks of Adobe Inc.
Operating Manual K16175 1

Warranty Terms
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.
Operating Manual K16175 2

Safety Precautions and Prerequisites
All test instruments should be correctly grounded during operation.
Do not install substitute parts or make unauthorized modifications to the test instrument or its accessories as
this may introduce additional risks and unknown hazards.
To ensure that all safety features in the instrument are maintained, it is strongly recommended that all repairs
and modifications be performed by Koehler Instrument Company, or one of their authorized repair service
centers.
Before using this test instrument, please read through the operating manual in its entirety. Make sure you
clarify any points that you feel unsure or uncertain about before using the instrument. Make sure you are
knowledgeable about the proper application, safety, potential hazards involved, and procedures in using the
test instrument.
The awareness for safety is an integral part of the job, and it cannot be over emphasized. Safety is the
responsibility of the user/operator.
The instrument should not be used to test insulation liquids with flash points < 110°C or 230 °F
This manual does not purport to address the issues of sampling to obtain a true representative sample of the
liquid dielectric to be tested. However correct sampling of oil is one of the most underestimated and often
overlooked issues that can impact the results of dielectric testing.
In general the sample should be transported in a clean, dry, non-permeable container. The container should be
sealed and shielded from light sources until it is ready to be tested. Clean, dry, darkened glass and sealable
containers, although not always practical in the field due to ease of breakage, are believed to be the best option
for housing the liquid sample. Plastic bottles although commonly used, are not recommended for the purposes
of housing the liquid dielectrics, particular for long periods of time as they are generally permeable and can
impact the results of the dielectric properties of the sample.
For further more detailed information please refer to guides and standards such as ASTM D923 that cover oil
sampling procedures.
Test vessels that house the oil during testing should be kept clean at all times. The cell and the electrodes should
be cleaned using lint-free wipes and a suitable solvent such as hexane,
heptane or petroleum ether. Care should be taking to ensure that all the solvent is removed from the cell before
performing any high voltage tests on the test vessel.
It is important to avoid touching the electrodes with bare fingers. It is recommended that powder free latex/
nitrile surgical gloves be used when handling the test vessel, oil and/or electrodes.
When the test vessels are not in use or being transported, it is recommended to store the cell with new oil in the
vessel. Discard this oil before the next use.
Operating Manual K16175 3

Contents
Safety Precautions and Prerequisites ... ...3
Unpacking the Instrument ... ...5
Introduction: ... .6
Specifications: ... ..8
Equipment Layout ... ..9
Test Vessel Layout Options ... ...10
Installation / Setup of Instrument ... ...11
Control Panel / User Interface ... .12
Powering Up the Instrument ... ...13
Test Sample and Test Vessel Preparation: ... ...13
Running a Test Standard ... .14
Running a Single Test ... ..16
Instrument Settings ... ...18
Replacing Printer Paper Roll: ... ...19
Replacing Printer Ink Ribbon: ... .21
Troubleshooting: ... .22
NOTES: ... ..23
Operating Manual K16175 4

Unpacking the Instrument
The instrument is packed in a well protected
padded box. On either side of instrument there
are padded foam inserts that mold themselves
around the instrument.
NOTE: To remove the instrument, grasp
the instrument on the back and the front as
indicated and remove the instrument. DO NOT
lift the instrument up by the side foam inserts
as they may shift away from the instrument
causing the instrument to fall. This may
result in injury to persons or damage to the
instrument.
While holding the instrument as shown, place
the instrument with foam packing side inserts
still attached onto a sturdy desk.
Carefully now remove one of the foam
inserts from one side, supporting the base
of the instrument so that is not no fall. Then
remove the other foam insert from the other
side of the instrument.
The instrument should now be standing on
its own on the desk.
Check if there is any transport damage to
the instrument. If there is, please notify
the shipping company and the supplier. Do
not discard the packing material if there
is damage to the instrument as it may be
required for insurance purposes.
Store the packing material for future Padded Foam
shipping / transportation requirements that Inserts
you may have.
Operating Manual K16175 5

INTRODUCTION:
The new Breakdown Analyzer Series of fully automatic oil testers are designed to measure the
breakdown strength of liquid dielectrics such as insulation oils used in electrical apparatus like
transformers, tap changers, circuit breakers, cables etc.
One of the properties used to determine the condition of an dielectric material is the measurement of
the dielectric strength of that material. The dielectric strength is the voltage at which the dielectric
can no longer sustain an applied electrical stress, resulting in a small arc or breakdown and a resulting
collapse of the applied voltage. The maximum RMS voltage at which the breakdown occurs is called the
breakdown strength or dielectric strength of the material. The applied voltage is AC and is in the power
frequency range. The applied voltage is increase at predetermined rates and is generally applied across
two electrodes. The liquid insulation oil being tested is placed inside a test vessel, filling the area in and
around the two electrodes. The higher the dielectric breakdown values, the better the dielectric properties
of the oil. Likewise, low dielectric breakdown values often indicate the presence of contamination and/or
degradation of the oil.
Dielectric breakdowns of insulation materials is a statistical process and can depend on several factors.
Various standards around the world exist that specify the procedures, hardware, reporting etc required to
perform these tests. These standards specify the numbers of test breakdowns to be performed, rate of rise of
voltage, timing sequences, cell and electrode configuration, test limits and ranges.
The oil testers are fully automatic and apart from filling up the test cell and ensuring the gap spacing
between the electrodes is according to the specified standard, the complete test routine is automatically
performed by the test instrument.
It is important to limit the energy into the breakdown. If too much energy is released during the breakdown,
degradation of the oil can occur and this may result and this may result in the following breakdown values
been influenced by any prior breakdowns in the oil. This is particularly true for silicon based insulation oils.
The oil tester limits this energy into the liquid sample by limiting the time and current allowed to flow once
the breakdown occurs.
Operating Manual K16175 6

DELIVERY OPTIONS
The following Items are supplied with the K16175 test instrument:
Description
Fully Automatic Portable Liquid Dielectric Oil Tester Model K16175
Including: Integrated Printer
User Manual
Calibration Sheet
Mains Power Cable
Other Options Accessories Include
Rugged ATA Approved Transport / Shipping Case
Protective Dust Cover
Ring Nut Wrench for Test Vessels
12V DC Power Supply Lead for connecting to a vehicle battery via cigarette
lighter socket (5m/15 ft)
Printer Ribbon for integrated printer (Usually Black)
Paper Roll for integrated printer
Setting Gauge 1mm
Setting Gauge 2mm
Setting Gauge 2.5mm / 0.1”
Setting Gauge 4mm
Setting Gauge 5mm
Test Vessel ASTM D1816 (0.4L) - comes complete with 1mm or 2mm spacer
gauge (Customer to Specify)
Test Vessel ASTM D877 (0.4L) - comes complete with 2.54mm/0.1”spacer gauge
Test Vessel IEC 156 Fig I (0.4L) - comes complete with 2.5mm spacer gauge,
magnetic stirrer and lifting stick for magnetic stirrer
Test Vessel IEC 156 Fig II (0.4L) - comes complete with 2.5mm spacer gauge,
magnetic stirrer and lifting stick for magnetic stirrer
Pair of Electrodes for ASTM D1816 / IEC 156 Fig. II (“VDE” Electrodes)
Pair of Electrodes for ASTM D877
Pair of Electrodes for IEC 156 Fig. I
Operating Manual K16175 7

Specifications:
Output Voltage
Voltage measurement accuracy
Voltage slew rate
Resolution (displayed)
Power supply External
Power consumption
Internal rechargeable battery
Switch-off Time On flashover
Measurement of oil temperature
Temperature Resolution
Display
Selectable Programs
Custom Specific Programmable
Automatic Test Sequences
PC Software
Printer
Printer Paper
Communication Interface
USB interface
Operating temperature
Storage temperature
Relative humidity
Dimensions W x H x D
Weight
Operating Manual K16175
Up to 75kV RMS symmetrical
0 … 75 kV ±1 kV
0.5…10 kV/s
0.1 kV
85 V … 264 V (47 Hz … 63 Hz) - AC Shore Power
12V External Supply from a vehicle cigarette lighter socket
(optional)
60 VA
1 x 12V / 7.2Ah (Allowing approximately 12 hours of
continuous use and 36 hours on standby)
< 5 μs Ultrafast, low energy breakdown interruption. 0…100
°C (32 … 212 °F)
1 °C (1.8 °F)
2.8”color ultra bright display
ASTM1816-04-1, ASTM1816-04-2, , ASTM877-02A, ASTM877-
02B, AS1767.2.1, BS EN60156, CEI EN, 60156,
IEC 156/95,
IRAM 2341/72,
JIS C2101/78, MSZ 20880/74, NBN C27-002, NEN 10 156,
NF EN60156, ÖVE EN60156, PA SEV EN60156, PN77/E-
04408, RVHP 1985, SABS EN60156, VDE370-5/96, UNE 21
309/70, UNE EN60156, UTE C27-221/74
Up to 20 user defined sequences
“K16175 Control Center”
Integrated Dot Matrix Printer
Standard 44.5 mm wide plain paper roll
Bluetooth ®
USB memory stick
-5 °C … 45 °C / 23 °F … 113 °F
-20 °C… +60 °C / -4°F… +140 °F
Non condensing
430 x 280 x 250mm / 16.9“ x 11“ x 9.85“ inches
22kg /48.5 lbs
8

Equipment Layout
Hinged Lid with
safety interlocks
Screen high voltage
chamber housing
the Test Vessel
On/Off
Button
Control Cursor
OK
Integrated Printer
Operating Manual K16175 9
Ultra-bright
Vibrant Color
Display
Carrying Handle
Auto Sensing
Variable AC Power
Input & 12V DC
Aux. Power Input
USB Flash Memory Drive
& Bluetooth Communication
Interface

Test Vessel Layout Options
ASTM D 1816
ASTM D1816 (0.4 L)
ASTM D 877
ASTM D877 (0.4 L)
IEC 1 5 6 Fig I
IEC 156 Fig I (0.4 L)
IEC 1 5 6 Fig II
IEC 156 Fig II (0.4 L)
Operating Manual K16175 10

Installation / Setup of Instrument
The instrument should be installed in dust free environment.
Allow sufficient space around the instrument for ventilation and moving of the mechanical parts such as
the lid opening etc.
The relative humidity should ideally be less than 90% and non-condensing. Ambient temperatures
should be -5 °C to 45 °C or 23 °F to 113 °F for operating the instrument.
Avoid excessive vibration.
Grounding: There is a ground screw at the back of the instrument next to the 12V DC input plug.
Connect a suitable earth to this location.
When connected to AC shore power make sure that the voltage input levels are as per the input
specifications. It is recommended to use an AC plug with a ground contact / prong. During AC power
input operation, the integrated battery will be in charging mode.
When connected to a DC 12V vehicle supply, make sure to use the optional cable supplied from the
manufacturer. Note: Integrated battery does not charge during external DC power input operation.
Operating Manual K16175 11

Control Panel / User Interface
ON / OFF Button:
To turn on the instrument, press the button for about 0.5-1 seconds.
To turn off the instrument, press and hold the off button for about 5
seconds.
Control Input: The “Click Wheel”.
The click wheel allows a simple, yet very effective user interface. In
general, clicking (pressing down momentarily) the OK button is
similar to clicking a ENTER or Select key on conventional
OK
Test Report Printout
Keyboards etc.
Pressing the Left / Right / Up / Down arrow keys allows for
navigating through the various menu options. In addition these keys
allow for changing the values or states of certain functions, such as
changing the date, time etc.
Test Report:
K16175
After the completion of a dielectric test the instrument
prints out the results providing a hardcopy record.
The test results page format may vary based on the
standard chosen and the parameters required within
those standards.
Operating Manual K16175 12
ASTM 1816-04 1mm
2008-08-22 3:05PM
Within Range Limits
Range 2.8kV
Mean: 41.2kV
Std. Dev: 1.1kV
T-Oil: 22 °C / 72 °F.
Test 5: 42.5kV
Test 4: 39.4kV
Test 3: 41.7kV

Powering Up The Instrument
To turn ON the instrument, press the On/Off button. OK
After a few seconds the display will indicate the version of firmware and other information related to the test
instrument.
A self test during the startup will alert the user to any abnormalities that may exist. Note that an
integrated battery inside the unit will allow the unit to turn on, if it is sufficiently charged.
When the instrument is connected to AC shore power or the external 12V DC supply the internal battery
automatically be charged.
If the unit does not come on under battery power, the battery may be discharged or in need of replacement. In
this case connect the instrument to either a AC or a DC external supply as specified.
During the startup, the printer will print and line feed. This will help verify that the printer has paper, has a
good ink ribbon, does not have a paper jam and is ready for operation.
Test Sample and Test Vessel Preparation:
Ensure that the correct test vessel / cell to be used is available.
Insert the test vessel into the high voltage chamber as shown. Note that the two arms of
the test cell that house the electrodes should be positioned on the two vertical high
voltage spring loaded contacts of the instrument.
The liquid test sample selected should be an accurate representative sample of the
larger body of oil from where it originates. Moisture and dirt should be avoided, as
this can contaminate the test sample. Clean, dry, sealable, amber glass bottles are generally the best containers
to house the sample. Consult guides and standards such as ASTM D923 that cover oil sampling procedures.
Ensure that the temperature of the oil is similar to ambient conditions when the oil is tested in the instrument.
Good housekeeping cannot be overstated enough.
Ensure that only skilled personnel sample the oil from the electrical apparatus and follow all applicable safety
procedure and regulations.
When the test instrument is completely setup as above, pour sufficient liquid sample to completely fill the test
cup. Make sure that the sample fills the complete test cell and more than adequately covers the electrodes. Do
not inject air bubbles and avoid turbulence and rapid agitation of the oil.
Follow the relevant national and international standards for sampling.
Operating Manual K16175 13

Running a Test Standard
Step Description Display Action
1 Main Screen MAIN MENU
Select the standard you would like to perform on the
liquid dielectric sample.
Choose SINGLE TEST option only if you want to
perform a single breakdown test on the oil sample.
Choose INSTRUMENT SETTINGS to change
date, time or paper fsfeed options etc.
2 Standards Menu In this case the standard menu screen for ASTM1816
is shown. In some cases the year the standard was
approved is shown - in this case in 2004. For
standards that have the same name, but then have a
option within that standard, in this case 1mm Gap,
that is also shown.
3 Start Standard Once the oil is ready to be tested and is in the test
vessel chamber, press the OK button to activate the
“START TEST”
The gap spacing as well as the rate of rise of voltage
required by the standard is shown. These parameters
are for information purposes only and cannot be
adjusted.
NOTE: It is up to the user to make ensure that the
gap spacing between the electrodes is set correctly
using the appropriate spacer gauge. The instrument
does not check or make any adjustment to the
electrode spacing. It is the user’s responsibility to
ensure that the spacing is done correctly.
To return to the Main Menu, select the “MAIN
MENU” icon and then press OK to return to the
main menu.
Operating Manual K16175 14

Step Description Display Action
4 Active Standards The current test cycle/standard is underway follow
Menu Test Mode ing the procedure as specified in the standard
selected. The test sequence occurs fully
automatically.
The breakdowns are recorded as they occur in the
sequence.
A test report is printed and a summary of the test
results appear on the screen.
If at any point during the test, the operator would
like to terminate the test, pressing OK will activate
the STOP TEST function and terminate the test.
5 Test Results After the completion of the Test cycle according to
the standard selected, the results are both displayed
on the screen and they are also printed.
Depending on the range / deviation limits of the test
results as specified in the Standard selected, the test
cycle will either be completed at that point, or the
user will be prompted to follow an addition instruc
tion based on the applicable requirements from the
standard.
(In this case, another test cycle is requested as the
test is out of acceptable range based on the criteria as
specified in the ASTM standard that was selected.)
Operating Manual K16175 15

Running a Single Test
Step Description Display Action
1 Select Single Test Choose the Single Test option -from the main menu -
from the Main Menu Press OK to select
2 Start Single Test To Start Single Test, highlight START TEST and
press OK.
3 Gap Spacing The user can change the gap spacing. This only
effects what is printed on the report.
NOTE: It is up to the user to make ensure that the
gap spacing between the electrodes is set correctly
using the appropriate spacer gauge. The instrument
does not check, or make any adjustment to the
electrode spacing. It is the user’s responsibility to
ensure that the spacing is done correctly.
Operating Manual K16175 16

Step Description Display Action
4 Rate of Rise (Single The user is able to change the rate of rise of the
Test Function) voltage applied to the test sample. Highlight the rate
of rise function, then press Left or Right Cursor on
the Click wheel to increase or decrease the voltage
rate of rise.
Units : kV/second
Range: 0.5kV to 5kV per Second in increments of
0.5kV/Sec.
To Return to Main Menu - Select and press MAIN
MENU.
5 Running the Single The instrument will apply the voltage at the pre
Test Function determined rate of rise voltage until a breakdown
occurs.
The breakdown is then captured, recorded and
printed.
If at any point during the test, the operator would
like to terminate the test, pressing OK will activate
the STOP TEST function and terminate the test.
6 Test Results The single test function results are displayed and
printed out.
Operating Manual K16175 17

Instrument Settings
Step Description Display Action
1 Instrument Settings Select Instrument Settings from the MAIN MENU
2 Change Instrument Date and Time: Select the Time or Date values that
Settings you want to change. Highlight the data field (in this
case the Hours field), then using the Left or Right
Cursor buttons on the Click Wheel, change the value
to that required.
Paper Feed: Select Paper Feed to line feed the
printer several increments. This is useful when
feeding a new paper roll through the printer
mechanism.
Battery: Percentage of battery charging is displayed
on the most menu screens. 100% is when the
integrated battery is fully charged.
To Return to main menu, select Main Menu and
press OK.
Operating Manual K16175 18

Replacing Printer Paper Roll:
To install a new or to replace an existing paper roll in the
instrument, do the following:
• Turn off the instrument.
• Swivel out and back the printer mechanism housing
by using your index finger to lever out the hinged
support plate as shown below.
Operating Manual K16175 19