Koehler K29300 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
K29300
High Temperature Evaporation Loss Tester

K29300 High Temperature Evaporation Loss Tester & Software
Operation and Instruction Manual
K29300-Manual -1-
CERTIFICATE OF CONFORMANCE
High Temperature Evaporation Loss Tester
K29300
This certificate verifies that part number K29300, High Temperature Evaporation
Loss Tester, was manufactured in conformance with the applicable standards set
forth in this certification.
Specifications: ASTM D2595
ASTM D2878
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..................................................................................................................4
1.1 Koehler’s Commitment to Our Customers .........................................................................................4
1.2 Recommended Resources and Publications.....................................................................................4
1.3 Instrument Specifications...................................................................................................................4
1.4 Software Specifications......................................................................................................................4
2Safety Information and Warnings...............................................................................5
3Getting Started.............................................................................................................5
3.1 Packing List........................................................................................................................................5
3.2 Unpacking..........................................................................................................................................5
3.3 Setup..................................................................................................................................................5
3.4 Software Installation...........................................................................................................................6
4Descriptions.................................................................................................................6
4.1 Instrument Controls............................................................................................................................6
4.2 Temperature Controller Operation.....................................................................................................7
5Operation......................................................................................................................8
5.1 Preparation of Apparatus...................................................................................................................8
6Safety Features............................................................................................................8
6.1 Over-Temperature Protection............................................................................................................8
6.2 Over-Power Protection.......................................................................................................................9
7Maintenance.................................................................................................................9
7.1 Routine Maintenance.........................................................................................................................9
7.2 Replacement Parts ............................................................................................................................9
8Diagrams and Charts.................................................................................................10
8.1 Unit Wiring .......................................................................................................................................10
8.2 K293-0-12 Flow Meter Calibration Chart.........................................................................................11
9Troubleshooting ........................................................................................................12
9.1 Unit does not power up....................................................................................................................12
9.2 Unit is on and keeps resetting into start up routine .........................................................................12
9.3 Unit is on but block does not heat up...............................................................................................12
10 Service........................................................................................................................12
11 Storage.......................................................................................................................12
12 Warranty.....................................................................................................................12
13 Returned Goods Policy.............................................................................................13
Notes..................................................................................................................................14

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Operation and Instruction Manual
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1 Introduction
The Koehler K29300 High Temperature
Evaporation Loss Tester and Data Acquisition
Software is the latest design for performing
evaporation loss tests on lubricating greases at
temperatures of up to 316°C (600°F) according to
the ASTM D2595 test method and related test
specifications. The K29300 can also perform the
ASTM D2878 test method with the installation of
the Oil Sample Cup assembly (purchased
separately).
This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and operating
instructions for the High Temperature Evaporation
Loss Tester and Data Acquisition Software. 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: [e-mail]
ASTM Publication:
ASTM D2595: Standard Test Method for
Evaporation Loss of Lubricating Greases
Over Wide Temperature Range
ASTM D2878: Standard Test Method for
Estimating Apparent Vapor Pressures and
Molecular Weights of Lubricating Oils
1.3 Instrument Specifications
Models:
K29300
Electrical
Requirements:
220-240V 50/60Hz,
Single Phase, 10.4A
Temperature
Range:
93 to 316°C (200 to 600°F)
Sample
Temperature
Stability:
±0.3°F
Exit Air
Temperature
Control:
Two 0-500W Variable control
heaters and Type IC
thermocouples (K29310 Digital
Thermometer sold separately)
Exit Air
Temperature
Stability:
±1.1°C (±2°F)
Capacity:
2 Samples
Air Flow Control:
2 externally mounted
flowmeters capable of
maintaining 2L/min flow at
standard temperature and
pressure
Heating Device:
Aluminum Block
1.4 Software Specifications
PC System
Requirements:
Intel® Pentium II Processor or
similar (minimum)
Operating
System:
Windows® 98 SE, 2000, NT,
XP, Vista

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Memory
Requirements:
256Mb RAM (512Mb RAM
recommended) 15 Mb Hard
Disk Space (minimum)
Other
Two RS-232 communication
ports
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 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.
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
K29300 High Temperature Evaporation Loss
Tester
K29300-Manual High Temperature Evaporation
Loss Tester and Data Acquisition Software
Operation and Instruction Manual
K29540 Evaporation Cell Assembly with Grease
Sample Cup (2)
K293-0-12 Thermocouple (2)
Additional Accessories (purchased separately):
K29320 / K29329 Digital Thermometer
250-000-03F/C ASTM 3F / 3C Thermometer
K29530 Evaporation Cell Assembly with Oil
Sample Cup (Required for ASTM D2878)
K29540 Evaporation Cell Assembly with Grease
Sample Cup
373-115-001 / 373-230-001 Electronic Balance
3.2 Unpacking
Carefully unpack and place the instrument and
accessories in a secure location. The unit is
shipped in a wooden crate with the unit packed in
an upright position. Remove the top lid of the box
and remove all cleats and hold-downs. Next,
remove the sides of the crates and remove the
bath from the crate by lifting the bottom. Install 4
adjustable feet, removed from shipping. Place the
tester on a firm level table capable of holding 175
lbs in an area with adequate ventilation or in a
hood. Remove all packing and wrappings from
around the unit, thermocouples and thermocouple
supports. 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. 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. Connect the flowmeter to the filtered
air supply in accordance with the ASTM method.
Calibrate the thermocouples to the temperature

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recorder to be used (not supplied). Install and
adjust the thermocouples in the thermocouple
support tube per the ASTM method. Install test
thermometer.
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.
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.
3.4 Software Installation
1. Installation. 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, 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 software is ready to run once
the installation has been completed.
NOTE: When first installed, the software is in
demo mode, it must be registered in order for
the software to work with the unit.
2. Registration. Start the program and then go
to >> Help >> Register. A registration screen
will appear with a registration number (Refer
to Figure 1, below). E-mail Koehler at
[e-mail] or call with
the registration number for the unlock code.
Once the software has been registered, it
must be restarted before tests are run.
Figure 1. Registration Screen
4 Descriptions
4.1 Instrument Controls
Figure 2: Instrument Descriptions
1. Power Switch. This switch controls the power
to the entire unit. When the power switch is in
the ON position, the digital temperature
controller is powered on.
2. Temperature Controller. The temperature
controller regulates the oven (sample)
temperature for the test procedure. Refer to
Section 4.2 for full operational details.
3. Variable Air Pre-heater Knob. Located on
left and right front of the unit. Used to regulate

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the amount of heat input to the left and right 0-
500W variable control heaters. Air
temperature can be displayed by means of a
Digital Thermometer not included with the
apparatus. These control knobs can be used
together with the Digital Thermometer to
maintain air temperature within ±1.1°C (±2°F).
4. Flowmeter. Located on left and right side of
the unit. Air flow through the apparatus can be
regulated by means of the valve located at the
bottom of the flowmeter. Capable of
maintaining 2 L/min flowrate at standard
temperature and pressure per ASTM
specification.
5. Evaporation Cell Assembly. Consists of a
Sample Cup (either Grease or Oil), Hood,
Cover and Eduction Tube, Gasket, and
Thermocouple Tube and Supports. Sample
cup holds the sample while heated air passes
over its surface. A thermocouple is placed
inside the assembly, where it detects the air
temperature and is then displayed on the
digital thermometer readout.
6. Thermometer Holder: Location where ASTM
3C or 3F thermometer is to be placed. The
thermometer detects the temperature of the
heating oven.
4.2 Temperature Controller Operation
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

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is a value observed in the upper red LED
display, add it to the calculated difference
obtained in the previous step. This is the
offset value.
c. Press the Program Key. The lower green
display will flash. Use the up or down keys
to adjust to the new calibration offset
value on the upper red display calculated
in the previous step. When the value has
been entered, the controller will
automatically store the value. The lower
green display will stop flashing. If further
adjustments are necessary, press the
Program Key again. Resume regular
operations by pressing the Exit / Function
key two times. Verify if the new calibration
is correct by observing the upper red
display and comparing the value with the
calibrated reference device.
Auto Tune. This routine allows the digital
temperature control to learn the heating
parameters needed for any particular set point
temperature. This operation should be done
when installing a new unit, after replacing or
changing the bath medium type, or utilizing a
different temperature set point 20% different
from the previously used set point
temperature.
a. Set the operating temperature to the
desired setting.
b. Press the up and down arrow buttons
simultaneously for about 5 seconds. When
Auto Tune is active, the lower green LED
display will blink TUNE. Auto Tune will
automatically toggle off when the set point
temperature is reached. Auto tune can be
terminated by pressing the up & down
buttons simultaneously again.
5 Operation
5.1 Preparation of Apparatus
1. Be sure to thoroughly clean all parts of the
evaporation cell assembly before proceeding with
test method.
2. Connect the cover-eduction tube to the hood.
Adjust thermocouple tube so that the bottom of the
tube is flush with face of the hood as shown. Insert
thermocouple in tube and adjust so that tip is flush
with bottom edge of tube. Fasten the
thermocouple securely in this position by
compressing the top edge of the tube. Remove the
tube thermocouple assembly and disconnect the
hood from the cover-eduction tube.
3. Place the cover-eduction tube thermocouple
assembly and gasket in the heating device (oven).
Fasten the cover securely in position.
4. Adjust the temperature of the heating device
to maintain the test temperature and control within
±1.0°C (±2.0°F) using the micro-processor based
temperature controller (1). Verify correct
temperature reading using the thermometer.
5. Regulate the air flow through the assembly to
2 L/min at standard temperature and pressure
using the flowmeter valve located at the bottom of
the flowmeter (4).
6. By regulating the air preheater, adjust the exit
air temperature to the specified test temperature
within ±1.1°C (±2°F) using the Variable Air Pre-
heater Knobs (3) and Digital Thermometer (sold
separately).
7. Maintain the temperatures of the heating
device (oven) and exit air and the air flow rate for
at lease a half hour prior to test.
8. Proceed with test procedure according to
required ASTM Test method.
6 Safety Features
The Koehler K29300 High Temperature
Evaporation Loss Tester is equipped with several
safety and protection features, which are
described in the following sections.
6.1 Over-Temperature Protection
The Koehler K29300 High Temperature
Evaporation Loss Tester is equipped with Over-
temperature Protection (OTP) circuitry, which
prevents the unit from exceeding unsafe operating
temperatures. If the unit cannot maintain the set
point temperature and begins to decline, the OTP
circuitry may have been activated. Please follow
these steps.
1. Turn off the unit power switch and disconnect
the line cord.