Koehler K41100 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: [e-mail]
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
K41100
Micro Conradson Carbon Residue Tester

CERTIFICATE OF CONFORMANCE
Micro Carbon Residue Apparatus
K411XX
This certificate verifies that part number K411XX, Micro Carbon Residue
Apparatus, was manufactured in conformance with the applicable
standards set forth in this certification.
Specifications: ASTM D4530
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

K41100
TABLE OF CONTENTS
1 - GENERAL ... ...3
1.1 - Safety rules ... ...3
1.2 - Instructions for use ... ...4
1.3 - After-sales service guarantee ... ..5
1.4 - Contact in case of emergency ... .5
1.5 - Symbols used ... ..6
2 - TECHNICAL ASPECT... ...7
2.1 - Scope of application ... ...7
2.2 - Technical characteristics ... ...7
2.3 - Description of the appliance ... .8
2.3.1 Front panel ... ...8
2.3.2 Rear Panel ... ...9
2.3.3 Accessories ... ...10
3 - COMMISSIONING ... ...11
3.1 - Installation ... ...11
3.2 - Appliance connections... ..11
3.2.1 Use of instant connectors ... ..13
3.3 - Starting up ... ..14
4 - USE OF THE APPLIANCE... ...15
4.1 - Description of the temperature regulator ... .15
4.2 - Starting a test... .15
4.3 - Interruption of a test ... ...18
4.4 - Alarm... ..19
4.4.1 Alarm during a test ... .19
4.4.2 Alarm in wait mode... .19
4.5 - Important remark ... .20
5 - INSPECTIONS AND GENERAL MAINTENANCE OF THE APPLIANCE ... ...21
5.1 - Inspections before each test... ..21
5.2 - General maintenance ... ...21
5.2.1 Maintenance of the oven... .21
5.2.2 Checking the oven temperature ... ..22
5.2.3 Monitoring the gas flows ... .22
6 - MAIN CAUSES OF POOR RESULTS ... ...23
7- LIST OF PART NUMBERS FOR ACCESSORIES AND SPARE PARTS ... ..24
8 - ANNEXES ... ..25
8.1 Flow meter abacus ... .25
9 - DIAGRAMS ... ...27
10 - INDEX ... ...29
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1- GENERAL
1.1 - Safety rules
Basic precautions must be observed when using Koehler Instrument Company, Inc.
instruments and their accessories.
1. Read and understand in full these instructions prior to use.
2. In the case of damage or dropping of the appliance, have it examined by a
qualified technician.
3. Do not touch parts of the appliance which become extremely hot.
4. Do not use with a defective connection cable.
5. Do not allow the connection cable to hang over the edge of a table or touch a hot
surface.
6. If an extension lead is necessary, use a cable suitable for the current intensity
that will be used. Using a cable of too small a cross-section may cause
overheating. The cable must not be twisted or stretched.
7. Disconnect the appliance from the mains power when it is not in use. Never pull
on the cable to disconnect it from the mains. Take hold of the plug and remove it
from the power socket.
8. Allow the appliance to cool completely before moving it. Wind the cable loosely
around it for storage.
9. To avoid danger of electrocution, do not immerse the appliance in water or any
other liquid.
10. Do not disassemble the appliance, but have it repaired by a qualified technician
when intervention is necessary. Any incorrect assembly may result in electric
shocks on restoring it to service. Before using the appliance, the operator must
have:
* Knowledge of manual methods and experience in the types of tests to be
performed.
* Knowledge of the risks resulting from handling products and samples.
Users are advised not to handle containers of hot samples. If it is necessary, this
operation must be performed with extreme caution.
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In all cases, the operator must wear the necessary protective
clothing: gloves, goggles, protective garments.
1.2 - Instructions for use
The appliance must be used solely:
►In conformity to the methods described in the instructions
►With the accessories supplied and designated in the instructions
►In accordance with the test and commissioning procedures described in the
instructions
During operation, the appliance must under no circumstances be left unsupervised.
The appliance must imperatively be located under an extraction hood with a smoke
extraction system: the work room must be adequately ventilated.
An inspection of the gas connections must be carried out at least one a month in
order to check satisfactory condition of pipes and their fastenings.
In the case of an incident that could result in damage to the appliance
(excess gas pressure, abnormal heating of the appliance, leaking or
spillage of a product), an internal and external examination of the
appliance must be performed by a competent person.
All maintenance interventions must be performed exclusively by an authorized
technician with the appliance at room temperature and switched off (except
when it must be switched on: e.g. calibration) and disconnected from the electricity and
gas mains supplies.
The maintenance functions described and detailed in the instructions must only be
performed by an authorized technician.
The functions and controls linked to the keyboard are clearly explained in the
instructions; the user must become familiar with these before handling the appliance.
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1.3 - After-sales service guarantee
KOEHLER INSTRUMENT CO. guarantees its products for a period of twelve months
from the date of dispatch. During this period, any part with defects in the materials of
construction or in operation and which is returned to KOEHLER INSTRUMENT CO. will
be replaced free of charge, except for consumables (lamps, printing paper, sample bowl,
etc.). Work under guarantee will be performed by KOEHLER INSTRUMENT CO.
If the guarantee work must be performed on site, the travel and subsistence costs will be
paid by the user.
Service under guarantee does not apply to an appliance of which the defect is the result
of incorrect use, connection to an unsuitable electricity supply, absence of ground, an
act of vandalism or caused by the forces of nature (thunder, flooding, earthquake, etc.).
KOEHLER INSTRUMENT CO. does not accept any liability for physical injury or financial
loss caused by a defective appliance during the guarantee period, whether under a
Service Contract or otherwise.
This guarantee replaces all other official or implicit agreements.
The guarantee will become null and void if the equipment is transported outside the
country where it was initially supplied by KOEHLER INSTRUMENT CO.
1.4 - Contact in case of emergency
KOEHLER INSTRUMENT CO. 1595 Sycamore Ave. Bohemia, NY 11716
Ph: 1 631 589 3800 - e-mail: [email protected]
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1.5 - Symbols used
Warning
To be respected scrupulously to avoid any physical injury or damage to
your appliance
Maintenance
Supplies important information concerning the maintenance of your
appliance
Remark
Provides useful advice for optimum use of your appliance
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2 - TECHNICAL ASPECT
2.1 - Scope of application
This appliance is intended for the treatment of samples in compliance with the
following standards:
ASTM D 4530
2.2 - Technical characteristics
Ambient temperature for use 15 to 30° C
Ambient relative humidity for use Max 85% non-condensing
Oven temperature range Ambient T° to 550° C
Oven temperature probe Thermocouple J
Resolution of temperature measurement 1° C
Type of oven Conform to the standard ASTM D 4530
Cooling of oven Accelerated by injection of compressed
air for forty minutes
Gas connections at the rear of the Instant connections dia. 4 mm for
appliance nitrogen and dia. 8 mm for compressed
air
Maximum upstream gas pressure 2 bar
Type of gas authorised Air for cooling the oven - nitrogen for the
oven
Maximum sample load 12 vials each of 2 ml
Maximum heating kinetic 15° C/min
Use voltage 230 V 50/60 Hz
Power 1500 W
Temperature safety device By separate J thermocouple set at
550° C
Electrical safety of electronic unit By fuse (10 A)
Supply voltage 230 V - 50 Hz
Dimensions (L x W x H) 250 x 300 x 600 mm
Weight 19 kg
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2.3 - Description of the appliance
2.3.1 Front panel
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2.3.2 Rear Panel
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2.3.3 Accessories
I
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3- COMMISSIONING
3.1 - Installation
Install the appliance on a horizontal and stable surface.
The environment must be clean and free from dust.
Avoid locations that would expose the appliance to direct sunlight or draughts. Unpack
and remove the protective packaging from the appliance and its accessories.
Check the equipment and ensure it suffered no damage during transport.
Check the delivery note and make sure all accessories are present.
Check that the electrical specifications marked on the manufacturer’s plate are the same
as those that will be used. Check that the supply line is protected by fuses and grounded
(green/yellow wire).
An appliance with traces of impacts or apparent defects after transport or
unpacking must not be commissioned.
To avoid risks of condensation, the appliance must be left at room temperature for
several hours before it is powered on.
3.2 - Appliance connections
Depending on the desired use, the appliance must be connected to a source of nitrogen
supplying a maximum pressure of 2.0 bar (200 KPa) and to an air source of maximum
pressure 2.0 Bar (200 KPa). In order to obtain a stable flow rate during the test, the gas
must be supplied through a pressure relief device to stabilize the upstream pressure.
During the first test, which must be a no-load test (without samples), it is
vital to check the value of the gas flows and to adjust these depending
on the upstream gas pressure.
For guidance, for a flow rate of 150 ml/min, the flow meter should be set
to 20.62 mm and for a flow rate of 600 ml/min, at 58.20 mm. Always
refer to the abacus received with the appliance.
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Position the flue extension.
No connection for smoke evacuation should
be made on the flue or its extension. The
flue must remain free to ensure optimum
exhausting. Any connection on the flue or
its extension risks causing:
-condensates on the appliance pipework
-a counter-pressure that would interfere with the test by modifying the
flow rates and causing leaks through the hot cover of the oven.
From the side of the appliance take the cover
handling hook and the sample vial (see photo opposite)
Use the mains cable to supply power to the appliance (check the mains voltage and
power are suitable for the appliance).
Reminder: Irrespective of the type of tests and the method used, the
appliance must be placed under an extractor hood to allow
evacuation of the smoke generated by the test.
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3.2.1 Use of instant connectors
3.2.1.1 Connection of a pipe
Simply push the pipe totally home in the connector. The connection and leak tightness
are made instantaneously.
3.2.1.2 Disconnection of a pipe
Press the push button on the outside of the connector.
Pull the pipe to disconnect.
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3.3 - Starting up
Power on the appliance by pressing the switch on the rear panel of the appliance.
When the temperature regulator is powered on, for three seconds it runs a series of
automatic tests. After each sequence, the display shows the temperature measured on
the upper display and displays ‘OFF’ on the lower display.
This display is called the At Rest page.
The appliance is ready for a test.
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4 - USE OF THE APPLIANCE
4.1 - Description of the temperature regulator
4.2 - Starting a test
The appliance must be placed under an evacuation hood to allow
evacuation of smoke generated by the test.
Reminder: It is vital to be familiar with the standards concerning the tests to be
initiated.
Reminder: The installing and removal of samples after the tests requires
working with a hot oven and hot samples.
The operator must wear safety equipment (thermal insulating gloves,
protective clothes and goggles) and use the appropriate accessories
supplied with the appliance.
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Prepare the sample or samples in compliance with the standard
(marking, weighing, etc.), and place on the
vial holder.

Check that the condensates container
is empty.
This operation can only be performed on
an oven where the temperature is below
100 °C
Remove the insulating cover
Remove the oven cover with the tool supplied (see
photo).
Caution: the oven may be hot, prudence is vital including at the start of the
test.
Check that the oven outlet is not blocked by
carbon deposits (see Para. Maintenance)
Place the vial holder in the oven using the tool
supplied (see photo)
Replace the oven cover (with the tool), placing
it correctly to ensure satisfactory air tightness
Replace the insulating cover on the oven
Ensure the gas supply valves are open (mains gas)
Check that the extractor hood is operating and that the extension is
correctly positioned on the oven flue
To start the test, press the key ( key on the right). The RUN LED
will light up. The appliance begins to heat up. ‘RUN’ is displayed on the
lower display.
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During a test, the regulator follows
five stages:
1. Hold time of ten minutes at the
oven temperature at the start of
the test. Entry of nitrogen to the
oven (high flow rate).
2. Heating according to a ramp of
12.5° C/min up to 500° C.
Entry of nitrogen in the oven (low
flow rate).
3. Hold time of fifteen minutes at
500° C.
Entry of nitrogen in the oven (low flow rate).
4. Cooling with compressed air for forty minutes. Entry of nitrogen in the oven (high
flow rate).
5. End of test. Switch off heating and gas supply.
During the test, check that the nitrogen flow rates are correct. For
guidance, for a flow rate of 150 ml/min, the flow meter should be set at
20.62 mm and for a flow rate of 600 ml/min, at 58.20 mm. Always refer to the
abacus received with the appliance.
When the test is completed, the RUN LED will flash. ‘END’ is indicated on
the lower display. The temperature regulator will remain in this status until it
is reinitialized.
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