Koehler K501 Series Guide

Operation and Instruction Manual
REV C
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
K501XX
Panel Coking Test Apparatus

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-1-
Table of Contents
1Introduction ...................................................................................................................2
1.1 Koehler’s Commitment to Our Customers..........................................................................................2
1.2 Recommended Resources and Publications......................................................................................2
1.3 Instrument Specifications....................................................................................................................2
2Safety Information and Warnings ................................................................................3
3Getting Started...............................................................................................................3
3.1 Packing List.........................................................................................................................................3
3.2 Unpacking...........................................................................................................................................3
3.3 Setup...................................................................................................................................................3
4Descriptions...................................................................................................................4
4.1 Instrument Controls.............................................................................................................................4
4.2 Temperature Controller Operation......................................................................................................5
4.4 Cyclic Timer Operation .......................................................................................................................7
5Operation .......................................................................................................................8
5.1 Before Test..........................................................................................................................................8
5.2 To Start Test .......................................................................................................................................8
5.3 Flow meter Calibration Data ...............................................................................................................9
6Maintenance...................................................................................................................9
6.1 Routine Maintenance..........................................................................................................................9
6.2 Replacement Parts ...........................................................................................................................10
7Assembly and Wiring Diagrams.................................................................................11
7.1 K50100 Unit Wiring...........................................................................................................................11
7.2 K50190 Unit Wiring...........................................................................................................................12
7.3 K50110 Unit Wiring...........................................................................................................................13
7.4 K50119 Unit Wiring...........................................................................................................................14
7.5 Control Cabinet Assembly ................................................................................................................15
7.6 Test Rig Assembly............................................................................................................................16
8Troubleshooting..........................................................................................................17
8.1 Unit does not power up.....................................................................................................................17
8.2 Unit is on and keeps resetting into start up routine...........................................................................17
9Service..........................................................................................................................17
10 Storage.........................................................................................................................17
11 Warranty.......................................................................................................................17
12 Returned Goods Policy...............................................................................................17
Notes..................................................................................................................................19

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-2-
1 Introduction
The Koehler Panel Coking Test Apparatus
determines the tendency of finished oils to form
coke (solid decomposition products) when in
contact with surfaces at elevated temperatures for
short periods of time. The unit consists of a digital
control cabinet, mechanical splasher, splash
chamber, and a sample oil reservoir. The test
panel temperature and oil sump temperature are
individually controlled by separate heaters with
digital temperature controllers. The mechanical
splasher has a variable speed 0-1800 RPM drive
motor with digital tachometer. A high accuracy
variable area flow meter permits the introduction of
air to increase the severity of the test. All models
are also equipped with a digital countdown timer.
Models K50110 and K50119 are also equipped
with an additional programmable cyclic timer for
customizing start and stop times of the mechanical
splasher. The Panel Coking Test Apparatus
conforms to the Federal Test Method specification
FTM 791-3462 and is suitable as a screening test
prior to performing engine tests.
This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and operating
instructions for the 8-Unit Oxidation Bath 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. Federal Test Method (FTM)
FTM Publication:
FTM 791-3462: Coking Tendency of Oil
1.3 Instrument Specifications
Models:
K50100, K50110
K50190, K50119
Electrical
Requirements:
115V 60Hz, 8.0A
220-240V 50/60Hz, 5A
Test Panel
Temperature
Range:
Ambient to 400°C (752°F)
Sample Oil
Temperature
Range:
Ambient to 210°C (410°F)
Temperature
Control:
Separate controls for test
panel and oil temperature,
with digital °C/°F digital
setpoint and display
Splasher Rate:
0-1800 RPM, with digital
display
Timer:
0-99.9 hr variable
countdown
Oil Reservoir
Capacity:
0.1 gal (0.35L)
Test Unit Net
Weight:
50 lbs (22.7kg)
Control Cabinet
Net Weight:
25 lbs (11.3kg)

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-3-
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
K501XX Panel Coking Test Apparatus
Consisting of:
- Mechanical Splasher
- Control Cabinet
- Splash Chamber
- Sample Oil Reservoir
K501XX-Manual Panel Coking Test Apparatus
Operation and Instruction Manual
Accessories (purchased separately)
K50101 Aluminum Test Panel
K50102 Stainless Steel Test Panel (Type 321)
3.2 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.
3.3 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. Position the Test
Rig (Mechanical Splasher and Splash Chamber)
so that the drive motor faces the operators left with
the splash chamber fill tube facing the operator.
This unit should be operated in a very well
ventilated area.
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.
Air Supply. Connect a regulated air supply to the
flow meter inlet of the Control Cabinet. Air inlet
pressure should not exceed 25 psi. Connect the
Cabinet air outlet to the air inlet on the test rig
using Tygon or other suitable tubing.
NOTE: Koehler Instrument does not supply air
source required for running instrumentation.
Assembly: Insert the oil reservoir support rod into
the fitting on the front side of the test rig and

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-4-
tighten the thumb screw. Clamp the Sample Oil
Reservoir into the glassware support and tighten.
Attach Tygon tubing from the reservoir outlet to
the horizontal fill pipe on the side of the splash
chamber. Attach the oil splasher shaft to the motor
drive coupling and tighten securely. Slide the
baffle plate into place.
Power. Plug in multi connector cable from the test
rig into the rear of the control cabinet. Plug in the
thermocouples from the test panel and oil sump
into the receptacles at the rear of the control
cabinet. 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 voided.
4 Descriptions
4.1 Instrument Controls
Figure 2: Instrument Front
Figure 3: Control Cabinet Back
1. Test Panel Temperature Controller. The
temperature controller regulates the
temperature of the strip heater located on top
of the test panel. Refer to Section 4.2 for full
operational details.
2. Oil Sump Temperature Controller. The
temperature controller regulates the oil sump
temperature for the test procedure. Refer to
Section 4.2 for full operational details.
Operation is identical to that of the Test Panel
Temperature Controller.
3. Line Switch. This switch controls the power to
the entire unit. When the power switch is in
the ON position, power is supplied to the unit.
4. Motor Switch. This switch controls turning
ON/OFF the drive motor of the mechanical
splasher.
5. Test Panel Heat Switch. This switch controls
turning ON/OFF the power strip heater located
on top of the test panel. When the Test Panel
Heat Switch is turned on initially, the Test
Panel Temperature Controller will illuminate
and perform a diagnostic check.
6. Oil Sump Heat Switch. This switch controls
turning ON/OFF the heat of the Oil Sump.
When the Oil Sump Heat Switch is turned on
initially, the Test Panel Temperature Controller
will illuminate and perform a diagnostic check.
7. Flow meter. For indicating and monitoring of
the Oxygen flow rate during the test.
8. Motor Speed Dial. For setting the drive motor
speed in RPM of the mechanical splasher.
The RPM value is displayed on the Digital
Tachometer (9).

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-5-
9. Digital Tachometer. Displays the RPM value
of the drive motor set from the Motor Speed
Dial.
10. Test Termination Indicator. Red Indication
light illuminates when test is complete.
11. Timer Reset Switch. This switch resets the
time on the Test Timer (13) to zero.
12. Test in Progress Indicator. Green Indication
light illuminates when test is running.
13. Test Timer. Set the entire run time of the test
using the three dials on the Test Timer. Unit of
measure on the Test Timer is Hours.
14. Test Rig Air Inlet. Connect suitable tubing
from Air Outlet on the Control Cabinet to this
Test Rig Air Inlet to supply air to the oil sump.
15. Motor. Powers the stirring shaft and
mechanical splasher of the test rig.
16. Oil Reservoir Support Rod. Provides
suitable elevation and support for the Sample
Oil Reservoir.
17. Glassware Support. Place Sample Oil
Reservoir and tighten.
18. Sample Oil Reservoir. Borosilicate glass oil
reservoir with drain cock outlet. Connect
suitable tubing from outlet to horizontal fill pipe
inlet on the side of the splash chamber (20).
19. Tubing. For connection from Sample Oil
Reservoir to Oil Sump.
20. Oil Sump. Location where test takes place.
Oil is drawn from the Oil Reservoir to the Oil
sump where it is then mechanically splashed
onto the test panel located at the top of the Oil
Sump.
21. Cyclic Timer. Allows for test to be broken up
into timed ON/OFF cycles. (Not Shown). Refer
to Section 4.3 for full operational details.
Available on K50110 and K50119 models.
22. Control Cabinet Flow meter Air Outlet.
Using Suitable tubing connect Flow meter Air
Outlet Port to Air Inlet Port on Test Rig.
23. Control Cabinet Flow meter Air Inlet.
Connect regulated air supply to Flow meter Air
Inlet port.
24. Test Panel Thermocouple Receptacle. Plug
Thermocouple from Test Panel into this port.
25. Oil Sump Thermocouple Receptacle. Plug
Thermocouple from Oil Sump into this port.
26. Multi Connector Cable Receptacle. Plug
Multi Connector Cable from the test rig into
this port.
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

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-6-
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 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.

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-7-
4.4 Cyclic Timer Operation
NOTE: Cyclic Timer comes standard with K50110 and K50119 models only.
Figure 5. Cyclic Timer
Overview
The cycle timer operates the drive motor by 2
independently adjustable on and off time periods.
The on and off time periods are repeated until the
main test timer turns off. The K5011X unit is
equipped with a timer bypass switch located to the
right of this timer to disable the cycle feature. This
switch will power off the timer, and allow the
sample motor to run continuously throughout the
test period.
Programming
The timer must be powered on to program it.
Power-on the unit by use of the line switch.
All motor and heater switches can remain off. Turn
off main timer reset switch, and the cycle timer
bypass switch. The Timer should now be powered
on. Proceed as follows:
1) Using the numeric keys, enter the ON time
period. Buttons 4 & 3 set Hours, Buttons 2 & 1
set minutes. Press the Key.
2) The Preset 2 indicator should now be lit. Using
the numeric keys, enter the OFF time period.
Buttons 4 & 3 set Hours, Buttons 2&1 set
minutes. Press the Key.
3) Turn on the Timer Bypass switch, then back to
off. This will power-cycle the timer. This
process updates the values from the previous
steps into the timer’s memory and restarts the
timer.
Batch feature:
The timer is equipped with a batch feature. While it
is unnecessary for operation of this instrument, it
may be useful to view how many on-off cycles
have occurred. Press the Key repeatedly until
the light next to “B” on the display is lit. The upper
display shows how many on-off cycles have
occurred. This value is retained in memory, so it
displays total cycles since the last time the counter
was reset.
To reset the Batch counter, simply press the E and
P buttons together. This will reset the value to zero
and stop the timer. To restart the timer, cycle the
Bypass switch on, and then off again, or reset the
main test timer.
NOTE: When the timer is not running, the 2
indicators next to the H and M on the display
will not be flashing. The motor will run
continuously if the motor switch is on. The
timer stops counting when the Batch Counter
is reset. It is important to restart the timer after
resetting the Batch Counter.

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-8-
5 Operation
WARNING: Be sure to read the safety and hazard
warnings, the installation procedure and any of the
standard test methods mentioned in the
introduction before operating this instrument.
CAUTION: Hazardous voltages may be present
on the panel Strip heater electrical wires, which
may be exposed when the test panel is loaded.
The Strip heater clamping plate provides
protection while the unit is in operation. It is
important to turn the MAIN switch off when
installing or removing the test panel to prevent the
possibility of electric shock.
5.1 Before Test
1. Add the test oil to the splash chamber
(approximately 300 mL). NOTE: The final oil
level is dependent on the temperature at
which the test will be conducted. It is
recommended to allow space for the oil to
expand and adjust the oil level in the splash
chamber when oil has reached operating
temperature.
NOTE: The oil reservoir stopper must be in place
whenever the petcock is open otherwise
the oil will drain into the splash chamber
regardless of the splash chamber oil level.
2. Place a prepared test panel onto the top of the
splash chamber, with thermocouple holes
facing the rear of the unit.
3. Place the strip heater on top of the panel so it
overlaps equally on both ends.
4. Next, place the strip heater clamping plate on
top of the heater.
5. Slide the screw clamp over the top of the
assembly and tighten.
6. Slide the thermocouple probe into the hole in
the test panel. Close the safety over the
splash chamber. The safety cover must
remain closed during the test period. A safety
switch prevents operation of the unit with the
cover open.
5.2 To Start Test
1. Turn on Line Switch.
2. Enter desired test duration into Test Timer
Module.
3. If cyclical ON/OFF test procedure is desired,
set cyclic timer for desired timing intervals (If
equipped. See section 4.3) If Cyclic timing is
not required, Turn the Timer Bypass switch
located to the right of the timer ON.
4. Turn On the panel heater switch. The panel
heater control display will illuminate. The
control will display the panel temperature on
the upper display, and the setpoint value on
the lower display. Using the arrows on the
controller, raise or lower the setpoint value to
the desired test temperature.
5. Turn on the oil sump heat switch. The unit is
identical in operation to the panel heat
controller. Raise or lower the setpoint value to
the desired temperature. The control will heat
up and control the oil temperature in the sump
at the setpoint value.
6. Turn on the drive motor and set the desired
RPM into the digital display.
7. If using air, determine the flow meter reading
by using the Flow meter Calibration Data in
section 5.3 of this Operation Manual.
8. The test will continue until the timer reaches
zero, at this point the unit will shut down.
When the unit has cooled down, open the
safety cover and carefully remove the test
panel. Proceed with the test per FTM 791-
3462.

K501XX Panel Coking Test Apparatus
Operation and Instruction Manual
K501XX-Manual
-9-
5.3 Flow meter Calibration Data
Flow meter K299-4-52
Max. Flow
1682 mL/min
Min. Flow
251 mL/min
Metered Fluid
Air
Tube Number
082-03-ST
Float Material
316 stainless steel
Float Density
8.04 g/mL
Standard Conditions
STP: 1 atm at 70°C
Room Temperature
70°F (21.1°C)
Metering Temperature
70.0°F (21.1°C)
Metering Pressure
14.70 psia
Metering Density
0.001200 g/mL
Density at STD. Cond.
0.001200 g/mL
Metering Viscosity
0.01812 cp
Accuracy
Standard
Barometric Pressure
760.0 mm of Hg
Scale Reading (mm)
Flow (mL/min)
150
1682.0
140
1578.0
130
1490.0
120
1412.0
110
1319.0
100
1223.0
90
1129.0
80
1028.0
70
937.0
60
835.0
50
730.0
40
618.0
30
488.0
20
375.0
10
251.0
6 Maintenance
WARNING. Disconnect power to the unit before
servicing to avoid exposure to high voltages
and/or temperatures which may result in personal
injury or death. If you have any questions about
maintaining your equipment, then please do not
hesitate to contact the Koehler technical service
department.
6.1 Routine Maintenance
Over the course of time, some instrument parts
may need to be replaced. When ordering
replacement part(s), please provide the model
number, serial number, and product shipment date
of your equipment so that we can ensure you will
receive the proper replacement part(s).