Koehler K877 Series Guide

Operation and Instruction Manual
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
K877XX
Automatic Tag Closed Cup Flash Point
Tester

CONTENTS
CONTENTS................................................................................................................................... 2
I - GENERAL................................................................................................................................. 4
- 1.1 – VERIFICATION AFTER TRANSPORT............................................................................ 4
- 1.2 – SAFETY INSTRUCTIONS .............................................................................................. 4
- 1.3 – IDENTIFICATION OF THE EQUIPMENT........................................................................ 4
- 1.4 – INSTRUCTIONS FOR USE............................................................................................. 5
- 1.5 – INSTALLATION INSTRUCTIONS .................................................................................. 5
II – TECHNICAL CHARACTERISTICS........................................................................................ 7
III - DESCRIPTION OF THE EQUIPMENT .................................................................................. 9
- 3.1 - PRESENTATION (SEE PRESENTATION DIAGRAM)............................................................... 9
3.1.1 – Control Panel ............................................................................................................ 9
3.1.2 – Middle front panel...................................................................................................... 9
3.1.3 – Lower front panel....................................................................................................... 9
3.1.4 – Rear panel ................................................................................................................ 9
3.1.5 – Working zone.......................................................................................................... 10
3.1.6 – Right side ............................................................................................................... 10
IV – ACCESSORIES SUPPLIED WITH THE EQUIPMENT ...................................................... 13
IV – ACCESSORIES SUPPLIED WITH THE EQUIPMENT ...................................................... 14
- 4.1 – ACCESSORIES SUPPLIED AS STANDARD............................................................... 14
- 4.2 – OPTIONS ..................................................................................................................... 14
- 4.3 – ACCESSORY MODELS .............................................................................................. 15
V – METHODS AND BRINING INTO SERVICE ....................................................................... 18
- 5.1 - STANDARDS................................................................................................................ 18
- 5.2 - METHODS.................................................................................................................... 18
- 5.3 - STARTUP..................................................................................................................... 18
5.3.1 – Connections on the back of the equipment........................................................... 18
5.3.2 – Connections to the front of the equipment ........................................................... 19
5.3.3 – Powering on the equipment.................................................................................. 20
VI – GENERAL DESCRIPTION OF THE SOFTWARE ........................................................... 21
- 6.1 – MAIN STANDBY SCREEN......................................................................................... 21
- 6.2 - MENUS FLOW CHART .............................................................................................. 21
VII – STARTING A TEST.......................................................................................................... 23
- 7.1 – CONDUCT OF A TEST............................................................................................... 23
VIII - PRINTING......................................................................................................................... 26
- 8.1 - TYPES OF PRINTER................................................................................................... 26
- 8.2 – PRINTING RESULTS OF TESTS IN PROGRESS...................................................... 26
- 8.3 - PRINTING RESULTS OF ARCHIVED TESTS ............................................................ 26
- 8.4 – PRINTING THE TEMPERATURE GRADIENT............................................................ 26
- 8.5 – MODEL PRINTOUT..................................................................................................... 26

- 8.6 – PRINTING OUT OF LOG........................................................................................... 27
IX – SAFETY DEVICES........................................................................................................... 28
- 9.1 – SAFETY DEVICE - ABSENCE OF SAMPLE PROBE ............................................... 28
- 9.2 – NO INCREASE IN SAMPLE PROBE TEMPERATURE............................................. 28
- 9.3 – ELECTRICAL SAFETY DEVICE ............................................................................... 28
- 9.4 - SAMPLE TEMPERATURE SAFETY DEVICE............................................................ 28
- 9.5 – GAS SAFETY DEVICE............................................................................................... 29
X – UPDATING OF SOFTWARE............................................................................................. 30
XI - CONFIGURATION............................................................................................................. 31
- 11.1 –
PASSWORD.......................................................................................................................... 31
- 11.1.1 – Creation of a password.................................................................................... 31
- 11.2 – SOFTWARE CONFIGURATION.............................................................................. 31
- 11.2.1 – Correction of the result..................................................................................... 31
- 11.2.2 – Stop cooling ..................................................................................................... 31
- 11.2.3 – Safety shutdown .............................................................................................. 32
- 11.2.4 – Enter presumed temperature............................................................................ 32
- 11.2.5 – Barometric pressure ......................................................................................... 32
- 11.2.6 - Buzzer ............................................................................................................... 32
- 11.2.7 – New version of software.................................................................................... 32
- 11.2.8 - New password.................................................................................................... 32
- 11.2.9 – Print out temperature gradient).......................................................................... 33
- 11.2.10 - ''Escaping'' from the software configuration item.............................................. 33
- 11.3 – HARDWARE CONFIGURATION ............................................................................... 33
- 11.3.1 - Language............................................................................................................ 33
- 11.3.2 - Units ................................................................................................................... 33
- 11.3.3 - Calibration .......................................................................................................... 33
- 11.3.3.A – Sample probe and bath .............................................................................................34
- 11.3.3.B – Barometric pressure ..................................................................................................35
- 11.3.3.C – Electrical network image ...........................................................................................36
- 11.3.4 - Checks ............................................................................................................... 37
- 11.3.4.A – Analogue readings ....................................................................................................37
- 11.3.4.B – Logical inputs/outputs ...............................................................................................37
- 11.3.4.C – Self diagnostic ..........................................................................................................37
- 11.3.4.D – Printing the log...........................................................................................................37
XII - INCIDENTS......................................................................................................................... 39
XIII – GENERAL MAINTENANCE............................................................................................. 40
- 13.1 - CALIBRATION ........................................................................................................... 40
- 13.2 – MISCELLANEOUS CHECKS .................................................................................... 40
XIV – ACCESSORIES AND PART NUMBERS......................................................................... 41
- 14.1 – ACCESSORY PART NUMBERS ............................................................................... 41
- 14.2 – ADDITIONAL ACCESSORIES (OPTIONS) .................................................................. 41
- 14.3 – ERROR CODES......................................................................................................... 41
XVI - YOUR CONTACT.............................................................................................................. 42
XVII – ELECTRICAL/ELECTRONIC DIAGRAMS...................................................................... 43

I – GENERAL
- 1.1 – VERIFICATION AFTER TRANSPORT
Check the condition of the packaging and make any reservations to the
transport operator in the event of any damage.
Compare the contents (accessories) with the list supplied.
Check the condition of the accessories.
- 1.2 – SAFETY INSTRUCTIONS
Before using the equipment, the operator must have:
Knowledge of manual methods and experience of the types of tests to be
performed.
Knowledge of the hazards associated with handling products and
samples.
Handling by the user of a hot cover/receptacle containing a sample should be
avoided. Otherwise, this operation must be performed with extreme caution.
In all cases the operator must wear the necessary personal protection:
gloves, goggles, protective clothing.
- 1.3 – IDENTIFICATION OF THE EQUIPMENT
The equipment has a manufacturer’s plate on its left hand side:

- 1.4 – INSTRUCTIONS FOR USE
The equipment must be used solely:
Using the methods indicated in the instructions.
Using the accessories supplied and indicated in the instructions.
In accordance with the test and start up procedures described in the
instructions.
When a test is in progress, the equipment should under no circumstances
be left unsupervised.
It is mandatory to place the equipment under a smoke extractor hood; the work
room must be adequately ventilated.
At least once a month the connections to the cryostat and to the gas must be
checked to ensure the pipes and their fastenings are in satisfactory condition.
The gas pipe must be changed before the expiry date indicated on it.
If an incident occurs (excess pressure of gas, abnormal overheating of the
equipment, leaking or tipping up of the product) which may have caused
damage, an internal and external inspection of the equipment by a qualified
person is mandatory.
All maintenance work must be performed only by a qualified technician on an
equipment restored to room temperature, switched off (except where necessary
for calibration) and disconnected from the electricity, refrigerant and gas supply
systems.
The maintenance functions described and detailed in the instructions shall only
be performed by a qualified technician.
The functions and commands attached to the keyboard are clearly explained in
the instructions; the operator must read these carefully before using the
equipment.
- 1.5 – INSTALLATION INSTRUCTIONS
The cooling circuit for the equipment must be connected to a cryostat
regulated to a temperature at least 15 °C lower than the desired bath
temperature (that is 32 °C below the expected temperature).
The connection to the cryostat must be made using the insulated pipes
and collars supplied as accessories.

The gas circuit of the equipment can be connected to mains gas of 50
mbar maximum with the pipes and collars supplied as accessories, or to a
removable gas bottle, supplied as an option with its connection
accessories.
The equipment should be placed on a stable, strong table or laboratory
bench.

The electrical supply must comply with that described on the rating plate
and the apparatus must be connected to the ground.

It is mandatory to place the equipment under a smoke extractor hood; the
workroom must be adequately ventilated.

Check the condition of the accessories.

II – TECHNICAL CHARACTERISTICS
Field of use
Determination of a flash point in a closed receptacle in accordance with the
standards:
ASTM D 56
IP 304

III - DESCRIPTION OF THE EQUIPMENT
- 3.1 - PRESENTATION (see presentation diagram)
3.1.1 – Control Panel
1 tactile touch keyboard (1)
1 liquid crystal backlight graphics display (2)
3.1.2 – Middle front panel
The flashpoint detection thermocouple connector (3)
The ionising detection cable connector (4)
The Pt 100 sample probe connector (5)
The bath probe connector (7)
The gas connections for the pilot light and test flame (6)
The plug power supply connectors (24)
3.1.3 – Lower front panel
The gas regulation valves for the pilot light (8), test flame (9)
The heating (10) and refrigeration (11) indicator lights for the bath
Potentiometer for adjusting electrical voltage supplying the electric
ignitor (35)
3.1.4 – Rear panel

The mains switch with protective fuse (12)
The RS232 connector for link with the PC (13)
The printer connection (14)
The gas connection (15)
The inlet (16) and outlet (17) to the cooling circuit.
Gas bottle fastenings (18) (option)
Output of barometric pressure sensor for calibration by pressure
simulation (19)
Barometric pressure sensor connector for calibration with a voltage
generator (20)
Bath over flow (21)
Bath bleed (22)
Drain for recovery of internal condensation (23)

3.1.5 – Working zone
Electrical plug connections (24)
Rest receptacle (25)
Bath (26)
Flame presentation (27) or electric ignitor
Pilot light (28)
Flame presentation door control arm (29)
Agitator connection rod (30)
Temperature measuring probe rest (32)
Bath filling intake (33)
3.1.6 – Right side
Rating plate (31)

IV – ACCESSORIES SUPPLIED WITH THE EQUIPMENT
- 4.1 – ACCESSORIES SUPPLIED AS STANDARD

1 mains cable
1 cover and a TAG cup
1 rest receptacle
1 flash detection thermocouple
1 ionising detection cable
1 glass Pt 100 probe for the sample
2 pipes with collars for attaching to the cryostat
1 gas pipe with collars
1 agitation spring
1 operator’s manual
1 certificate of conformity and attestation of final inspections
1 ticket printer with connector cable + recharge transformer
1 electric ignition coil
1 dipstick (small bath)
1 funnel

- 4.2 – OPTIONS
Removable gas bottle with support bracket and connections

- 4.3 – ACCESSORY MODELS

V – METHODS AND BRINING INTO SERVICE
- 5.1 - STANDARDS
This equipment complies with the following standards:
ASTM D 56
IP 304
Determination of the flashpoint in a closed cup of petroleum products and liquid
mixtures practically free of foreign matter.
- 5.2 – METHODS
- 5.3 – STARTUP
5.3.1 – Connections on the back of the equipment
Connection of utilities:
Connect the refrigeration inputs/outputs, tighten the collars, open the
cryostat valve (with the equipment in use) and check there are no leaks.
Connect the overflow and the drain to a waste pipe (avoid any siphoning
by the hoses).
Connect the gas (50 mBars maximum pressure), tighten the collars (the
electro-valve is closed except during testing, check the flame regulation
valves are closed), open the gas and check there are no leaks.
Plug in the printer cable.
Plug in the mains cable (mains voltage: 230 V +/- 10%).

Filling the bath:
Remove the plug from the bath orifice
Using a funnel, slowly pour in the liquid (water and glycol) until it
runs through the overflow (discharged to the rear)
Fill the bath under the receptacle with appropriate liquid (water if the
tests are at positive temperatures, add glycol for negative temperatures)
using the dipstick supplied
Replace the filling plug
Note: This apparatus has an exchanger. It is not mixture between the bath
and the coolant liquid of the cryostat
Do not fill the bath with only water. You must add anti freeze.
5.3.2 – Connections to the front of the equipment
Connect:
The Pt 100 glass probe.
The ionising detection cable (the spring on the cover ground must be
correctly positioned against the cable connector)
Possibly, the thermocouple detection cable.
Use with electrical ignition :
Remove the presentation flame nozzle
Remove the 2 silicone gas supply pipes
Isolate the equipment from the gas supply
Place the electric ignition coil in its holder
Check the position of the electric ignition with the edge of the trap, by pushing
with finger the mechanism: the filament of the electric ignition must not touch the
edge of the trap.
Connect the two electrical supply wires of the heating plug to the two power
supply terminals (see diagram).
Adjust the potentiometer for the ignition coil supply to 7/8 for the first time of use.
Configure the equipment (see functions flow chart) for electrical ignition.
Note: the electric ignitor is supplied by low voltage AC.

5.3.3 – Powering on the equipment
Note: Ensure the mains electricity supply is compatible with the equipment.
Throw the switch on the back of the equipment.
Initialisation of the CPU requires a short wait during which the screen will remain blank.
After about 20 seconds, the equipment is operational; the screen will indicate the values
(see standby screen).
If the equipment is connected to a printer, power on the printer after the equipment.