Tanaka AD-6 User manual

Automated Distillation Tester
Model: AD-6
Instruction Manual
Ver 3.01 100105
Read this manual thoroughly before using the product,
and store in a safe place for future reference.
TANAKA SCIENTIFIC LTD, TOKYO, JAPAN

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(Blank Page)

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FOREWORD
Thank you for purchasing the Automated Distillation Tester Model AD-6 from Tanaka
Scientific Limited.
This instruction manual provides necessary information for using the AD-6. Read this
manual thoroughly before use and ensure that you have understood its contents.
This manual employs the following precautionary notation. For your safety, ensure that
you understand these precautions and heed them at all times.
! WARNING:
Warnings indicate a significant risk of death or serious
physical injury if the information is ignored.
! CAUTION:
Cautions indicate a significant risk of physical injury or
property damage if the information is ignored.
USES
! WARNING: This product is only to be used for distillation
measurements, as prescribed in ASTM D86 "Standard
Test Method for Distillation of Petroleum Products at
Atmospheric Pressure", ASTM D850 “Standard Test
Method for Distillation of Industrial Aromatic
Hydrocarbons and Related Materials” and ASTM
D1078 “Standard Test Method for Distillation Range of
Volatile Organic Liquids”.
This product automates the testing procedures
prescribed in ASTM D 86, D850 and D1078 for
making distillation measurements and is not to be
used for any other purpose.

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About This Manual
zThis manual is intended for all operators of the AD-6.
The reader is assumed to have sufficient knowledge of ASTM procedures and
standards as well as knowledge of the correct handling procedures for hazardous
materials.
zThe content this manual is subject to change without notice due to enhancements to
the performance and functionality of the tester.
zIf this manual is lost or damaged, contact Tanaka Scientific Limited or an authorized
distributor for a replacement copy.
zThe contents of this manual have been thoroughly reviewed. If any pages are
missing, out of order, or the manual contains spelling, grammatical or descriptive
errors, please contact Tanaka Scientific Limited or an authorized distributor.
BEFORE USE
zBefore using the product, ensure that you have read this manual thoroughly and
have understood all of the content.
If you have any questions, be sure to contact Tanaka Scientific Limited or an
authorized distributor.
zKeep this manual in a safe, easily accessible place.
zThis product is to be used for its intended purpose only.
zAdhere strictly to all procedures given in this manual. Ensure that you understand
and abide by all (
!Warnings) and ( !Cautions) given in this manual.

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WARNINGS AND CAUTIONS FOR SAFE USE
Failure to follow all of the warnings and cautions listed below may result in
damage to the tester and/or serious personal injury.
Tanaka Scientific Limited will not assume any responsibility for faults or
accidents arising from failure to adhere to these instructions.
Installation Environment
! Warning: The tester must be installed in a well-ventilated
environment.
As samples release inflammable and/or toxic gases,
inadequate ventilation may result in poisoning.
! Warning: Install the tester on a strong level table.
Keep inflammable substances away from the tester.
Ensure that a fire extinguisher is kept near the tester.
If the table is unstable, the tester may fall down
causing a fire.
Electric Connection
! Warning: Observe the following instructions when handling
power cables and electric connections:
·Do not connect or disconnect any cables or
electrical connections when the mains power is
ON.
·Do not handle any cables or electrical
connections with wet hands.
·Never use the cord to pull a plug from an outlet.
·Do not place heavy items on cords or cable.
·Do not use force to bend any cords or cables.
·Ensure that all electric connections (plugs,
sockets, connectors, etc.) are free of dust.
·Keep all cables and electrical connections free of
water and other liquids.

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Failure to adhere to the above precautions may result
in electric shock, damage to the tester, cords and/or
cables, and/or fire due to overheating.
! Warning: Ensure that supply voltage meets the specifications of
the product.
Do not turn the power on until all electric connections
are secured.
Incorrect power supply specifications or loose electric
connections may damage the tester and result in
electric shock and/or other electrical accidents.
! Warning: Ensure all ground wires are securely grounded.
Loose or disconnected ground wires may result in
electric shock.
Never connect the ground wires to gas pipes.
Doing so may result in a fire or explosion.
Ground wires may be connected to one of the
following:
·Ground terminal of a power outlet
·Copper bar buried 65cm or more underground
·Water pipes as authorized by your local water
bureau as a grounding object
Handling Precautions
! Warning: Be sure to confirm test configuration prior to every test.
Testing using incorrect parameters or with no boiling
chips may cause a sample to bump and catch fire.
! Warning: Never touch the flask with bare hands after testing.
The danger of burns exists, even after cooling.
! Warning: Never discard hot samples.
If a hot sample is discarded into a container containing
low flash point waste oil, a fire or explosion may result.

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Operational Precautions
! Warning: Never touch the heater section with bare hands during
operation.
The cell is heated to high temperatures during
operation and can cause serious burns.
! Warning: The tester is not to be operated unattended.
Great danger exists if the tester falls or is knocked over.
For safety reasons, an operator should always be in
the same room as the running tester.
! Warning: If the tester makes any abnormal noises or exhibits any
abnormal behavior, stop operation immediately, turn
the power off at the mains, and contact Tanaka
Scientific Limited or an authorized distributor.

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Consumables, Accessories and Replacement Parts
! Caution: Use only Tanaka Scientific Limited genuine
consumables, parts and accessories or such parts as
recommended by Tanaka Scientific Limited.
Repairs, Alterations and Maintenance
! Warning: Do not make any modifications or alterations to the
tester without the approval of Tanaka Scientific
Limited.
! Warning: Do not attempt to repair the tester yourself. In the event
that the tester exhibits any abnormal behavior
whatsoever, contact Tanaka Scientific Limited or an
authorized distributor.
! Warning: Only Tanaka Scientific Limited service personnel or
authorized representatives are to repair or maintain the
tester.

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(Blank Page)

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Contents
FOREWORD..................................................................................................................................2
USES ………………………………………………………………………………………………………..2
About This Manual .........................................................................................................................3
BEFORE USE................................................................................................................................3
WARNINGS AND CAUTIONS FOR SAFE USE ............................................................................4
Contents.........................................................................................................................................9
1Section Names and Functions ...........................................................................................11
2Installation.......................................................................................................................... 14
2.1 Installation Site............................................................................................................14
2.2 Setting of Fire Containment Shutter............................................................................14
2.3 Electrical Connections................................................................................................. 14
2.4 Nitogen Gas Connection (for fire containment) ...........................................................15
2.5 Supplying Circulating Solution .................................................................................... 16
3Routine Daily Inspection ....................................................................................................17
4Prior to Testing ..................................................................................................................18
4.1 Starting the Tester.......................................................................................................18
4.2 Drying the Condenser Tube ........................................................................................19
4.3 Setting a Sample.........................................................................................................19
5Starting a Test ...................................................................................................................20
5.1 Starting a Test.............................................................................................................20
5.2 Test Sequence............................................................................................................21
5.3 Test without a 100% Sample in the Graduated Cylinder............................................. 22
6Terminating a Test.............................................................................................................23
6.1 Termination and Dry Point (D.P CUT).........................................................................23
6.2 Termination at a Set Distillation Percentage (% CUT) ................................................23
6.3 Termination at Set Temperature (°C CUT).................................................................. 23
6.4 Termination after 5min from 95% recovery (Time, Cut) ..............................................23
7Reprinting and Resending Data after Residue...................................................................24
7.1 Setting the Residue Again...........................................................................................24
7.2 Reprinting....................................................................................................................24
7.3 Resending................................................................................................................... 24
7.4 Displaying and Printing Previous Distillation Data....................................................... 25
8Attaching the Temperature Sensor and Dry Point Sensor .................................................26
8.1 Attaching the Temperature Sensor ............................................................................. 26
8.2 Attachment Location of the Dry Point Sensor and Temperature Sensor for BTX........27
9Setting Test Parameters ....................................................................................................28
9.1 Select Mode ................................................................................................................28
9.2 How to Set Test Parameters .......................................................................................29

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9.3 Manual Heater Control ................................................................................................ 31
10 Maintenance ......................................................................................................................32
10.1 Inspecting and Replenishing Circulating Solution ....................................................... 32
10.2 Replacing Circulating Solution .................................................................................... 33
10.3 Fire Containment Shutter ............................................................................................ 34
10.4 Error Status and Fault ................................................................................................. 34
11 Inspection and Post-sale Service....................................................................................... 36
11.1 Periodic Maintenance.................................................................................................. 36
11.2 Consumables and Accessories................................................................................... 36
11.3 Troubleshooting .......................................................................................................... 37
11.4 Period of Warranty ......................................................................................................37
11.5 Period of Availability of Maintenance Tools.................................................................37
12 Post-delivery Notes............................................................................................................38
12.1 Long Periods of Dormancy..........................................................................................38
12.2 Lost Instruction Manuals .............................................................................................38
12.3 Transfer.......................................................................................................................38
12.4 Disposal ...................................................................................................................... 38
13 Specifications.....................................................................................................................39
Product Warranty .........................................................................................................................44

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1 Section Names and Functions
Fig. 1 Model AD-6
(1) (2)
(3)
(4)
(5)
(6)
(11)
(10)
(7)
(8)
(12)
(16)
(15)
(14)
(13)
Top
Left Front Right
(17)
．
(18)
(19)
(9)
(20)

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(1) Temperature Sensor Connector: Connect the temperature sensor here.
(2) Dry Point Sensor Connector: Connect the dry point sensor (option) here.
(3) Fire Containment Shutter: Closes to prevent a fire if a flask breaks, a sample catches fire, or
the thermofuse blows. Do not close when starting a test, thermofuse blows.
(4) Circulating Water Verification Window: Allows the user to view the level and status of the
internal circulating solution.
(5) Heater Door: Open this door when inserting or removing a flask. Be sure to hold the knob
because the door becomes very hot.
(6) Heater Height Adjustment Dial: Raises or lowers the heater unit to set the flask in the correct
location.
(7) Printer (Option): Prints distillation data and plots a distillation curve.
(8) Fire Containment Nitrogen Inlet Port: Used to discharge nitrogen gas into the heater section
in case of fire. If the nitrogen line is connected, the solenoid valve opens automatically,
similarly to the fire containment shutter, if the thermofuse is blown. The nitrogen gas in
combination with the shutter helps to control fires and prevent the spread of flames.
The size of the inlet port is PT1/4 female, and recommended Nitrogen gas pressure is 500 kPa.
(9) Heater unit level adjuster: Can be adjusted to keep the unit level
(10) LCD display: Displays various configuration menus, distillation data, distillation curves and
error messages.
(11) Operating Panel: Contains START, COOL, RESET and other keys for operating the tester.
Tester settings for each mode can be changed using the keys on this panel.
(12) Temperature Sensor Holder: Insert the temperature sensor here during pre-cooling.
(13) Heater Status Lamp: Continuously lit during heating, flashing during temperature adjustment.
(14) Condensation Drain: Drains condensation pooled in the receiver compartment.
(15) Manual Fire Containment Shutter Activator: Press this button to test the fire depressant
shutter. This switch can also be used to manually close the shutter if the shutter fails to close
automatically during a fire.
(16) RS-232C Connector: Connect a personal computer with LIMS communication software and
Tanaka's ADManager (option) installed to this communications port.
(17) Circuit Breaker: Pops out and cuts power to the tester to protect the circuits if excess current
is detected. To reset, turn the main switch off once, rectify the cause of the current overload,
and press the circuit breaker button.
(18) Mains Power Switch: Turns the tester on and off.
(19) Power Cable Socket: Connect one end of the power cable to this socket and the other end to
an outlet meeting the specifications.
(20) Temperature Sensor Rest: Place the temperature sensor when stand-by.

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Fig. 2 Model AD-6 Operator Panel
(1) DISP CHANGE Key: Press this key to toggle between the STANDBY and RUN screens.
(2) PRINT Key: Press this key to reprint test results, plot distillation curves, and to print
temperature correction values, test parameters, and other settings if optional printer is installed
(3) MANUAL CUT Key: Press this key to stop testing manually.
(4) FUNCTION Key: Press this key to change from the RUN screen to the Distillation Curve screen
while a test is running. Also, the menu can be displayed by pressing this key and the RESET
key at the same time.
(5) Up and Down Keys: Use these keys to select a test mode (long cursor) or to change an item
or increment or decrement a value at the cursor (short cursor).
(6) Left and Right Keys: Use these keys to move the cursor (short cursor). This is mainly used
when changing test parameters (on the STANDBY screen).
(7) Enter Key: Use this key accept the mode name and move the cursor to the test parameters to
allow them to be changed.
(8) RUN Lamp: Lights at the start of a test. (Red)
(9) COOL Lamp: Lights while the heater section is cooling after a test. (Green)
(10) START Key: Press this key to start a test.
(11) COOL Key: Press this key to cool the heating section as required. If this key is pressed during
testing, the test is terminated and the heater section cooled for 10 minutes.
(12) RESET Key: This key is mainly used to abort testing or cooling. Pressing this key returns the
tester to the standby state and displays the STANDBY screen shown in Fig.5 on Page 18.
(1) (2) (3) (4)
(5)
(5)
(6)
(7)
(8) (9)
(10) (11) (12)
(6)

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2 Installation
2.1 Installation Site
! Warning: The tester must be installed in a well-ventilated
environment.
! Warning: Install the tester on a strong level table.
Keep inflammable substances away from the tester.
Ensure that a fire extinguisher is kept near the tester.
If the table is unstable, the tester may fall down
causing a fire.
Install the tester on a strong, level bench in a well-ventilated location.
Do not expose the tester to any of the following:
·High temperatures (> 30 °C)/ low temperatures (< 10 °C) or high humidity (> 90%)
·Direct sunlight
·Dust
·Rapid temperature changes
2.2 Setting of Fire Containment Shutter
Lift and fix the Fire Containment Shutter to the hook.
2.3 Electrical Connections
! Warning: Observe the following instructions when handling
power cables and electric connections:
·Do not connect or disconnect any cables or electrical
connections when the mains power is ON.
·Do not handle any cables or electrical connections
with wet hands.
·Never use the cord to pull a plug from an outlet.
·Do not place heavy items on cords or cable.
·Do not use force to bend any cords or cables.
·Ensure that all electric connections (plugs, sockets,
connectors, etc.) are free of dust.

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·Keep all cables and electrical connections free of
water and other liquids.
Failure to adhere to the above precautions may result
in electric shock, damage to the tester, cords and/or
cables, and/or fire due to overheating.
! Warning: Ensure that supply voltage meets the specifications of
the product.
! Warning: Ensure all ground wires are securely grounded.
Loose or disconnected ground wires may result in
electric shock.
Never connect the ground wires to gas pipes.
Doing so may result in a fire or explosion.
Ground wires may be connected to one of the
following:
·Ground terminal of a power outlet
·Copper bar buried 65cm or more underground
·Water pipes as authorized by your local water
bureau as a grounding object
Connect the power cable to the right side of the tester when viewed from the front and the power
plug to an outlet meeting the tester specifications. (1)
The maximum power consumption of this tester is 1.5 kW. When sharing an outlet with other
electrical appliances, make sure that the total power consumption does not exceed the outlet
capacity.
Note (1)The standard power cable comes with a three-prong plug. If the plug does not fit
your outlet, you will need to change the plug.
If the outlet does not have a ground terminal (as in ordinary home outlets), connect
the power cable through a ground adapter (triangular add-on). In this case, be sure
to ground the tester with an extension ground cord.
2.4 Nitogen Gas Connection (for fire containment)
Connect nitrogen gas piping to inlet port (see Fig. 1 (8)).
The size of the nitrogen gas inlet port is PT1/4 female. Connect PT1/4 male joint.
The recommended nitrogen gas pressure is 500 kPa.

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2.5 Supplying Circulating Solution
Check the circulating solution is already filled or not. Some of AD-6s are shipped without filling
circulation solution to avoid freezing in transit. If the slotion is empty, pour in the solution to the
AD-6 as follows. The solution capacity is about 1.6 liters.
Recommended solution is as follows
Lowest ambient temperature < 5oC: Distilled water + Antifreez*
*: Cooling capacity will be decrease if Antifreez propotion will be over 10%.
Lowest ambient temperature > 5 oC: Distilled water
(1) Remove the circulating solution verification window from the left side of the tester (see Fig. 3).
(2) Remove the cap of the circulating solution tank and pour the solution to MAX (see Fig. 4).
(3) Replenish the solution to MAX again after lower the solution level. When the solution reaches a
water pump, surface descent will stop.
(4) Turn ON the MAIN switch of the AD-6, solution surface will descent again. Replenish the
solution to MAX again.
(5) Return the removed items to their original positions.
Fig.3 Check window
Solution check window
Remove this screw
Fig.4 Solution tank
Solution tank

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3 Routine Daily Inspection
The following should be checked routinely before using the tester:
Table 1: Checklist
Item Description
Appearance
Electrical connections
(Before turning the
main power on…)
Operation of each
component
·The tester has no apparent damage.
·The power cable is not damaged.
·The power plug is fully inserted into the outlet.
·The grounding cable is properly connected (only
applicable if using the ground adapter)
·The circulating solution is filled to the specified level.
< After turning the main power on…>
·The display appears to be functioning correctly
·The circulating solution is circulating normally.
·Each key functions normally when pressed.
·The condenser bath and receiver compartment are at
the set temperatures.
·Fire containment shutter closes correctly by pressing
Manual Fire Containment Shutter Activator. (See 10.3
on page 33)
! Warning: Do not attempt to repair the tester yourself. In the event
that the tester exhibits any abnormal behavior
whatsoever, contact Tanaka Scientific Limited or an
authorized distributor.

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4 Prior to Testing
! Warning: Do not use flasks having a deformed bottom, fine
scratches or cracks, as these may break and cause a
fire during testing.
! Warning: To prevent a sample from accidentally catching alight,
adhere to the following three precautions:
·Do not leave the laboratory unattended during
testing.
·Ensure that a fire extinguisher is located nearby.
·Do not place any inflammable substances near the
tester.
! Caution: The standard graduated cylinder contains a Viton
O-ring. Do not use acetone, methyl ethyl ketone, acetic
ethyl, or any other solvent, as solvents may cause the
ring to inflate and damage the graduated cylinder.
※Optional graduated cylinder with Perfluoroelastomer O-ring is available
! Caution: Use boiling chips (Small stones or small porous
ceramics) to avoid irregular boiling.
4.1 Starting the Tester
Turn on the main power switch. The test unit comes on and displays the screen shown in Fig. 5.
< STANDBY 1 > BAROMETER 1013 hPa
1 GASOLIN(300) INIT TEMP1 250.0oC
2 KEROSIN(300) INIT TEMP2 450.0oC
3 NAPHTHA(300) HEAT/FREEZ 95.0 %
4 KEROSIN(400) FINAL H (AUTO) + 0.0 %
5 GAS-OIL(400) TEMP RANGE 300
6 RESIDUE 1.0 %
7 DIST.RATE 4.5 %
8 SETBATH 0.5 oC
9 SET REC 15.0
oC
10
11 START TEMP 25.0oC
12 BATH TEMP 12.3 oC
13 REC TEMP 18.0 oC
(Mode Selection) (Mode Parameters)
Fig. 5 STANDBY Screen
(1) Use the ↑and ↓keys on the operating panel to move the cursor and select a mode (2).

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Note (2)For information on setting mode parameters, refer to "9.2 Setting Test Parameters"
on Page 29.
(2) Wait until the condenser bath and receiver compartment reach the specified temperatures.
Note: Bath temperature is maintaind at 4oC when STANDBY even if set bath temperature is 0
oC to avoid icing. Once start a test, bath temperature will be mainatned at set
temperature.
4.2 Drying the Condenser Tube
Attach a piece of cloth, such as dry gauze, to one end of a steel wire of length 70 cm and insert it
into the condenser tube from the bottom, wiping moisture and dirt off the inside wall of the tube.
If the tester is used in a very humid environment, condensation may occur near the bottom of the
exposed section of the condenser tube in the receiver compartment, and accumlate in the
receiver cover. Be sure to wipe moisture from this section. If condensation drips into the
graduated cylinder, test results may be incorrect.
4.3 Setting a Sample
(1) Prepare cooled test samples, flask and guraduated cylinder according to ASTM
D86/D850/D1078. Do not use flasks having a deformed bottom, fine scratches or cracks, as
these may break and cause a fire during testing.
(2) Measure the sample precisely up to the 100% graduation (top mark) of the graduated
cylinder, then immediately transfer the entire sample to the distillation flask.
(3) Add few boiling chips (small stones or small grass beads) to the sample to avoid an
irregular boiling (bumping).
(4) Attach the temperature sensor with centering device directly to the distllation flask to
prevent vapor from escaping, then clamp the sensor into place so that it will not come off
during testing.(3)
Note (3) For details on attaching the temperature sensor, refer to "8.1 Attaching the
Temperature Sensor" on Page 26, and for attaching the dry point sensor, refer to "8.2
Attaching the Dry Point Sensor" on Page 27.
(5) Place the assembled flask in the heater unit.
Attach silicon-rubber stopper No.0 to the vapor tube of the flask to secure the connection
to the condenser tube. Turn the knob on the front of the heater until the flask support
board comes into firm contact with the bottom of the flask and makes the flask straight.
The diameter of the hole in the flask support board should be chosen by following the
testing method of section 4.3 (1).
Do not close the Fire Containment Shutter after setting the flask.
(6) Place the graduated cylinder used in 4.3 (1) into the receiver compartment.
To do this, lift the receiver cover along the condenser tube. With the cut-out on the bottom
plate of the graduated cylinder facing the tester, tilt the cylinder and put the top inside the
compartment. Push the cylinder up and swing the base across into the receptacle of the
monitor assembly. After checking that the graduated cylinder is seated straight, lower the
receiver cover until it comes into firm contact with the top of the graduated cylinder.
<<This completes the test preparations>>