Koehler K24394, K24308, K24304, K24398 Instruction Manual

K243XX

Programmable Muffle Furnace

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

Operation and Instruction Manual

K243XX Ashing Furnace

Table of Contents

1 Introduction ...................................................................................................................3

1.1 Koehler’s Commitment to Our Customers.............................................................................................3

1.2 Recommended Resources and Publi cations.........................................................................................3

1.3 Instrument Specifications.......................................................................................................................3

2 Safety Information and Warnings ................................................................................4

3 Getting Started...............................................................................................................4

3.1 Unpacking ..............................................................................................................................................4

3.2 Setup......................................................................................................................................................4

4 Temperature Controller.................................................................................................5

4.1 Description of Controller.........................................................................................................................5

4.2 Controller Features.................................................................................................................................8

4.3 Entering Information............................................................................................................................... 9

4.4 Setting/Changing Parts of the Controller .............................................................................................11

4.5 Extra Functions ....................................................................................................................................12

4.6 Saving Programs..................................................................................................................................13

4.7 Calling Programs..................................................................................................................................13

4.8 Program Start.......................................................................................................................................14

4.9 Program Change during Execution......................................................................................................14

4.10 Brief Program Interruption.................................................................................................................15

4.11 Terminating a Program.....................................................................................................................15

4.12 Segment Skip Key ............................................................................................................................15

4.13 Info Menu..........................................................................................................................................15

4.14 Configuration/ Customer-Specified Settings.....................................................................................16

4.15 Configuration Options in Configuration Level 1................................................................................16

(Password = “0”).........................................................................................................................................16

4.16 Configuration Options in Configuration Level 2................................................................................17

(Password = “2”).........................................................................................................................................17

4.17 Auto Tune..........................................................................................................................................17

5 Operation .....................................................................................................................18

5.1 General Notes ......................................................................................................................................18

5.2 Regulating the air supply......................................................................................................................18

5.3 Maintenance and fault clearance.........................................................................................................18

6 Service Trouble Shooting...........................................................................................19

6.1 Replacing the heating plates or heating coil ........................................................................................19

6.2 Repairing the lining (only furnaces with brick insulation) .....................................................................19

6.3 Controller Troubleshooting...................................................................................................................20

7 Electrical Trouble Shooting........................................................................................22

8 Service..........................................................................................................................23

9 Storage.........................................................................................................................23

10 Warranty......................................................................................................................23

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Operation and Instruction Manual

K243XX Ashing Furnace

12 Returned Goods Policy...............................................................................................23

Notes..................................................................................................................................24

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Operation and Instruction Manual

K243XX Ashing Furnace

1 Introduction

The Koehler K243XX Muffle Furnace is the
latest design for performing Ashing of petroleum
products according to the ASTM test methods
listed in Section 1.2.

This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and operating
instructions for the Koehler Muffle Furnace. 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 19428­2959, USA
Tel: [phone]
Fax: [phone]

http://www.astm.org

email: [e-mail]

ASTM Publication:

 ASTM D482: Standard Test Method for

Ash from Petroleum Products

 ASTM D874: Standard Test Method for

Sulfated Ash from Lubricating Oils and
Additives

 ASTM D3174: Standard Test Method for

Ash in the Analysis Sample of Coal and
Coke from Coal

 ASTM D4422: Standard Test Method for

Ash Analysis in Petroleum Coke

 ASTM D5184: Standard Test Methods for

Determination of Aluminum and Silicon in
Fuel Oils by Ashing, Fusion, Inductively
Coupled Plasma Atomic Emission
Spectrometry, and Atomic Absorption
Spectrometry

1.3 Instrument Specifications

Models:

K24305, K24306,
K24307, K24308,
K24395, K24396,
K24397, K24398

Electrical

Requirements:

208V, 50/60Hz single
phase
240V, 50/60Hz single
phase

Temperature Range:

Temperature Control

Stability:

Open Volume:

Ambient to 1100°C

±3°C

0.07cu. ft. model: 3L

0.16cu. ft. model: 5L

0.33cu. ft. model: 9L

0.47cu. ft. model: 15L

Power:

0.07cu. ft. model: 1.2KW

0.16cu. ft. model: 2.4KW

0.33cu. ft. model: 3.0KW

0.47cu. ft. model: 3.6KW

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Operation and Instruction Manual

K243XX Ashing Furnace

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.

Disposal. Upon delivery the furnace does not
contain any material which is to be classified as
hazardous waste. However, process residues
may collect in the insulation during operation.
These may be dangerous to health and/or
dangerous to the environment.

Therefore we recommend proceeding as follows:
 Remove electrical components and dispose of

as electrical waste.

 Remove insulation and dispose of as special/

hazardous waste (wear a protective mask P2,
protective gloves and a protective suit).

 Dispose of the housing as scrap metal

3 Getting Started

assume that the user is aware of the contents of
this document, which lists the warranty conditions
and important precautions.

3.1 Unpacking

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.

The instructions for preparing the equipment

Carefully unpack and place the instrument and

3.2 Setup

3.2.1 Installation Site

Place the furnace on a non-flammable support
(stone, metal or similar). Keep a safe distance
from flammable components, 0.5 meter from the
furnace sides and 1meter from the top. The
minimum distance between the furnace sides and
non-flammable materials can be reduced to 0.2
meters.

Ventilation. Provide sufficient room ventilation to
carry off exhaust heat and gases which develop
during the process. Non-observance can result in
a fire risk and danger to health.

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Operation and Instruction Manual

K243XX Ashing Furnace

3.2.2 Assembling the Ventilation Pipe

 In all cases, we recommend connecting the

furnace to an exhaust ductwork, leading the
arising gasses out of the facility

 A standard ventilation pipe of metal with

NW80 – NW 210 can be used. It must be laid
at a constant slope and fastened to the wall or
ceiling.

 Caution: The exhaust gases can only be

carried off if the room is ventilated by a
corresponding fresh air opening.

3.2.3 Electrical Connection

 Plug the main plug in a corresponding

receptacle which is protected sufficiently
depending on the rated power of the furnace.
If the furnace is ordered / delivered without a
plug, a qualified electrician must connect the
furnace.

 NOTE

: Using extension cables and/or junction

boxes may lead to a reduced furnace output
due to the voltage drop in the lines. The

power is also reduced if the connection line to
the junction box is very long, and the furnace
will not reach its nominal temperature. Please
have the connection checked by an
electrician. The voltage may not drop below
the rated load by more than 10%.

WARNING

: For safety, disconnect the power

when performing any maintenance and/or
cleaning.

3.2.4 Initial Heating Procedure

 To dry out the brick lining and to create an

oxide protection layer on the resistance wire,
an initial heat run must be performed prior to
testing. This may cause an unpleasant smell.
Provide sufficient ventilation.

 Heat the empty furnace up to 1050ºC over the

course of 6 hours. Maintain this temperature
for one hour, then let the furnace cool down
on its own.

 The furnace is now ready to operate.

4 Temperature Controller

4.1 Description of Controller

4.1.1 Power Switch/ Control Current Switch

The power switch / control current
switch is located below or next to the keyboard
block. Stop running a heating program before
turning off the furnace with the power switch.

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4.1.2 Turning on the Controller/Furnace

Operation and Instruction Manual

K243XX Ashing Furnace

Switch the power switch to the “I” or ON position.
The controller first displays the controller type and
version number and then the temperature display.
Once the temperature is displayed, the controller
is ready to operate.

All necessary settings for proper function of the
furnace have been preconfigured at the factory.

The controllers for the heating program must be
configured on a process- or user- specific basis.

NOTE: Some functions depend on the version
number of the controller. Turn the controller off

4.1.4 Control Panel

and then on again to briefly display the version
number of the controller

4.1.3 Turning off the Controller/Furnace

Turn the main switch to position “O”

NOTE

: End all heating programs before turning

the furnace off at the main switch, otherwise the
controller will generate a fault message when it is
turned back on. See faults/fault messages in the
troubleshooting section.

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4.1.5 Display Panel

Operation and Instruction Manual

K243XX Ashing Furnace

4.1.6 Keypad

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