K16500, K16591, K16502, K16592

Rapid Flash Tester, Closed Cup

Operation and Instruction Manual

REV B

Koehler Instrument Company, Inc.

1595 Sycamore Avenue • Bohemia, New York 11716-1796 • USA
Toll Free: 1-800-878-9070 (US only) • Tel: +1 631 589 3800 • Fax: +1 631 589 3815
http://www.koehlerinstrument.com • e-mail: info@koehlerinstrument.com
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
 CERTIFICATE OF CONFORMANCE

Rapid Flash Point Tester

K165XX

This certificate verifies that part number K165XX, Rapid Flash Point Tester, was
manufactured in conformance with the applicable standards set forth in this
certification.

Specifications: ASTM D3278

ASTM D3828
ASTM D4206
DOT CFR 49-173.115
IATA
ISO 9038

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
 K16500, K16591, K16502, K16592
Operation and Instruction Manual

Table of Contents
1 Introduction ................................................................................................................... 2
1.1 Koehler’s Commitment to Our Customers ............................................................................................. 2
1.2 Recommended Resources and Publications ......................................................................................... 2
1.3 Instrument Specifications ....................................................................................................................... 3

2 Safety Information and Warnings ................................................................................ 3

3 Getting Started............................................................................................................... 4
3.1 Unpacking .............................................................................................................................................. 4
3.2 Assembly ................................................................................................................................................ 4
3.3 Preparation of Dry Ice/Acetone Slurry (Optional) ................................................................................... 5

4 Descriptions ................................................................................................................... 5

5 Operation ....................................................................................................................... 7
5.1 Flash Point Determination ...................................................................................................................... 7
5.1.1 Ambient to 572°F (300°C) Testing ................................................................................................ 7
5.1.2 Sub-Ambient Testing ..................................................................................................................... 7
5.2 Flash/No Flash Test ............................................................................................................................... 8
5.2.1. Ambient to 572°F (300°C) Testing .................................................................................................. 8
5.2.2. Sub-Ambient Testing ....................................................................................................................... 9
5.3 Method for Determining Dilution of a Flammable Liquid by another Flammable Liquid ...................... 10
5.3.1. Sampling ........................................................................................................................................ 10
5.3.2. Procedure ...................................................................................................................................... 10
5.3.3. Application ..................................................................................................................................... 10
5.3.4. Conclusion ..................................................................................................................................... 11

6 Calibration.................................................................................................................... 11
6.1 Instrument Calibration .......................................................................................................................... 11
6.2 Barometric Pressure Correction ........................................................................................................... 11

7 Maintenance ................................................................................................................. 11
7.1 Test Cup Fails to Heat ......................................................................................................................... 11
7.2 Temperature Control Does Not Regulate ............................................................................................ 12
7.3 Assembly Diagram ............................................................................................................................... 13

8 Service.......................................................................................................................... 14

9 Storage ......................................................................................................................... 14

10 Warranty ....................................................................................................................... 14

11 Returned Goods Policy ............................................................................................... 14

Notes .................................................................................................................................. 15

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Operation and Instruction Manual

1 Introduction 1.2 Recommended Resources and

Publications
The Rapid Tester is specifically designed for
ascertaining the flash point of a volatile material or Test cup and lid and shutter are dimensionally in
whether the flash point temperature of a material accord with ASTM, IP, ISO and BSI requirements
is within established limits (Flash / No Flash as delineated in their standards:
Procedure). Instruments utilize equilibrium, closed
cup technology. 1. American Society for Testing and Materials
(ASTM)
This manual provides important information 100 Barr Harbor Drive
regarding safety, technical reference, installation West Conshohocken, Pennsylvania 19428-
requirements, operating condition specifications, 2959, USA
user facility resource requirements, and operating Tel: +1 610 832 9500
instructions for the Rapid Flash Tester, Closed Fax: +1 610 832 9555
Cup. This manual should also be used in http://www.astm.org
conjunction with applicable published laboratory email: service@astm.org
procedures. Information on these procedures is
given in section 1.2. ASTM Publication:
 ASTM D3278: Flash Point of Liquids by
1.1 Koehler’s Commitment to Our Small Scale Closed Cup Apparatus
Customers  ASTM D3828: Flash Point by Small Scale
Closed Tester
Providing quality testing instrumentation and
technical support services for research and testing 2. International Organization for Standardization
laboratories has been our specialty for more than (ISO)
50 years. At Koehler, the primary focus of our 1, rue de Varembé
business is providing you with the full support of Case postale 56
your laboratory testing needs. Our products are CH-1211 Geneva 20, Switzerland
backed by our staff of technically knowledgeable, Tel: 41 22 749 01 11
trained specialists who are experienced in both Fax: 41 22 733 34 30
petroleum products testing and instrument service http://www.iso.org
to better understand your requirements and
provide you with the best solutions. You can ISO Publication:
depend on Koehler for a full range of accurate and  ISO 3679: Determination of Flash Point –
reliable instrumentation as well as support for your Rapid Equilibrium Closed Cup Method
laboratory testing programs. Please do not
 ISO 3680: Determination of Flash / No
hesitate to contact us at any time with your Flash – Rapid Equilibrium Closed Cup
inquiries about equipment, tests, or technical Method
support.
 ISO 9038: Test for Sustained
Combustibility of Liquids
Toll Free: 1-800-878-9070 (US only)
Tel: +1 631 589 3800
3. Energy Institute (IP)
Fax: +1 631 589 3815
61 New Cavendish Street
London, WIM 8AR, United Kingdom
Email: info@koehlerinstrument.com
Tel: 44 (0)20 7467 7100
http://www.koehlerinstrument.com
Fax: 44 (0)20 7255 1472
http://www.energyinstpubs.org.uk/

IP Publication:
 IP 303: Determination of Closed Flash
Point – Mini Equilibrium Method

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Operation and Instruction Manual

4. British Standards Institute Dimensions: 15.0x3.4x5.3 in.

389 Chiswick High Road (38.1x8.64x16.25 cm)
London
W4 4AL Net Weight: 6lbs (2.7kg)
United Kingdom
Tel: 44(0)20 8996 9001 2 Safety Information and Warnings
Fax: 44(0)20 8996 7001 Safety Considerations. The use of this
http://www.bsigroup.com equipment may involve hazardous materials and
operations. This manual does not purport to
BSI Publication: address all of the safety problems associated with
 BS 3900 Part A11: the use of this equipment. It is the responsibility of
 BS 3900 Part A13 any user of this equipment to investigate,
 BS 3900 Part A14: research, and establish appropriate safety and
health practices and determine the applicability of
Accepted by: regulatory limitations prior to use.
 CPSC: United States Consumer Products
Safety Commission Equipment Modifications and Replacement
 DOT: United States Department of Parts. Any modification or alteration of this
Transportation equipment from that of factory specifications is not
 EPA: United States Environmental recommended voids the manufacturer warranty,
Protection Agency product safety, performance specifications, and/or
 NFPA: National Fire Protection certifications whether specified or implied, and
Association may result in personal injury and/or property loss.
 OSHA: United States Occupational Safety Replacement parts must be O.E.M. exact
and Health Administration replacement equipment.

1.3 Instrument Specifications Unit Design. This equipment is specifically

designed for use in accordance with the applicable
Models: K16500, K16502 standard test methods listed in section 1.2 of this
K16591, K16592 manual. The use of this equipment in accordance
with any other test procedures, or for any other
Electrical purpose, is not recommended and may be
Requirements: 98-132V, 50/60Hz extremely hazardous.
196-264V 50/60Hz
Flash Point Chemical Reagents Information. Chemicals and
Temperature reagents used in performing the test may exhibit
Range: -36° to 572°F potential hazards. Any user must be familiarized
-30° to 300°C with the possible dangers before use. We also
recommend consulting the Material Data and
Temperature Safety Sheet (MSDS) on each chemical reagent
Display: Digital °F/°C LCD display for additional information. MSDS information can
and mercury-in-glass be easily located on the internet at
thermometer dual scale 30 http://siri.uvm.edu or http://www.sigma-
to 600°F and 0 to 316°C aldrich.com.
Cup Type: Closed, equilibrium test
WARNING: Flash point testers aid in determining
Operational the temperature at which application of a test
Sample Size: 2ml to 212°F (100°C) flame causes the vapors of a sample to ignite
4 ml above 212 to 527°F under specified conditions of test. Flammable and
(100 to 300°C) potentially explosive materials are involved in the
presence of a source of ignition. It is the direct
Repeatability: In accordance with Industry responsibility of the user to establish appropriate
Test Method safety and health practices for all personnel. The
Reproducibility: In accordance with Industry test procedures contained in this manual are for
Test Method reference purposes only. The user of the Rapid

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Operation and Instruction Manual

Tester® is to follow the instructions, warnings, and 230V service or export, the cord does not
the cautions contained in the industry test contain a plug. Its three conductors are
methods. stripped of insulation and ready for termination
in user supplied plug. The record contains
Under no circumstances should this product be three No. 18 AWG conductors. When
used except by qualified, trained personnel and attaching the plug, be sure to connect the
not until the instructions, labels or other literature green, ground conductor. The instrument
accompanying it have been carefully read and circuitry is internally grounded to its enclosure
understood and all precautions followed as set and integral power cord receptacle.
forth herein.
7. Check that the instrument primary power
3 Getting Started switch is in the OFF (switch depressed to "O")
position. Verify that the voltage stated on the
3.1 Unpacking label below the primary power receptacle is
Carefully unpack, account for and inspect the the same as your primary power source.
Rapid Tester, thermometer, fuel supply, syringe, Connect the power cord to the instrument and
cord and plug and optional accessories if ordered. then to your power supply receptacle.
Inspect each item for possible shipping damage.
Be careful not to discard any components that 8. If testing is at temperatures above 400°F
may be enclosed in packing material. (204°C), remove the silicone test cup o-ring
seal. Be sure that the groove is clean. Then
3.2 Assembly place gasket partially into groove. Lower lid of
lid and shutter to slowly press gasket into
1. Place instrument on a level bench top in a groove. Fasten lid with locking handle. The
draft free area. gasket will withstand the higher temperature
but is not as resilient and therefore the silicone
2. Remove the two screws from the thermometer 0-ring is recommended for testing below
hold down bracket. Remove the wood dowel 400°F (204°C).
thermometer substitute if provided.
9. Engage the threads of the fuel supply valve
3. Remove the thermometer from its shipping assembly to the fuel tank. Be sure that threads
tube and inspect. If the mercury column is are fully engaged to prevent leakage of
separated, the thermometer must be cooled butane. Place fuel tank in its instrument well.
and the mercury shaken down into the bulb. Press the clear tubing onto the fuel supply
valve and onto the fuel inlet of the lid and
4. Each instrument is supplied with a small shutter assembly. Turn the red knob of the
package of Heat Transfer Compound. Apply fuel tank clockwise until the container valve is
the compound to the bulb of the thermometer closed. The shaft actuated by turning the red
so that full contact will be made with the walls knob, first opens the container valve and then
of its well when inserted into the cup. closes it. Then turn the red knob
counterclockwise one (1) full turn. This will
5. Insert the thermometer carefully into the test open the container valve. Light the pilot on the
cup. Rotate the thermometer to position the lid and shutter assembly. Turning the red knob
scale for convenient reading of degrees of the fuel tank clockwise will cause reduction
Fahrenheit or Celsius. Position the in flame extension. Adjustment of the pinch
thermometer so that its end which is the high valve over the clear plastic tubing will cause
temperature reading will be fully under the the test flame to become the same size as the
clip. Replace the screws. To avoid breaking 0.157 inch (4mm) diameter gauge circle on
the thermometer, do not tighten the screws to the lid of the lid and shutter assembly. Turn off
cause more than a soft contact of the clip on fuel supply by turning the red knob of the fuel
the glass. tank clockwise.

6. The primary power cord has an internationally WARNING: Fuel tank includes butane, use with
uniform plug for connection to the instrument. care to avoid accidental fires. Do not puncture or
The plug which mates with the U.S. standard, incinerate. Exposure to temperatures above 120°F
115v grounded receptacle is standard. For (49°C) may cause bursting. Be sure Rapid Tester

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Operation and Instruction Manual

is fully assembled when in use. Internal barrier 7. Stir the mixture to ensure temperature
insulation reduces ambient temperature for fuel uniformity. There should be a slow but steady
tank. stream of carbon dioxide bubbles rising from
the bottom of the refrigerant charged cooling
10. Press primary power switch to "I" (ON). Adjust block.
temperature control knob while depressing
Preset and turn temperature control knob to 8. Replace the top cap to prevent excess venting
cause digital readout to be at approximately of acetone vapor.
149°F (65°C). Release the Preset switch. The
digital readout and the mercury-in-glass 9. Remove the bottom cap just before inserting
thermometer will indicate rising cup the cooling block into the test cup.
temperature. Turn the temperature control
knob counterclockwise and switch instrument 4 Descriptions
primary power switch to "O" OFF.

3.3 Preparation of Dry Ice/Acetone Slurry

(Optional)
Solid carbon dioxide in equilibrium with carbon
dioxide vapor at one atmosphere will provide
cooling to a temperature as low as -78°C /
109.3°F. The liquid acetone provides good thermal
contact throughout the bath. It also prevents air
from diluting the carbon dioxide gas at the surface
of the dry ice. The test cup must not be cooled to a
temperature below -38.4°C, the freezing point of
mercury.

1. Extinguish the pilot and test flames. Figure 1. Instrument Descriptions

2. Remove the top cover of the refrigerant Electrical Circuitry

charged cooling block and fill the cylinder one- The primary voltage of 115/230V, 50/60 Hz is
quarter to one-half full with acetone. DO NOT regulated to provide instrument control which is
FILL TO HIGHER LEVEL. virtually constant. Each instrument is internally
connected for user's nominal voltage of 115 or
3. Pulverize some dry ice with a grinder or by 230v prior to shipment. Its voltage connection is
wrapping chunks of dry ice in a tower and stated below the primary power inlet.
crushing them with a mallet.
Sample Size
WARNING: Use tongs or insulated gloves when The sample size for testing at 212°F (100°C) and
handling dry ice. lower is 2 ml. Above 212°F (100°C), the sample
size is 4 ml.
4. Add small quantities of pulverized dry ice to
the cylinder with a spatula. This dry ice will Syringe
evaporate almost immediately and cause An adjustable syringe is standard. It includes a
considerable foaming at the surface. holder with adhesive backing to allow mounting
on, for example, a laboratory bench or onto the
5. Add additional, small amounts of pulverized Rapid Tester enclosure above the digital display.
dry ice, waiting after each addition until the Spacers are provided to simplify 2 ml or 4 ml
foaming subsides. sampling. Materials of higher viscosity such as
adhesives, a 2 or 4 ml by volume sample is placed
6. Eventually, some dry ice will begin to directly into the cup by use of a spatula (user
accumulate at the bottom of the cylinder. At supplied).
this point, small chunks of dry ice can be
added without causing serious foaming.
O-ring/Gasket

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Operation and Instruction Manual

The seal between the cup and lid & shutter as requirements of applicable domestic and
shipped is silicone for testing to 400°F (204°C). A international standards which are:
separate gasket is also supplied for testing from
ASTM D 3243, D 3278 and D 3828
400 to 572°F (204 to 300°C).
IP 303
Temperature Displays ISO 3679 and 3680
BS 3900 Parts A11, A14
The Closed Cup Model covers the temperature
range of -36 to 572°F (-38 to 300°C). The The standard cup is aluminum. An optional cup
refrigerant charged cooling block, is required for with its companion lid and shutter of 316 stainless
below ambient testing. The standard dual scale steel material is available for higher corrosion
thermometer, reads to low temperatures of 32°F resistance.
and 0°C. For lower temperatures, the (-36 to The test cup is insulated with 1 inch (2.54 cm) sur-
105°F) or (-38 to 40°C) thermometers will be rounding sides and 1.5 inch (3.81 cm) at its bottom
needed. The thermometers are traceable for of low thermal conductivity ceramic fiber. When
accuracy to the U.S. National Institute of the test cup is at 300°F (148°C), the cold face
Standards and Technology. temperature of the ceramic is 100°F (38°C). This
attention to restricting heat flow achieves a higher
The digital temperature indicator compliments the
degree of repeatable flash points than feasible in
thermometers and a simple switch action changes
prior designs. Heating rates for the aluminum cup
the reading to either °C or °F. Its range is ambient
and/or 316 stainless steel cup are on the order of
to 572°F (300°C). The digital temperature indicator
7 minutes from ambient, 68°F/20°C to
provides instantaneous readings as compared to a
212°F/100°C.
mercury-in-glass thermometer which gives an
average indication at the instance of reading. Timer
Therefore the slight fluctuation is a reminder of An electronic timer includes switching for either 1
instant and actual temperature portrayal and the or 2 minutes and an associated red LED. The light
need to record the average or the digit between glows red when the timer is actuated and is
the high and low. If the average digital switched off when the period elapses and a signal
temperature display differs by more than 2°F or is emitted.
1°C from the thermometer reading, it may be
Cooling Block
desirable to cause the Rapid Tester to heat within
the range of your normal temperature usage, from The Metal Cooling Block, is primarily used to help
low to high temperature. Record the thermometer lower the cup temperature quickly to prepare for
readings and simultaneously the digital display the next test. One or more may be stored in a
every 20°F or 10°C to provide data points for a refrigerator for this purpose.
graph depicting any variation. This graph can then
For some testing at elevated temperatures, it may
be referred to when recording the digital display require one or more applications to cause required
and correcting to the thermometer. cooling.
Set-a-temp control permits simple adjustment and Refrigerant Charged Cooling Block (Optional)
automatic regulation of test temperatures higher
than ambient. Press the Preset switch while turn- This accessory is a thermally insulated cylinder
ing the temperature control knob until the target with an aluminum alloy base (for thermal transfer)
temperature is displayed. Release the switch and which fits the test cup recess. It includes a top and
set-a-temp takes over. The test cup is automati- bottom cover.
cally heated until the target temperature is
attained. The instrument automatically maintains For test temperature above 40°F/5°C, the cylinder
may be charged with a mixture of crushed ice and
the target temperature. Slight movement of the
temperature control knob may be necessary to distilled water.
obtain a specific target temperature.
For test temperature below 40°F/5°C, the cylinder
Test Cup may be charged with dry ice/acetone slurry. Refer
to Section 3.3 for directions to prepare dry
Instrument utilizes closed cup type equilibrium test
ice/acetone slurry.
technology. Dimensions of test cup and lid and
shutter assembly meet the exact dimensional

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WARNING: Safety glasses and gloves should be comparatively large flame appears and
used when preparing acetone/dry ice slurry. propagates over the surface of the liquid.
Sporadically, when near the actual flash point
Repeatability and Reproducibility temperature, application of the test flame may
give rise to a blue halo (circular band); this
As the test cup with its lid and shutter assembly is
should be ignored.
in accord with dimensions required by applicable
standards, the repeatability and reproducibility are
9. Close gas control valve after each test.
also in accord with the respective standards.
Record barometric pressure. Report FLASH or
NO FLASH. Once the test flame has been
5 Operation applied to the sample, the test is terminated
5.1 Flash Point Determination and a fresh sample must be used for each
successive test.
5.1.1 Ambient to 572°F (300°C) Testing
1. Inspect sample well and lid/shutter for 10. To prepare for the next test, unlock the lid and
cleanliness and freedom from contamination. shutter. Soak up the sample using paper
tissues and thoroughly clean the lid and
2. Switch instrument to “I” (ON). shutter assembly. The filling orifice should be
cleaned with a pipe cleaner or similar device.
3. Adjust temperature control knob while Do not lubricate the shutter slide. Clean the
depressing Preset switch until digital meter syringe.
reads a temperature that is at least 9°F (5°C)
below expected flash point temperature. 11. If No Flash has been observed, at the initial
estimated flash point temperature, repeat the
4. When the digital display reaches the Preset test at a 9°F (5°C) higher temperature. Again,
temperature, the red light will extinguish. It if No Flash is observed, repeat the test at
may be necessary to make a slight adjustment additional 9°F (5°C) higher intervals until a
using the temperature control knob. The red Flash is observed.
light will glow whenever the instrument is
heating the cup to maintain the specified 12. If a Flash was observed during the initial test,
temperature. use a test temperature 9°F (5°C) lower and
repeat the procedure. If a Flash is again
5. Be sure that the syringe is clean and dry. observed, repeat at 9°F (5°C) lower intervals
Draw 2 ml of sample [test temperatures of until No Flash is observed.
212°F (100°C) or less] or 4 ml [test
temperatures of 212°F (100°C) or higher] after 13. Having established a Flash within two
target temperature is reached and discharge temperatures 9°F (5°C) apart, repeat either
into the sample well. procedure at 2°F (1°C) intervals from the
lower of the two temperatures until a Flash is
6. Open the gas control valve and light pilot/test observed. Record the temperature of the test
flame. Turn the gas control valve clockwise to when the Flash occurs as the Actual Flash
reduce the pilot flame. The pilot flame is to be Point.
a minimum size to automatically relight test
flame. Adjust test flame size with the pinch 14. Close gas control valve after each test.
valve to match the 0.157 inch (4mm) diameter
gauge ring on the lid and shutter. 15. Record the barometric pressure.

7. Set timer by pressing its switch to "1 min" [test 16. This Flash Point will be to the nearest 2°F. If
temperatures of 212°F (100°C) or less] and "2 closer accuracy is needed, further testing at a
min" [test temperatures of 212°F (100°C) or 1°F (0.5°C) lower temperature is required.
higher].
5.1.2 Sub-Ambient Testing
8. When the time has elapsed, slowly and 1. When the tests are to be made at
uniformly open and close the slide completely temperatures lower than ambient, it is
over a period of 2fi seconds while watching for necessary to use the sub-ambient
a flash. The material has flashed if a

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Operation and Instruction Manual

thermometer. This substitution should be 9. To prepare for the next test, unlock the lid and
carried out in accordance with Section 3.2, shutter. Soak up the sample using paper
Assembly. When the sub-ambient tissues and clean the lid and shutter
thermometer is installed, care must be taken assembly. The filling orifice should be cleaned
not to exceed +105°F (+40°C). with a pipe cleaner or similar device. Do not
lubricate the shutter slide. Clean the syringe.
2. Lower test cup temperature by use of the
Refrigerant Charged Cooling Block. For flash 10. If No Flash has been observed at the initial
point temperatures above 40°F (5°C), the cyl- estimated flash point temperature, repeat the
inder may be charged with a dry ice/acetone test at a 9°F (5°C) higher temperature. Again if
slurry. Refer to Section 3.3 for directions to No Flash is observed, repeat the test at
prepare dry ice/acetone slurry. additional 9°F (5°C) higher intervals until a
Flash is observed.
3. Cool the sample and syringe in a cooling
medium to a temperature approximately 10 to 11. If a Flash was observed at the initial estimated
20°F (5 to 10°C) below the estimated flash flash point temperature, use a test
point temperature. temperature 9°F (5°C) lower and repeat the
procedure. If a Flash is again observed,
4. Remove the cooling source and dry the test repeat at additional 9°F (5°C) lower intervals
cup. Close the lid and shutter assembly. until No Flash is observed.

5. Ensure that the syringe is clean and dry. 12. Having established a Flash within two
Charge with 2 ml of sample. Introduce the temperatures 9°F (5°C) apart, repeat either
sample using the syringe, both of which have procedure at 2°F (1°C) intervals from the
been pre-cooled to a temperature of 10 to lower of the two temperatures until a Flash is
20°F (5 to 10°C) below the target temperature. observed. Record the temperature of the test
Do not switch on the timer! when the Flash occurs as the Actual Flash
Point.
6. Open the gas control valve and light pilot/test
flame. Turn the gas control valve clockwise to 13. Close gas control valve after each test.
reduce the pilot flame. The pilot flame is to be
at a minimum size to automatically relight the 14. Record the barometric pressure.
test flame. Adjust test flame size with the
pinch valve to match the 0.157 inch (4mm) 15. This Flash Point will be to the nearest 2°F. If
diameter gauge ring. closer accuracy is needed, further testing at a
1°F (0.5°C) lower temperature is required.
7. Allow the cup temperature to rise under ambi-
ent conditions. When the specified 5.2 Flash/No Flash Test
temperature is reached, slowly and uniformly
open and close the slide completely over a 5.2.1. Ambient to 572°F (300°C) Testing
period of 2fi seconds while watching for a
flash. The material has flashed if a 1. Inspect sample well and lid/shutter for
comparatively large blue flame appears and cleanliness and freedom from contamination.
propagates over the surface of the liquid.
Sporadically, when near the actual flash point 2. Switch instrument to "I" (ON).
temperature, application of the test flame may
give rise to a blue halo (circular band); this 3. Adjust temperature control knob while
should be ignored. depressing Preset switch until digital meter
reads required temperature. Release Preset
8. Close gas control valve after each test. switch.
Record barometric pressure. Report FLASH or
NO FLASH. Once a test flame has been 4. When the digital display reaches the Preset
applied to the sample, the test is terminated temperature, the red light will extinguish. It
and a fresh sample must be used for each may be necessary to make a slight adjustment
successive test. using the temperature control knob. The red
light will glow whenever the instrument is

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Operation and Instruction Manual

heating the cup to maintain the specified thermometer is installed, care must be taken
temperature. not to exceed +105°F (+40°C).

5. Be sure that the syringe is clean and dry. 2. Lower test cup temperature by use of the
Draw 2 ml of sample [test temperatures of Refrigerant Charged Cooling Block. For flash
212°F (100°C) or less] or 4 ml [test point temperatures above 40°F (5°C), a
temperatures of higher than 212°F (100°C)], mixture of water and crushed ice placed in the
transfer to the filling orifice after target cylinder may be suitable. For temperatures
temperature is reached and discharge into the below 40°F (5°C), the cylinder may be
sample well. charged with a dry ice/acetone slurry. Refer to
Section 3.3 for directions to prepare dry
6. Set timer by pressing its switch to "1 min" [test ice/acetone slurry.
temperatures of 212°F (100°C) or less] and "2
min" [test temperatures of 212°F (100°C) or 3. Cool the sample and syringe in a cooling
higher]. medium to a temperature approximately 10 to
20°F (5 to 10°C) below the specified
7. Open gas control valve and light pilot/test temperature.
flame. Turn the gas control valve clockwise to
reduce the pilot flame. The pilot flame is to be 4. Cool the test cup until the temperature
at minimum size to automatically relight test declines to approximately 10 to 20°F (5 to
flame. Adjust the test flame size with the pinch 10°C) below the specified temperature.
valve to match the 0.157 inch (4mm) diameter
gauge ring on the lid of the lid and shutter. 5. Remove the cooling source and dry the test
cup. Close the lid and shutter assembly.
8. When the time has elapsed, slowly and
uniformly open and close the slide completely 6. Ensure that the syringe is clean and dry.
over a period of 2fi seconds while watching for Charge with 2ml of sample. Introduce the
a flash. The material has flashed if a sample using the syringe, both of which have
comparatively large flame appears and been pre-cooled to a temperature 10 to 20°F
propagates over the surface of the liquid. (5 to 10°C) below the target temperature. Do
Sporadically, when near the actual flash point not switch on the timer!
temperature, application of the test flame may
give rise to a blue halo (circular band); this 7. Open the gas control valve and light pilot/test
should be ignored. flame. Turn the gas control valve to reduce the
pilot flame. The pilot flame is to be at minimum
9. Close gas control valve after each test. size to automatically relight test flame. Adjust
Record barometric pressure. Report FLASH or test flame size with the pinch valve to match
NO FLASH. Once a test flame has been the 0.157 inch (4mm) diameter gauge ring.
applied to the sample, the test is terminated
and a fresh sample must be used for each 8. Allow the cup temperature to rise under
successive test. ambient conditions. When the specified
temperature is reached, slowly and uniformly
10. To prepare for the next test, unlock the lid and open and close the slide completely over a
shutter. Soak up the sample using paper period of 2fi seconds while watching for a
tissues and clean the lid and shutter flash. The material has flashed if a
assembly. The filling orifice should be cleaned comparatively large flame appears and
with a pipe cleaner or similar device. Do not propagates over the surface of the liquid.
lubricate the shutter slide. Clean the syringe. Sporadically, when near the actual flash point
temperature, application of the test flame may
5.2.2. Sub-Ambient Testing give rise to a blue halo (circular band); this
should be ignored.
1. When tests are to be made at temperatures
lower than ambient, it is necessary to use the 9. Close gas control valve after each test.
sub-ambient thermometer. This substitution Record barometric pressure. Report FLASH or
should be carried out in accordance with NO FLASH. Once a test flame has been
Section 2 -Assembly. When the sub-ambient applied to the sample, the test is terminated

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and a fresh sample must be used for each material. Do not open sample containers
successive test. unnecessarily and do not transfer the sample to
the cup unless its temperature is at least 20°F
10. To prepare for the next test, unlock the lid and (10°C) below the expected flash point. Samples
shutter assembly. The filling orifice should be from leaky containers should not be used.
cleaned with a pipe cleaner or similar device.
Do not lubricate the shutter slide. Clean the 5.3.2. Procedure
syringe.
Using a fresh sample of the lubricant being tested,
measure into 2 oz. bottles, 49.7 ml, 49.5 ml, 47.5
5.3 Method for Determining Dilution of a ml and 45.0 ml of the standard lubricant
Flammable Liquid by another respectively. Then pipet into each bottle sufficient
Flammable Liquid amount of the standard fuel under test to equal 50
NOTE: This procedure utilizes an example of ml, resulting in lubricants with volume
engine lubricant dilution by fuel to portray method. concentration of 0.6%, 1.0%, 2.0%, 5.0% and
10.0% contaminants.
This is a suggested procedure for determination of
volatile, flammable liquid dilution or contamination NOTE: When residual fuel such as residual JP-4
of turbine or reciprocating engine lubricants. is to be determined in lubricants, the fuel should
be distilled off below 275°F and discarded (about
Slight dilution of lubricants with fuel can reduce the 55%). Use the remainder (about 45%) in
lubricity of the lubricant and dangerously lower its preparation of the calibration samples. Other
flash point. This may result in a fire and/or loss of temperatures may be selected as agreed upon.
an engine.
Determine the flash point of each mixture
Dilution/Time characteristics may identify degree according to the procedure (Section 3). Shake
of engine component wear. each test sample bottle for thorough mixing before
extracting a test specimen. When barometric
Materials Required: pressure differs from 760 mm (101.2 kPa),
 Rapid Tester, Closed Cup Model calculate the flash point temperature by means of
the equation in Section 6.2.
 Refrigerant charged cooling block
 Barometer
Construct a graph plotting the percent contaminant
 Burette Type II Style I, Class B- Fed. Spec. as the abscissa and the flash point temperature as
NNN-B 789-50 ml the ordinate.
 Pipet Type I, Class B- Fed. Spec. NNN-P-
350-10 ml. 5.3.3. Application
 Bottles, 2 oz., glass, wide mouth
 Fuels, standard, as required After determining the flash point temperature of a
 Lubricants, standard, as required lubricant sample which may be diluted with a
 n-Decane, n-Undecane, n-Tetradecane and volatile, flammable liquid such as a fuel, refer to
n-Hexadecane or other verification the graph. At the point where the temperature
standards, as required, for checking the intersects the curve, the percent dilution if any,
Rapid Tester can be determined by locating the corresponding
number of abscissa. This information will assist an
 Cooling Mixture of ice water or dry ice (solid
investigation as to the source of the
CO2) and acetone
contamination.
 Heat transfer paste
If there is a percent of dilution that is acceptable,
5.3.1. Sampling
use the graph to determine the correlating
Obtain at least 100ml samples from the bulk temperature. Then use the Flash / No Flash
source and store in nearly full, tightly closed clean procedures in Section 5.2 to rapidly determine
glass containers or in other containers suitable for acceptable lubricant.
the types of liquid being sampled.
By knowing the minimum flash point temperature
Erroneously high flash points may be obtained if of acceptable lubricant, using the Flash / No Flash
precautions are not taken to avoid loss of volatile procedure in Section 5.2, acceptable quality can

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be determined for lubricants that may be diluted by 6.2 Barometric Pressure Correction
other volatile, flammable material.
When the barometric pressure differs from 760
5.3.4. Conclusion mm Hg (101.2 kPa), calculate the flash point
This procedure is provided as a guide for initiating temperature by means of the following equations:
a method whereby flash point testing can be a
useful tool in determining dilution of a flammable Calculated flash point = F + 0.06 (760 -P)
liquid by another flammable liquid. = C + 0.03 (760 -P)

6 Calibration Where: F,C = observed flash point, °F (or °C) and

P = barometric pressure, mm Hg.
6.1 Instrument Calibration
 Determine the flash point of the check or Determine the corrected specification flash point
reference standard that has a flash point by the following equation:
temperature that is near your target
temperature by following the direction in F = S -0.06 (760 -P)
Section 4. When the instrument is operating C = S -0.03 (760 -P)
properly, the flash point temperature for that
check fluid will be obtained within the 7 Maintenance
tolerances stated. If the flash point is not
within the tolerance stated, refer to Section 7.1 Test Cup Fails to Heat
7.
 Check electrical supply and power cord. Be
 Typical specifications for flashpoint check or sure power switch is “O” (OFF). Disconnect
reference standards. Refer to the reference power cord. Use ⁄ inch (0.64cm) wide screw
standard supplier certification for the batch driver blade and turn fuse holder cover
you are using. counterclockwise. Test fuse. Replace if
necessary, install and replace fuse cover.
- n-Decane Reconnect power cord.
 Specific Gravity: 60/60°F
(15.5/15/6°C), 0.73 nominal  Check temperature control potentiometer.
 Boiling Point: 345.38°F (174.1°C) Disconnect primary power cord. Remove
 Melting Point: 21.46°F (-29.7°C) thermometer by disengaging the two screws
minimum on the thermometer hold down bracket.
 Flash Point: 115 ± 1°F (46.1 ± Remove and place thermometer where it will
0.5°C) acceptable range not be damaged. Remove four screws, two
- n-Undecane front and two at back which hold top cover
 Specific Gravity: 60/60°F
to base of instrument. Remove top cover
(15.5/15/6°C), 0.74 nominal
carefully and invert onto soft material to
 Boiling Point: 386.15°F (196.75°C)
cushion switches, etc. Remove the three
 Melting Point: -14.8°F (-25.6°C)
 Flash Point: 140 ± 2°F (60 ± 1.0°C) conductors from the electronic circuit board
- n-Tetradecane terminal strip. Test potentiometer. It is rated
 Specific Gravity: 60/60°F 2K ohms, 10 turns. Replace as necessary.
(15.5/15/6°C), 0.7628 nominal
 Boiling Point: 488.6°F (253.7°C)  Check condition of the following by
 Melting Point: 42.6°F (5.9°C) sequentially removing their conductors from
 Flash Point: 211 ± 2°F (99 ± 1.0°C) the electronic circuit board terminal strip and
- n-Hexadecane replacing the conductors after test
 Specific Gravity: 60/60°F component is found to be operational:
(15.5/15/6°C), 0.77 nominal
 Boiling Point: 548.6°F (287°C) - Separately, check that the two cartridge
 Melting Point: 64.4°F (18°C) heaters are each rated 115V, 50W.
 Flash Point: 275 ± 2°F (135 ± 1.0°C) - Primary conductors from transformer.

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- Conductors from primary power

receptacle. Check for continuity
between conductors and blades in
receptacle.

7.2 Temperature Control Does Not

Regulate
 If electronic circuit board is potential cause,
replace it. Identify and remove all
conductors not from circuit board. Remove
the four hold down screws. Pry board gently
to cause switch retainers to release. When
installing a circuit board be sure that the four
switches and five LEDs are oriented to be
inserted into the switch bezels and LED
cups. Replace screws and conductors.
 If the thermocouple is suspect, replace by:

- Disconnecting the thermocouple leads

and cartridge heater leads from the
circuit board terminals. Release the
conductors from retaining devices.
Remove the nuts from the two studs
at the bottom of the white ceramic
thermal insulator. Remove the
ceramic insulator and protect the
conductors as they slip through their
outlet.
- Disengage the set screw in the base
of the test cup. The thermocouple can
be drawn from the test cup. Reverse
when installing a replacement.

 If either cartridge heater requires

replacement, a similar procedure is
required. The two set screws in the bottom
of the test cup each retain a cartridge
heater. Disengage the threads of a set
screw releases the inoperative heater. Draw
out and replace the heater. Engage the
threads of the set screw until it holds the
cartridge heater in place. Do not over tighten
as the heater jacket could be pierced. Re-
assemble.

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7.3 Assembly Diagram

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responsibility of Koehler Instrument Company and

8 Service the purchaser’s exclusive remedy for any claim
arising out of the purchase of any product is the
Under normal operating conditions and with repair or replacement of the product. In no event
routine maintenance, the Rapid Closed Cup Flash shall the cost of the purchaser’s remedy exceed
Tester should not require service. Any service the purchase price, nor shall Koehler Instrument
problem can be quickly resolved by contacting Company be liable for any special, indirect,
Koehler’s technical service department either by incidental, consequential, or exemplary damages.
letter, phone, fax, or email. In order to assure the KOEHLER INSTRUMENT COMPANY, INC.
fastest possible service, please provide us with the DISCLAIMS ALL OTHER WARRANTIES,
following information. EXPRESSED OR IMPLIED, INCLUDING ANY
IMPLIED WARRANTIES OF FITNESS FOR A
Model Number: PARTICULAR PURPOSE. Please save the
Serial Number: shipping carton in the event the equipment needs
to be returned to the factory for warranty repair. If
Date of Shipment: the carton is discarded, it will be the purchaser’s
responsibility to provide an appropriate shipping
9 Storage carton.
This laboratory test instrument is equipped with
electrical components. Storage facilities should be 11 Returned Goods Policy
consistent with an indoor laboratory environment.
This testing equipment should not be subjected to To return products for credit or replacement,
extremes of temperature and/or moisture. please contact Koehler Customer Service with
your purchase order number, our packing
This equipment was shipped from the factory in list/invoice number, the item(s) to be returned and
a corrugated cardboard container. If long term the reason for the return. You will be issued a
storage is anticipated, re-packing the instrument in Returned Authorization (RA) number, which must
a water-resistant container is recommended to be prominently displayed on the shipping
ensure equipment safety and longevity. container when you return the material to our
plant. Shipping containers without an RA number
prominently displayed with will be returned to the
10 Warranty sender. Goods must be returned freight prepaid.
We, at Koehler, would like to thank you for your Returns will be subject to a restocking charge, the
equipment purchase, which is protected by the application of which will depend upon the
following warranty. If within one (1) year from the circumstances necessitating the return. Some
date of receipt, but no longer than fifteen (15) returns cannot be authorized, including certain
months from the date of shipment, Koehler products purchased from outside vendors for the
equipment fails to perform properly because of convenience of the customer, products
defects in materials or workmanship, Koehler manufactured on special order, products shipped
Instrument Company, Inc. will repair or, at its sole from the factory past ninety (90) days, and
discretion, replace the equipment without charge products which have been used or modified in
F.O.B. its plant, provided the equipment has been such a way that they cannot be returned to stock
properly installed, operated, and maintained. for future sale.
Koehler Instrument Company must be advised in
writing of the malfunction and authorize the return
of the product to the factory. The sole

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Notes

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Notes

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