5) Service Manual KB - KBF

Service documentation series KB/KBF
bin
Chapter 1 Trouble shooting
Chapter 2 Cooling System
Chapter 3 Calibration
Chapter 4 Maintenance
Chapter 5 Function
Chapter 6 Pictures of construction

(showing the different states)
BB / JTU 25.06.2000
Introduction
The KBF series exists since 1993 in following states:
(Controler / Humidity control)
SM + RD2.1 Controller + Humidity Control Board

Æ 9/1997
EM2-Board
L3-Board
The EM2-Board was used since beginning of Production of the KBF climatic
chamber.
The L3-Board was used since following Data:

KBF 115 Æ Production Series 1/98
KBF 240 Æ Production Series KW7/98
KBF720 Æ No Data available
D2 Controller
9/1997 Æ
L3-Board
SPS-Control / Binder Humidity Board
The SPS-Control and the Binder Humidity Board are in use since:
KBF115 Æ 990086
KBF240 Æ 990176
KBF720 Æ 990444
BB / JTU 25.06.2000
Chapter 1
Trouble Shooting
KB/KBF
Fault description Fault cause
No or to low cold output x Ambient temperature 22°C? For each Kelvin that the ambient
temperature is above 22°C, the cold output will be approx. 1.5K
lower.
x Compressor switched on? Warm air must be present on the left of
the unit (condenser). Copper pipe between compressor and
condenser must be hot.
x KB: Measure the cold output on the RD2.1 controller
x KBF: Check the operation of the Solid valve
x Condenser is soiled
x Air-Supply troubled
x In normal operation, the pipe of the pressure side had to heat up
to 50°CÆ70°C. If not, there is a fault at the compressor.
x If everything is in order electrically, it is likely that the cold gas has
leaked. Critical points are all bends, the condenser (soldering
joint) or an old chamber (rock wool).
Condensation at Suck Side of x There is an overfill of the refrigerant

the Compressor
built-in a interface-card to SM- see separate check list
humidity controller
Humidity too less see separate check list
(D2 controller)
RH% sporadically to high In the older KBF’s mechanical relays (K3) were fitted instead of
semiconductor relays (K3/K4). Due to the contacts sticking, the
electrodes were charged for too long, causing excessive humidity
fluctuations. Change it and fit in semiconductor relay
Fault on the humidity board A red LED is located on the humidity board, which can indicate the
EM2 following faults:
x Red LED flashes – the humidity control has a fault. Switch the unit
off and on again to check again – change EM2-Board
x Red LED ON, the max. cylinder level has been reached. The inlet
valve is blocked for approx. 30 sec.
Fault on the humidity board L3 Three LED are located on the humidity board. The LED are showing
to the bottom of the I-box. The LED are to see with a look under the
board respectively with a sheet paper (reflections) respectively to
make it visible at a mirror. The LED shows following information.
x Green LED the humidity board is in operation
x Yellow LED steam production
x Red LED flashes – the humidity control has a fault. Switch the unit
off and on again to check again – change L3-Board
Red LED ON, the max. cylinder level has been reached. The inlet
valve is blocked for approx. 30 sec.
BB / JTU 25.06.2000
Check List - Humidity too less (D2-Controller and SM-Controller)
Most common faults with KBF is too less humidity take this list for trouble shooting
Pos. Remark
1 Water conductivity
2 Waterinlet pressure 1-10bar
3 Wateroutlet without any counterpressure
4 Test function of the Solid valve with 230V
5 Test the swimming switch, down position OK (located behind the steam cylinder)
6 Set controller to 80% r.H.
7 Measure voltage at controller pin 343 and 342 (new D2 controller with the green text
display) , or between pin 42-43 (old SM controller) The correct voltage for max. steam
production is 4,5 V
8 Measure voltage 4 and 5 from the humidity board (target of above point)
9 Water level in the steamgenerator (plastic bottle)?
10 Measure current which is flowing between the electrodes
11 L3 board: LED at the humidity board (LED shows to the bottom)
green voltage OK
yellow steam production
red blinking error message, permanent steam generator full
Or in case of old EM2-board:
Blinking red LED means faulty humidity board
Highlighted red LED means max. filling level of the steam cylinder is reached (means too
less water conductivity)
BB / JTU 25.06.2000
Retrofitting of a RS232 interface card on SM humidity controller with KBF
series up to 9/1997
To enable communication between APT-COM or a other data acquisition system with a SM humidity
controller of elder KBF climatic chambers it is necessary to retrofit a interface card inside the
controller.
Following steps have to be carried out:

A) Plug in the interface card inside the controller
B) place a rectangle hole for the interface socket trough the rear wall directly beside the interface
socket which already exists for the RD2 temperature controller
C) connect the interface wire (with soldered female 25 pin SUB-D interface socket) with the controller
D) Enter the correct parameters on the controller
A) Unscrew the controller with the screw at its B) place a rectangle hole (size
front panel to pull it out of its frame. Insert the 42 X 11 mm) for the interface
interface card BINDER Part. No. 5014-0036 to socket trough the rear wall
this position: directly beside the interface
socket which already exists for
the RD2 temperature controller
C)Insert the interface cable BINDER part No.

5023-0007 and fasten its socket in the hole.
Connect the cable to following connectors of the

SM controller:
RxD No . 91 ------- 2
SM humidity controller for KBF until September TxD No- 93 ------- 3
1997 GND No. 90 ------7
Bridged at the connector side: 4+5 and 6+8+20
D) Some controller parameters have to be

adjusted.
To enter the parameter level you have to unlock
the controller parameter level at first. DIP-switch
S201 No. 2 (of the switch block located next to the
front panel) to OFF (= downwards).
Normal status for comparison is only 1 and 5 off.
BB / JTU 25.06.2000
To enter the parameter level go on as following:
x Press the and keys twice together. The following display will appear:
---
Sd.01
You can toggle through the levels with button “W“ from one parameter to the next
e.g. Sd.01 –Sd.02 - Sd.03...
On level Sd. 01 and Sd 04 you have to go in by pressing Enter to change parameter C112 resp.
C411,C412 and C413 as descried on following parameter list.
Sd01
C111
C112 0001
C113
C114
C115
C121 All other parameters remain unchanged.
Sd02
C211 Confirm any change with enter and go after all is
C221 done out with exit.
C222
C223 After this adjusting set the DIP-switch No.2 back to
C231 ON to avoid further changes.
Sd03
C311
C312
C313
Sd04
C411 0001
C412 0810
C413 0000
C414
Sd05
and so on
Now switch the unit on and after 10 seconds on again.

The interface card is now ready installed.
Hint on connection with APT-COM:

If the KBF chamber is equipped with 2 serial interfaces RS 232 it needs two 9m connection cables and
two COM-ports at the PC. A RS232 Extension port offered by BINDER (see APT-COM price list) is
necessary if the PC does not have two free serial interfaces RS 232.
BB / JTU 25.06.2000
Chapter 2
Cooling System
Refrigerants used
The following refrigerants have been and/or are used for units with cooling systems. The quantity
given here is the maximum filling quantity. R12 and R502 refrigerants are halogenised
refrigerants, which may no longer be used. However, a replacement coolant is available on request.
APT-Line
KB; KBF; KBWF; KBW 53, 115, 240 R134a; 300g
KB; KBF; KBWF; KBW 720 R134a; 500g
Since September 98
KB 53, 115 R134a; 150g
KB, KBW 240 R134a; 300g
KB, KBW 720 R134a; 500g
KBF 115 R134a; 200g

KBF 240 R134a; 300g
KBF 720 R134a; 500g
New series without injection valve (capillary tube)

KB/KBF/KBW/KBWF all sizes since 1999 respectively serial no. 990001
Chamber Since Capillary tube/ Capillary tube/ Quantity

serial no. plate evaporator humidity evaporator refrigerant R134a
KB53 990001 500mm --- 150gr.
KB115 990001 500mm --- 150gr.
KBF115 990086 500mm 1800mm 200gr.
KB240 990016 500mm --- 200gr.
KBF240 990086 500mm 1500mm 200gr.
KBW 240 990156 500mm --- 200gr.
KBWF 240 990166 500mm 1500mm 200gr.
KB720 990348 1000mm --- 250gr.
KBF720 990363 1000mm 1300mm 250gr.
KBW720 990423 1000mm --- 250gr.
PT-Line
KBW all sizes R12; 500g
KB all sizes R12; 300g
Compressors used
KB/KBF/KBW/KBWF 53, 115 and 240 GL60TB
KB/KBF/KBW/KBWF 720 GP12TB
Chamber Description
KB/KBF/KBW/KBWF 53,115 and GL60TB
240
KB/KBF/KBW/KBWF 720 GP12TB
BB / JTU 25.06.2000
Look in the cooling System of the KB/KBF Chamber
Dehumidifier Pressure Side Suck Side

Compressor
Behind the sheet metal
casing lies the Liquefier Semiconductor
Capillary Tube Relay (K2)
Components of the KB/KBF cooling system:
¾ Compressor
¾ Evaporator (inside the chamber)
¾ Dehumidifier
¾ Liquefier
¾ Capilary Tube
¾ Semiconductor Relay (K2)
BB / JTU 25.06.2000
Trouble Shooting KB / Cooling System
Assumption: No Cooling
Do Controller (N1) emits a Signal to the Solid State Relay (K3) ?
ÆYES Check the Solid State Relay (K3)
ÆNO Change the Controller (N1)
Does the Solid State Relay (K3)
ÆYES Check the voltage at the Terminal-Block
ÆNO Solid State Relay (K3) defect
Is there a current at the Compressor ?
ÆYES Compressor is defect, change the Compressor
ÆNO Check the cabling
Trouble Shooting KBF / Cooling System
Assumption: No Cooling
Does the Controller (N1) emits a Signal?
ÆYES Check the Compressor and Solenoid Valve
ÆNO Controller (N1) is defect
Does the Compressor work?
ÆYES Possible that there is no refrigerant inside the chamber
ÆNO Check the voltage at the Terminal-Block
Is there a voltage at the Compressor?
ÆYES Compressor is defect
ÆNO Check the cabling
BB / JTU 25.06.2000
Description Binder Humidity board Art. No. 9505-0036

for climatic chambers type KBF and KBWF
Identification printed on the board H1.001/03-03-212
Functions:
A) Measuring voltage 230V AC on the filling level detector electrode of the steam cylinder.
B) Measuring of current between the electrodes for steam production
C) Measuring of the low-level DC voltage which is the humidity demand coming from the process
controller DICON 1000/1001
As well forward transfer o this states as binary messages to the PLC humidity control as signals
0 or +24V DC.
Description A)
A pair of electrodes in a plastic container is set under voltage 230V AC to generate steam for
controlled humidification.
This container is filled with tap water via a solenoid valve until the current between the two electrodes
reaches about 2A.. In case this maximum current is not reached until maximum filling of the container
the filling limitation electrode gets 230V AC (plug connectors L1/B1 against N)
+24V are given out via plug connector “SPS I 0.1” to the PLC as message that maximum filling level is
reached.
Caution !
High Voltage about plug connectors L1/B1 and N
Do not touch!
Description B)
The alternating current trough the steam electrodes is brought via a short induction path to the
BINDER humidity board. Loop between plug connectors L1 and L2.
The exact setting of the maximum permissible current between the steam electrodes becomes
adjusted via potentiometer R4 or R5 to set the switching point to 2A as limit for the current through the
steam electrodes.
With smaller current than 2A the red LED illuminates and plug connector SPS I 0.5 gives +24V DC to
the PLC as message that the 2A not reached yet..
With higher current through the electrodes the red LED extinguishes and the voltages at plug
connectors SPS I 0.5 gets reduced to 0V as message that the 2A is reached.
Caution !
High Voltage about plug connectors L1 and L2
Do not touch!
BB / JTU 25.06.2000
Description C)
Humidity demand is given out from the process controller types DICON 1000/1001 (= D2 and PD2) as
a binary signal 0V or 24V to the control side of the two solid state relays for the electrode current path
(see wiring diagram KBF).
0V = no humidity demand
24V = steam production necessary
The binary signal is taken there and gets via plug connector HLR + and – to the BINDER humidity
board.
The Binder Humidity Board switches +24V on plug connector SPS I 0.0 as message for the SPS that
there is a humidity demand.
L1/B1 N - HLR +HLR M SPS L+

230V AC < 24V power supply 24V
L2
induction
path
230V AC
L1
Registration outputs to the PLC

+24V DC
I 0.1 max. filling level reached

I 0.0 humidity demand
I 0.5 max. current 2A not reached
BB / JTU 25.06.2000
* On this point the ( IC pin 3) the voltage divider between the two adjustment potentiometers
for the max. electrode current can be measured. Default setting is somewhat higher than 12 V.
This voltage divider determines the switching point for the water inlet valve.
The voltage on IC pin 3 and therewith the maximum tolerated electrode current can be
adjusted by turning on one of them.
Following table shows the coherence between measured voltages on IC pin 3 and the current through
the electrodes inside the steam cylinder.
Due to the tolerances of the components this values can not be taken as exact ones or all chambers.
But the ratio between difference in current and difference in voltage are constant for all KBF with PLC
and BINDER humidity board. It is round about 0,33V/A.
voltage on pin 3 current through the

of the IC * steam cylinder
10,5V 1,3A
11,5V 1,7A
12,5V 2,0A
13,5V 2,3A
14,5V 2,6A
BB / JTU 25.06.2000
Chapter 3
Calibration
Binder controllers can be adjusted by the customer to suit his particular operating conditions, i.e. the
controller has a calibration mode which, for example, can be used to match the temperature in the
chamber to the one shown on the controller‘s display.
Binder calibrates each chamber before it is dispatched to the customer. High-quality measuring
systems are used for this, whose accuracy is tested annually. However, if the measured temperature
does not match the displayed temperature, please follow the instructions below.
Tolerance of the adjustment

When is it worth to correct a deviation between the value measured and the value displayed on the
controller?
The following table gives you the conditions for an ideal adjustment of a temperature deviation,
Measured value Measured range Adjustment if deviation

Binder unit
is higher than:
designation
KB, KBW Temperature 0 up to 99,9°C 0,3K
KBF, KBWF Temperature 0 up to 100°C 0,3K
Humidity 10 up to 90% r.H. 1,5% r.H.
Deviations which lies within this statements do not require an adjustment.
Important:
The values on the above chart can only be used if the value of measurement uncertainty on the
calibration certificate of the measuring instrument is smaller than the values of the chart.
When this is not the case, then you must take as limit value for an adjustment the
measurement uncertainty value of the calibration certificate.
Adjustment of the working set point. One and Two points adjustment.
Ideally the adjustment should be made to the customer’s most used set points.
Example: the customer works at 37°C, adjustment of the controller at 37°C.
If the customer uses different set points, the following instructions have to be taken in consideration:
When the difference of temperature between the most used set points is small:
Choose an adjustment value lying between this temperatures.
Example : The customer ‘s set points are 40 and 60°C, adjustment of the controller at 50°C.
When the controller gives the possibility of a two points adjustment:

The smaller and the higher working set points will be choose for the adjustment.
Example : The customer‘s set points are 40 and 60°C, adjustment of the controller at 40°C and 60°C.
Adjustment over the complete range of temperature on a controller allowing one-point

adjustment
If the customer uses the complete range of temperature, but the controller only allows a one-point
adjustment the adjustment will be done on the middle point. The following list gives the optimal values
for a one-point adjustment.
Type of chamber type of controller Optimal adjustment Company
with standard
KB, KBW RD2 50°C 37°C
BB / JTU 25.06.2000
After an adjustment, the following chart gives you the tolerance permitted on one control-
measurement over the complete operating range.
Type of chamber type of controller range tolerances over the
compl. operating range
KB, KBW RD2 0°C up to 99,9°C +/-3K
The deviation over the complete operating range should be written down on a chart and fixed to the
chamber for reference.
Adjustment over the complete range of temperature on a controller allowing

two-points adjustment.
Adjustment over the complete range of temperature on two working points. EX: A KBF chamber on
20% and 80% r.H.
A two points adjustment will be carried out when the customer uses the complete temperature range
and the controller allows a two points adjustment.
The following chart shows you the optimal values for a two points adjustment according to the
correspondent controller.
Type of chamber Type of controller 2 points Work settings

adjustment
KBF, KBWF D2, PD2 20 und 80°C 37°C
20 und 80% r.H. 20 und 80% r.H.
After an adjustment, the following chart gives you the tolerance permitted on one control-
measurement over the complete operating range.
Type of chamber Type of controller 2 points adjustment Tolerances over the

compl. operating
range.
KBF, KBWF D2, PD2 Bis 100°C +/-2K
bis 90% r.H. +/-4% r.H.
The deviation over the complete operating range should be written down on a chart and fixed to the
chamber for reference.
Example: KBF adjustment by 20°C and 80°C .

Nominal-/actual-value Measuring instrument Deviation
appliance
10°C 8°C -2K
20°C 20°C 0K
50°C 51°C +1K
70°C 71°C +1K
80°C 80°C 0K
BB / JTU 25.06.2000
RD2.1 Calibration Instructions

x Insert the measuring instrument probe at the measuring point, located in the centre of the usable
volume.
x Ventilation flap open or closed (depending upon the user application).
x Set the required nominal temperature.
x Operate the unit until it reaches the required nominal temperature and allow to settle. When the
unit has reached the required temperature, please allow it to continue running for approx. 1 hour -
only then is the unit reliably set for calibration.
x Read off the temperature displayed on your measuring instrument and compare this with the
controller display.
x Any variation can be changed on the controller. To do this, press the start/stop button and stop
the controller. Now press the actual/set value button, the mode button, the arrow up and arrow
down buttons simultaneously. A point will flash in the display. Now you can input the temperature
displayed on your measuring instrument by repeatedly pressing the button “arrow up” or “down”.
Confirm the entry by pressing the actual/set value button. Now press the start/stop button to start
the controller.
Re-check the input temperature with your measuring instrument once the unit has been re-
heated. This adjustment on the controller must be performed rapidly, in order to ensure that any
variation is as small as possible.
Reset of the calibration

To do this, press the start/stop button and stop the controller. Now press the actual/set value
button, the mode button, the arrow up and arrow down buttons simultaneously. A point will flash
on the display. Now you have to press the arrow up and arrow down buttons simultaneously. The
calibration is reset. You can leave the calibration mode with pressing the actual/set value button.
Now press the start/stop button to start the controller.
SM Calibrating instructions
x Switch the unit off at the main switch. Turn the fastening screw of the controller tray (lower centre
of the control panel of the controller) anti-clockwise until you can remove the controller tray.
x The S 301 multiple circuit breaker (large DIP Switch Block) is located on the CPU board. In order
to access the appropriate sub-menu for calibration, DIP switch 2 must be set.
x Push the controller tray back into the housing and turn the fastening screw in the clockwise
direction again.
x Switch on the unit again with the main switch.

Press the ”Pgm” and ”Enter” keys together twice. ”SD01” appears on the display. For calibration
you must call up sub-menu SD06 with ”Pgm” (just press ”Pgm” 6).
SD06 must be confirmed with ”Enter”. C611 appears in the display.
In order ”reset”, you must set C611 to zero. To do this you must use the increase or decrease
button. C612 must also be set to zero. ”Err30” now appears in the display. This symbol indicates
that a ”reset” has been performed.
x Insert the humidity measuring instrument probe at the measuring point, located in the centre of
the usable volume.
x In order to perform a precise calibration, it is essential that the nominal temperature of the device
is reached and remains steady (factory setting 37°C).
x Set the required relative humidity on the SM controller.

BB / JTU 25.06.2000
x Operate the unit until the required humidity is reached and allow to settle (cf. Point 10). When the
unit has reached the required humidity, please allow it to continue running for approx. 0.5 hours -
only then is the unit reliably adjusted and ready for calibration.
x Read off the humidity displayed on your measuring instrument (%r.H.) and compare this with the
controller display.
x If the controller display deviates from the measured value, parameter C611 and/or C612 must be
re-entered into the ”SD06” sub-menu.
Two fixed points can be set with C611 and C612, where C611 corresponds to the pivot of the
characteristic curve and C612 corresponds to the top fixed point.
It is also possible to change only the top fixed point ”C612”, whereby a linear displacement of the
whole characteristic curve is obtained. This method is only recommended if you are working with
one humidity value.
The unit is calibrated at 20% r.H. or 80% r.H. at the factory
If you are working with two or more humidity values, you must proceed as follows:
Enter the measured value (lower value) at C611 (you must do this even if the value of the
measuring device does not deviate from the controller value !).
Enter a set value again (higher than the first), and wait for a steady condition again. Compare the
controller display with the value displayed on the measuring device. If there is a variation you
must enter the value displayed on the measuring device at C612.
You can return to the original menu by using the ”Enter” key and then ”Pgm”.
x Switch the unit off at the main switch. Remove the controller tray from the controller housing as
described above. Set the S 301.2 separate switch and insert the controller tray into the controller
housing again.
BB / JTU 25.06.2000
D2 KBF Calibrating instructions
G R U N D S T E LLU N G
5X P gm
C O N F IG U R A T IO N 2 E xit
E nter
C O D E -N R . 0000
3X n
C ode-N r. 0003
E nter
D IS P LA Y
3X P gm
R E C A LIB R A T IO N E xit
C O D E -N R . 0000
4X n
C ode-N r. 0004
E nter
C O R R E C T IO N C O R R E C T IO N
IN P U T 2 IN P U T 1
P gm (hum idity) P gm (tem perature)
E nter E nter
F U LL S C A LE 1 P gm S T A R T V A LU E 0
S et w ith m n S et w ith m n
E nter E nter
E xit
For reset the calibration please set the start value and the end value to the same value. After reset the
start value is set to 0 and the end value to 1.
As from the firmware version E045.01.100 you come directly into the menu re-calibration with the
buttons and , which have to be pressed together for about 10 sec.
The firmware inquiry is effected by pressing the buttons PGM and at the same time.
BB / JTU 25.06.2000
Chapter 4
Maintenance
Cooled incubators and climatic chambers
Binder’s cooled incubators and climatic chambers allow you to achieve constant conditions with a
temperature capacity of 0.0°C to 99.9°C.
Cooled incubators are used in biotechnology, medicine, the food industry, pharmaceutical and
cosmetics industry, botany and zoology.
Climatic chambers are intended for stability and durability tests for pharmaceutical products. Their
constant climatic conditions also make them suitable for sample conditioning for material tests of
paper, textiles, plastics or building materials.
The growth chamber variant also enables the simulation of day/night conditions.
The precise control technology, the efficient refrigeration system and humidification system allow the
greatest possible maintenance intervals.
During maintenance, all mechanical and electrical as well as electronic components are subjected to a
visual and functional inspection.
In addition, the control systems and sensors are checked with special
measuring instruments and re-adjusted if necessary.
BB / JTU 25.06.2000
Cooled incubators and climatic chambers

01 The contamination of the filter and the functionality of the electrovalve are checked.
02 The functionality of the lye pump is checked by pumping out water.
03 The water tank is removed and the seal on the support foot checked for ageing or wear.
04 The water tank is dismantled and the electrodes examined for wear or deposits. The complete
water tank (exchangeable water tank) is replaced if the electrodes are not in order.
05 The water tank is checked for deposits. If too many deposits are detected, the complete water
tank is replaced.
06 The chamber is inspected visually for general condition, wear and corrosion.
07 The doors are checked for serviceability, corrosion, functionality and condition. The door gaskets
are examined for wear, seat and damage.
08 The serviceability and functionality of the hinges are tested.
09 The closing mechanism is checked for serviceability and functionality.
10 The seal of the glass doors is checked. The glass doors are examined for damage.
11 The temperature controller is operated, set values input and all keys checked for functionality.
12 The class is tested for functionality.
13 The warning lamp is tested.
14 The humidity controller is operated, set values input and all keys checked for functionality.
15 The latest parameters are checked and input where necessary.
16 The temperature change/timer with weekly program, interior lighting, main fan and growth lamps
17 are tested for functionality.
18
19
20 The sensor cover is checked for damage and contamination.
21 The current consumption of the heating is measured.
22 A complete visual inspection of the refrigeration system is performed.
23 The functionality of the refrigeration fan is tested, and the condenser is cleaned.
24 The functionality of the refrigeration system electrovalve is checked.
25 The availability of the Operating Manual (e.g. for safety information) is checked.
26 The VDE test including determination of leakage current and insulation resistance is performed.
27 The temperature and humidity controllers are adjusted.
28
BB / JTU 25.06.2000
Maintenance schedule cooled incubators, climatic chambers

Typ:
Serialnumber:
bin
Working hour: THE TEMPERATURE COMPANY
Calibration: Yes No
Contractnumber: Typnumber:
Working step Component Remark
In the humidity box

01 Solid valve (water inlet)
02 Waste water pump
03 Sealing (support)
04 Electrodes
05 Steam bottle
Operating level
06 Oven
07 door, door sealing
08 Hinges
09 Closing mechanism
10 glass door, closer
11 Temperature controller
12 safety class 3.1
13 red control lamp
14 Humidity controller
15 Parameter ”update”
16 Alternate temperature / week unit
Interior of the oven
17 Interior light
18 Main fan
19 Crows illumination tubes
20 Cap humidity sensor
In the I-box
21 Heating
22 Visual test cooling system
23 Ventilator / condenser
24 Solid valve
security test
25 Operating instruction
26 VDE test
Adjustment
27 Temperature
28 Humidity
Implementation features:
Maintenance issued by: Date: signature :
Customer confirmation Date signature :
Calibration certification handed over: Date: signature :
BB / JTU 25.06.2000
Explanation incubators, climatic chambers

Working step Working instruction Supplement
01 Check, cleaning
02 Check, cleaning
03 Check
04 Cleaning (exchange)
05 Cleaning (exchange)
06 general state (optical test), wear, corrosion
07 wear, corrosion, compactness, function, state
08 wear, corrosion, function
09 wear, corrosion, adjust
10 function, adjust
11 Function
12 Function
13 Function
14 function
15 Adjust
16 function,
17 Function
18 function, adjust
19 function
20 Advisable cleaning
21 Function
22 Check
23 function, cleaning
24 Function
25 available ?
26 Leackage current, insulation resistance
27 adjust temperature, 1 point measurement with one value
28 Adjust relative humidity, 1 point measurement with one value
Symbol Meaning
X Defects
without error
/ not existence
BB / JTU 25.06.2000
Chapter 5
Function
Heating up time / Cooling down time

The heating up curve is for a KB unit.
Heating up time The chamber was empty and the
100,00°C nominal temperature was set to 99°C.
90,00°C
80,00°C
Temperature
70,00°C
60,00°C
50,00°C
40,00°C
30,00°C
20,00°C
10,00°C approx. time in minutes
00,00°C
00:00
12:30
21:00
33:30
46:00
58:00
70:30
83:00
94:00
99:00
Figure 4.1
The cooling down curve was recorded

Abkühlzeit with an empty chamber and with a
nominal temperature of -9.9°C.
120,00°C The ambient temperature in which the
incubator was operated, was not higher
than 22°C.
100,00°C
80,00°C
Temperatur
60,00°C
40,00°C
20,00°C ca. Zeit in M inuten
00,00°C
00:00
04:00
17:00
29:00
41:30
54:00
67:00
79:00
92:00
Figure 4.2
BB / JTU 25.06.2000
Hot gas injection
In the case of the KBF unit, hot gas injection with the PD2 and D2 controllers is a standard function.
The humidity accuracy is influenced by the hot gas injection. When hot gas is injected into the
dehumidification tube humidity is released, and therefore the humidity sensor registers a greater
humidity at the time of injection.
The function is switched off by the controller when the nominal temperature exceeds 23°C.
The following injection times are set in the controllers when the hot gas injection is activated:
KBF size Pulse pause in sec. Pulse duration in sec.

115 90 4
240 135 7
720 180 10
The following menu shows how the hot gas injection can be switched off at an actual temperature of
25°C +/- 1°C. This flow chart is for controller version E045.01.1001.
GRUNDSTELLUNG
X x Pgm
CONFIGURATION 1
Enter
Input Code-Nr. 0002
Enter
1XPGM
LIMIT COMPARATOR
PGM Enter PGM
LIM.COMPARATOR 2 LIM.COMPARATOR 1 LIM.COMPARATOR 3
Enter Enter Enter
3*Pgm 3*Pgm 3*Pgm
LIMIT 90 LIMIT 23. LIMIT 94.
Ex.. 90s evtl. shorten 23°C change to 25°C Ex. 94s evtl. extend
Pause Temp. at which the hot gas Total time of

duration injection will be deactivated. the period
(Pulsation +Pause)
Figure 4.3
BB / JTU 25.06.2000
KBF function connection diagram

Cold gas circuit
The cold gas is pumped by the compressor towards the condenser. In the condenser the cold gas is
cooled down, then it passes through the drier. In the drier humidity is removed from the cold gas. The
Electro valve is controlled by the controller and is opened as the temperature demands, thus passing
cold gas through the evaporator plate. The injection valve is located between the electrovalve and the
evaporator plate. The injection valve controls the flow of cold gas via a sensor, so that the evaporator
plate and compressor do not ice up.
Cold gas which returns to the compressor from the evaporator plates must be gaseous, as otherwise
the compressor can be damaged.
Humidification
Humidification occurs through a steam cylinder in the humidity module. The humidity is measured by a
capacitive humidity sensor (4-20mA) which is temperature-compensated. The controller drives the
humidity board via a 0-10V output. The humidity board charges two electrodes which are located in
the steam cylinder. The current which flows between the two electrodes can be regulated via the water
level.
Dehumidification
In order to maintain a constant humidity in the KBF, the inner chamber is permanently dehumidified.
Cold gas is conducted into the W pipe after the drier by means of a capillary tube. The
W pipe is a copper pipe which is located behind the rear panel between the interior and exterior
chambers.
Due to the cold gas, the W pipe is the coldest point in the inner chamber. The humidity condenses on
the W pipe and then runs down into the steam container.
Hot gas
Before the evaporator the warm cold gas is sprayed into the W pipe by means of an Electro valve,
thus preventing icing up. The pulse duration and pulse length are controlled by the controller.
dryer injection
valve evaporator
solenoid
valve
condenser
capillary tube
compressor
dehumidification
solenoid valve
Hot gas
Figure 4.4
BB / JTU 25.06.2000
Humidity controller SM
On the controller’s main plate there are 2 plugs strips (E1/E2) which can be plugged onto the front-end
plates. The front-end plated determine the type of signal that can be processed. E1 is in direction
contacts and E2 is in direction front cover.
Front-end type Remark No

PT100 Wire bridge from 1 to 2, 3 to 4
0(4) to 20 mA Plate 91309
0 to 10V Plate 91312
As the SM controller, the front-end 1 is being used for the humidity sensor.
The power supply for the humidity sensor is put out on Pin 95+ and 96-.
The humidity sensor delivers a signal 0 to 20mA onto the front-end 1 (Pin 111+ and 112-).
Via the exit 1 (Pin 42 a. 43) the humidity control is being controlled by means of a signal 0-10V.
The humidity control switches as follows:
Exit controller in V Humidity control

up to 2,3V OFF
from 2,3V to 2,8V Undefined
as from 2,8V ON
Solid-state relay for the humidity control

In the KBF ”old version” there was installed a mechanical relay for the humidification. In case the
mechanical relay are being replaced by solid-state relay, 2 cables for the control tension of the solid
state relay have to be connected at the plate of the humidity control (see figure).
- +
Figure4.5 solder side humidity control
BB / JTU 25.06.2000
Humidity control using a D2/PD2 controller and L3 humidity board.

The controller receives a signal of 4 to20 mA from the humidity sensor measuring the humidity value
in the oven. When more humidity is necessary, the controller will send a signal in the range of 3,5V to
7V to the humidity circuit board L3. .
D2/PD2 Controller
When the humidity level in the oven is smaller as the set value, the controller sends, in relation with
the parameter and the temperature, the following voltages:
Examples of parameters to Controller output voltage

Parameter 1 0°C 15°C 3,5V
L3 Humidity circuit board

The humidity circuit board controls the water inlet Solid valve, the drainage pump and the electrodes.
As soon as the humidifier is switched ON, the green LED on the circuit board lights on indicating
“power on” and the drainage pump is activated
How long the pump is going to stay on, can be adjusted using the potentiometer P2 on the circuit
board.(Factory setting 10-15 sec.)
When the controller sends a humidity request signal, the board activates the water inlet Solid valve
and stays on until a precise current flows through the electrodes and/or the cylinder is full. The precise
current to achieve steaming can be calculated using the following formula:
Formula for current calculation
I = Iges x S1 x L1
Example: temperature value 20°C:

I = 6,5 x 0,4 x 0,4 = 1,1A approx.
6,5A x 4V x 40%
I between the electrodes = max. I x V from controller at 15°C x Pot. setting 40%
standard
I = current flowing between the electrodes
Iges = Maximum current
S1 = Voltage signal from controller.
L1 = Setting of the steam output limitation.(Potentiometer P1 on circuit board L3)
BB / JTU 25.06.2000
KBF with PLC function connection diagram.

Cooling fluid cycle.
The cooling gas is pumped from the compressor to the condenser. In the condenser the cooling gas is
cooled and liquefied, then it flows through the dryer. In the dryer the humidity in the cooling fluid is
dried out. The controller activate the Electro-valve, under pressure the cooling fluid becomes gas
going through the Electro-valve. This gas flows then through the capillary tube and the cooling
evaporators. Due to its length and diameter, the capillary tubes prevent the icing of the cooling
evaporators and compressor.
To avoid damaging the compressor, the cooling gas flowing through the evaporators to the
compressor as to stay on a gaseous state.
Activation of the cooling evaporator‘s Electro-valve.

The controller activates the Electro valve for a minimum of 60 seconds when a over temperature
difference of 0,6 k of the set point is detected. The Electro-valve will be deactivated after the 60
seconds and/or when the precise set point has been reached.
Humidification system.
The humidity is produced through steam generated in a container located in the humidity module. The
humidity is measured by a capacitive humidity Sensor (4-20mA) which is temperature compensated.
The controller activates the PLC through a 0-24V output. The humidity circuit board feeds the two
electrodes contained in the steam container. The current flowing through the electrodes is regulated
via the water level.
Dehumidification
In order to maintain a constant humidity in the KBF, the inner chamber is permanently dehumidified.
After the dryer , cold gas is injected through an Electro-valve in the dehumidification evaporators. The
dehumidification evaporators are of the same construction as the cooling evaporators. They are
located behind the rear panel of the inner chamber. (See picture 4:7)
Due to the cold gas, the dehumidification evaporators are the coldest point in the inner chamber. The
humidity condenses on the dehumidification evaporators and then flows down into the steam
container.
Icing prevention.
To prevent the icing of the dehumidification evaporators, the plates are activated alternatively every
3,5 days. To avoid an irregular humidity during this transfer process, the previously inactive evaporator
will be ON for 0,5 seconds and every 30 seconds a 0,5 second will be added. After one hour it will be
constantly ON, and the other dehumidification evaporator will start being deactivated, 0,5 second and
every 30 seconds a 0,5 second deactivation will be added until it is completely deactivated. See
following chart.
Time in second Output SPS Q0.0 Output SPS Q0.1
Electro valve Y3 Electro valve Y4
Electro-valve status Electro- valve status
After 3 days ON OFF ON OFF
0 to 30 s. Constant -- 0,5 s. 29,5 s.
30 to 60 s. Constant -- 1,0 s. 29,0 s.
60 to 90 s. Constant -- 1,5 s. 28,5 s.
90 to 120 s. Constant -- 2,0 s. 28,0 s.
120 to 150 s. Constant -- 2,5 s. 27,5 s.
Etc...
3600 to 3630 s. Constant -- Constant --
3630 to 3660 s. 29,5 s. 0,5 s. Constant --
3660 to 3690 s. 29,0 s. 1,0 s. Constant --
3690 to 3720 s. 28,5 s. 1,5 s. Constant --
Etc...
BB / JTU 25.06.2000
C apillary tube
Dryer C ooling evaporators
S olenoid-
valve
C ondenser
S olenoid-
valve
C ompressor
Deshumidification evaporators
BB / JTU 25.06.2000
Chapter 6
Following pictures show the different states of KBF construction mentioned in the
overview of chapter 1.
BB / JTU 25.06.2000
Construction of climatic chambers
KBF 720 KBWF 240
INTELLIGENTE TEMPERATURTECHNIK
Construction of KBF/KBWF V 06/00 page 1

KBF outer kettle
Pressure test to find any

leakage.
Afterwards the kettle is
insulated with PU-foam

KBF different dehumidification systems
elder type with w-formed current type with two flat

dehumidification tube evaporators

KBF cooling system

KBF control of cooling system

KBF inner view of upper box

KBWF inner view of upper box

KB(W)F humidification system
EM2
and later
L3
humidity
board
steam cylinder
humidity sensor
current binder humidity board

5) Service Manual KB - KBF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5) Service Manual KB - KBF

Uploaded by

Copyright:

Available Formats

Service  documentation series KB/KBF

Chapter 1 Trouble shooting

Chapter 2 Cooling System

Chapter 6 Pictures of construction

SM + RD2.1 Controller + Humidity Control Board

The L3-Board was used since following Data:

SPS-Control / Binder Humidity Board

Condensation at Suck Side of x There is an overfill of the refrigerant

Following steps have to be carried out:

C)Insert the interface cable BINDER part No.

Connect the cable to following connectors of the

Bridged at the connector side: 4+5 and 6+8+20

D) Some controller parameters have to be

Now switch the unit on and after 10 seconds on again.

Hint on connection with APT-COM:

KBF 115 R134a; 200g

New series without injection valve (capillary tube)

Chamber Since Capillary tube/ Capillary tube/ Quantity

Look in the cooling System of the KB/KBF Chamber

Dehumidifier Pressure Side Suck Side

Components of the KB/KBF cooling system:

Trouble Shooting KB / Cooling System

Do Controller (N1) emits a Signal to the Solid State Relay (K3) ?

ÆYES Check the Solid State Relay (K3)

ÆNO Change the Controller (N1)

Does the Solid State Relay (K3)

ÆYES Check the voltage at the Terminal-Block

ÆNO Solid State Relay (K3) defect

Is there a current at the Compressor ?

ÆYES Compressor is defect, change the Compressor

ÆNO Check the cabling

Trouble Shooting KBF / Cooling System

Does the Controller (N1) emits a Signal?

ÆYES Check the Compressor and Solenoid Valve

ÆNO Controller (N1) is defect

Does the Compressor work?

ÆYES Possible that there is no refrigerant inside the chamber

ÆNO Check the voltage at the Terminal-Block

Is there a voltage at the Compressor?

ÆYES Compressor is defect

ÆNO Check the cabling

Description Binder Humidity board Art. No. 9505-0036

L1/B1 N - HLR +HLR M SPS L+

Registration outputs to the PLC

I 0.1 max. filling level reached

voltage on pin 3 current through the

Tolerance of the adjustment

Measured value Measured range Adjustment if deviation

Deviations which lies within this statements do not require an adjustment.

When the controller gives the possibility of a two points adjustment:

Adjustment over the complete range of temperature on a controller allowing one-point

Adjustment over the complete range of temperature on a controller allowing

Type of chamber Type of controller 2 points Work settings

Type of chamber Type of controller 2 points adjustment Tolerances over the

Example: KBF adjustment by 20°C and 80°C .

RD2.1 Calibration Instructions

x Ventilation flap open or closed (depending upon the user application).

x Set the required nominal temperature.

Reset of the calibration

x Switch on the unit again with the main switch.

x Set the required relative humidity on the SM controller.

The unit is calibrated at 20% r.H. or 80% r.H. at the factory

Cooled incubators and climatic chambers

Service documentation series KB/KBF

3Pgm 3Pgm 3*Pgm