Binder KBF Series Service Manual
  1. Manuals
  2. Brands
  3. Binder Manuals
  4. Climate chamber
  5. KBF Series
  6. Service manual

Binder KBF Series Service Manual

Constant climate chambers with program control
Hide thumbs Also See for KBF Series:
Table of Contents

Advertisement

Quick Links

KBF (E5.2)
Constant climate chambers with program control
Service Manual
valid for the following models of
Model
KBF 115 (E5.2)
KBF 115-UL (E5.2)
KBF 240 (E5.2)
KBF 240-UL (E5.2)
KBF 720 (E5.2)
KBF 720-UL (E5.2)
Issue 04-2015
KBF, starting with serial no. 09-11327:
order no.
9020-0139, 9120-0139
9020-0184, 9120-0184
9020-0150, 9120-0150
9020-0176, 9120-0176
9020-0108, 9120-0108
9020-0168, 9120-0168
order no. 7001-0203

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KBF Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Binder KBF Series

Summary of Contents for Binder KBF Series

  • Page 1 KBF (E5.2) Constant climate chambers with program control Service Manual valid for the following models of KBF, starting with serial no. 09-11327: Model order no. KBF 115 (E5.2) 9020-0139, 9120-0139 KBF 115-UL (E5.2) 9020-0184, 9120-0184 KBF 240 (E5.2) 9020-0150, 9120-0150 KBF 240-UL (E5.2) 9020-0176, 9120-0176 KBF 720 (E5.2)
  • Page 2 Service Manual...
  • Page 3 Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. BINDER GmbH, 2015 Service Manual KBF (E5.2) 04-2015...

  • Page 4: Table Of Contents

    Table of content Table of content Preface ............................... 6 General guidelines ..........................6 Syntax..............................6 Safety instructions structure ........................ 7 1.3.1 Safety instructions structure ........................ 7 1.3.2 Warning levels ............................. 7 1.3.3 Safety symbol ............................8 1.3.4 Warning symbols ..........................8 1.3.5 Imperative symbols ..........................
  • Page 5 Table of content Replacing the power cord with plug ....................77 Replacing the line filter (-1Z1) ......................78 Checking and replacing the main switch (-1S1) and the humidity switch (-8S1) ......79 Removing the electric mounting plates from the machine room ............80 Components of the electric mounting plate (standard) ..............

  • Page 6: Preface

    Additional options are indicated in the text. The service manual of the KBF will be updated if necessary. Always use the latest version of the service manual. In case of doubt about the validity of this service manual, contact the BINDER Service Hotline (see Imprint).

  • Page 7: Safety Instructions Structure

    Preface Safety instructions structure This service manual employs the terms and symbols below to describe dangerous situations, in line with the harmonization of ISO 3864-2 and ANSI Z535.6. 1.3.1 Safety instructions structure  Instruction how to avoid the hazard: mandatory action ∅...

  • Page 8: Safety Symbol

    Preface 1.3.3 Safety symbol Danger of injury. Follow all the directions indicated by the safety symbol in order to avoid injury or death. 1.3.4 Warning symbols Danger of electric shock Danger of cutting injuries Danger of injuries by jumping off mechanical components Stability hazard Danger of scalding Danger of excessive humidity...

  • Page 9: General Safety Instructions

    To be able to carry out the service work the enforcing personnel must be qualified and familiar with the ser- vice and the operation of the KBF. Sufficient qualification is achieved by: Electro technical training Technical training by BINDER GmbH Knowledge of the present service manual Knowledge of the operating manual of the KBF to be serviced...

  • Page 10: Dangers

    General safety instructions Dangers DANGER! Danger of electric shock. Danger to life.  The unit must be switched off and disconnected from the power supply prior to perform- ing most of the described service tasks.  Take all precautionary measures that a unit which is disconnected from the power sup- ply will not be inadvertently connected to the power supply.
  • Page 11 General safety instructions CAUTION! Danger of damaging the electronics. Circuit boards might be damaged by handling malpractices and touching of its compo- nents.  Prior to work at electronic components the technician must take appropriate protective measures against electrostatic discharge. Wearing ESD shoes and a grounding brace- let have shown to be useful.

  • Page 12: Maintenance

    Maintenance Maintenance The mechanical and electronic components of the KBF must be checked and maintained at least once a year by a qualified service technician (chap. 2.1). When using tap water the maintenance interval according to amount of calcium deposit in the humidification module may be reduced to several times a year. Maintenance schedule for the annual maintenance work Component Check step / Actions...
  • Page 13 Maintenance Component Check step / Actions Inner chamber and outer enclosure - Glass door Check the glass door and the door hinges for damages. - Closure of glass door Check the door hinges for well running. - Glass door supports at the sides Check the glass door for alignment and tight fit.
  • Page 14 Maintenance Component Check step / Actions Humidification module variant A Check the freshwater and waste water hoses for wear, damage and Freshwater hose, leakproofness. waste water hose ⇒ If necessary, replace the humidification module, chap. 9.1.6 Check the inlet tank and outlet tank for soiling, damage and leakproof- ness.
  • Page 15 Maintenance Component Check step / Actions Humidification module variant B Check the freshwater and waste water hoses for wear, damage and Freshwater hose, leakproofness. waste water hose ⇒ If necessary, replace the freshwater and waste water hoses. Check the inlet tank and outlet tank for soiling, damage and leakproof- Drain tank ness.
  • Page 16 Maintenance Component Check step / Actions Cooling system Piping, Check the tubes, especially the soldering joints, and the components of the cool- ing system for damages and corrosion. dryer (-J1, -J2), If necessary, have repaired the cooling system (chap. 10ff, page 114). step motor valve (-7Y3) Insulation Check the insulation of the cooling system for damages...

  • Page 17: Safety Check Acc. To Din Vde 0701-0702

    Maintenance Safety check acc. to DIN VDE 0701-0702 During the yearly maintenance and following repair we recommend an inspection acc. to DIN VDE 0701- 0702. This inspection comprises the following points: 1. Visual inspection Check the unit and all electrical connecting lines visible damages and defects. Replace damaged parts and electrical connecting lines.

  • Page 18: Troubleshooting

    Troubleshooting Troubleshooting Alarm and error messages as well as basic measures the operator himself may take to clear them described operating manual. Please make sure these measures have been tried before looking further for any other possible error causes. The troubleshooting diagrams below are built up as follows: Error pattern Possible error cause Remedial measure...

  • Page 19: General Electrical Faults

    Troubleshooting General electrical faults Operating state pilot lamp at the con- troller triangle does not work No indications on the controller display (-3N1) Fan not working Power plug (-X1) connected? Connect power plug Main switch (-1S1) set to ON? Set main switch to ON Facility-side power supply available? Ensure facility-side power supply.
  • Page 20 Troubleshooting Connect plug at the main switch Plug at the main switch (-1S1) connected? (chap. 8.4, page 79) Replace main switch Main switch (-1S1) defective? (chap. 8.4, page 79) Replace power cord with mains plug Power cord with mains plug (-X1) defective? (chap.

  • Page 21: Faults Of The Heating System

    Troubleshooting Faults of the heating system Temperature of inner chamber does not in- crease to set temperature Controller regularly displays the operating parameters Setting of safety controller MB1 I/O-board ex- Operating error (see operating manual) ceeded? Optional class3.1 overtemperature set too low? Operating error (see operating manual) Replace solid state relay (chap.
  • Page 22 Troubleshooting Condensation glass door and / or the outer door Does the outer door fit closely? Adjust the outer door (chap. 6.1, page 41) Replace outer door gasket and / or glass Outer door gasket and / or glass door gasket door gasket (chap.

  • Page 23: Faults Of The Cooling System

    Troubleshooting Faults of the cooling system Temperature of inner chamber does not de- crease to set temperature below ambient temperature Controller regularly displays the operating parameters Optional class 3.3 undertemperature set too Operating error (see operating manual) high? Does the outer door fit closely? Adjust the outer door (chap.
  • Page 24 Troubleshooting Binary outputs: Controller BA 1→ Cooling release MB1 I/O- BA 2→ Solenoid valve (-7Y1) board Replace controller MB1 I/O-board large plate evaporator (-3N2) BA 3→ Solenoid valve (-7Y2), (chap. 8.8.1) defective? small plate evaporator Check acc. to chap. 4.4 Have replaced the capillary tubes Capillary tubes blocked? (chap.

  • Page 25: Functional Check Of The Cooling System

    Troubleshooting Functional check of the cooling system To test the function of the cooling system you can use the following functions tables. During program course use a multimeter to measure the output signal at the analog output AA1 (pins 17 and 18) of the controller MB1 I/O-board (-3N2).
  • Page 26 Troubleshooting When cooling or dehumidifying, the compressor (-6M1) is operating continuously. So is the condenser. Please check the condenser at its fan wheel, which must continuously operate to carry off the heat. In standard case the injection points (a → cooling) and (b → dehumidification) (Figure 59) of the capillary tubes are cold.

  • Page 27: Errors In The Humidification Module

    Troubleshooting Errors in the humidification module Fault localization Humidification module variant A • Correct manipulation, but no steam enters the useable volume Humidity switch (-8S1) defective? Replace humidity switch (chap. 8.4) See error description on next page Steam boiler (-9A10) heats up? “Steam boiler doesn’t heat up”...
  • Page 28 Troubleshooting • The set humidity above ambient humidity is not reached • The steam boiler (-9A10 ) does not heat up Humidity switch off? Switch on humidity switch No water in the inlet tank, or with option ex- ternal water cans there is no water in the Check water inlet (tap) and fill up water.
  • Page 29 Troubleshooting Control board (-9N10) of the humidity module defective? e.g. with no water in the Replace the humidification steam boiler, after 90 s (time-out) the module, chap. 9.1.6) buzzer on the control board of the steam boiler does not sound. Water pump of steam boiler (-9M10) Replace the humidification defective?
  • Page 30 Troubleshooting • The steam boiler releases steam via the safety valves through the silicon tubes into the outlet tank. Double manometric switch (-9F30) defective? Replace the humidification Switch doesn’t open even if pressure module, chap. 9.1.6) > 1.5 bar • The steam boiler lets off water via pressure hose with metal braiding Union nuts of the steam boiler...
  • Page 31 Troubleshooting Error messages (chap. 9.1.8) • • Buzzer on control board (-9N10) of 90 sec time-out for filling the steam  the humidification module sounds boiler exceeded • • Error message “HUMID ALARM” at during filling of the inlet tank more than the controller MB1 I/O-board (-3N1) 5 minutes have passed Water in the inlet tank?
  • Page 32 Troubleshooting Fault localization Humidification module variant B In spite of correct handling, no steam enters the inner chamber Humidity switch (-8S1) defective? Replace humidity switch (chap. 8.4) humidification module itself extensive features error detection. Please see the messages in the controller display and the LEDs on the control board of the humidification module.
  • Page 33 Troubleshooting Continuation • Upper float switch of the boiler defective Drain Valve Functional test drain valve failed during sys- • Lower float switch of the boiler defective Timeout State10 tem startup • Steam valve defective / does not open • Drain defective / does not open •...

  • Page 34: Repair Work At The Housing

    Repair work at the housing Repair work at the housing Replacing the housing cover at the lower front Housing cover Spare parts: KBF standard (order no.4001-0611) KBF option temperature safety device class 3.3 (order no. 4001-0627) KBF with chart recorder (order no. 8001-0185) KBF with chart recorder with option temperature safety device class3.3 (order no.

  • Page 35: Replacing The Pen Recorder (-14P1)

    Repair work at the housing Lateral control panel right Chart recorder (-14P1) Switch of chart recorder (-14S1) Screws Housing cover Lateral control panel left Figure 1: Replacing the housing cover at the lower front Replacing the pen recorder (-14P1) • 2-channel pen recorder 500d (order no. 5016-0003) Spare parts: •...

  • Page 36: Replacing The Rear Panel

    Repair work at the housing Replacing the rear panel Spare parts: Rear panel (order no. 4001-0616) Necessary Torx screwdriver, size T20 tools: CAUTION! Danger of cutting injuries by sharp edges!  Wear protective gloves against cutting injuries during mounting and dismantling of inner chamber parts because the sheet metal components are sharp-edged.

  • Page 37: Replacing The Silicone Access Port

    Repair work at the housing Replacing the silicone access port Spare parts: 2 x silicone access port (order no. 6016-0033) Plug for silicone access port (order no. 6016-0035) 2 x conical nipple (inside / outside; order no. 6016-0034) Fixing disk (order no. 4020-0509) 4 x nut M6 A2 / stainless steel (order no.
  • Page 38 Repair work at the housing A Conical nipples D Plug for silicone access port B Silicone access ports E Nuts M6 A2 / stainless steel C Fixing disk F Stud bolt Figure 4: Replacing the silicone access port Service Manual KBF (E5.2) 04-2015...

  • Page 39: Replacing The Castors

    Repair work at the housing Replacing the castors Spare parts: 2 x castors 16x50 (order no. 6006-0028) 2 x castors 16x50 with lock (order no. 6006-0029) Fork lifter or elevating truck Drift punch 6-8 mm / 0.24 x 0.31 in Necessary tools: Rubber mallet...
  • Page 40 Repair work at the housing Disconnect the unit from the mains. Remove the lower housing cover at the front (chap. 5.1, page 34) Remove the rear panel (chap. 5.3, page 36) Lift the unit from the front or the rear with a fork lifter or lifting truck as much as necessary to replace the castors.

  • Page 41: Repair Work At The Outer Door

    Repair work at the outer door Repair work at the outer door Aligning the outer door 6.1.1 Aligning the door hinges Spare parts: 12 x cover (order no. 6002-0008) Necessary tools: Allen wrench size 4 Disconnect the unit from the power supply. Remove the outer door gasket (chap.

  • Page 42: Aligning The Adjustable Door Holder Lug With Pulley

    Repair work at the outer door 6.1.2 Aligning the adjustable door holder lug with pulley Disconnect the unit from the power supply. Remove the outer door gasket (chap. 6.2.6). By turning the adjusting screw (A) you can change the horizontal position of the door holder lug (B).

  • Page 43: Checking And Replacing Outer Door Components

    Repair work at the outer door Checking and replacing outer door components 6.2.1 Dismounting the interior side of the outer door Necessary tools: Crosstip screwdriver, size 2 Disconnect the unit from the power supply. Remove the door gasket (chap. 6.2.6,). Remove the screws (F) of the holders (E) of the interior side of the door.
  • Page 44 Repair work at the outer door Figure 8: Dismounting the interior side of the outer door A Door frame E Holder of interior side of the outer door B Cable of door heating and temperature sensor F Screws C Interior side of the outer door G Fastening spigot D Grounding cable Service Manual KBF (E5.2) 04-2015...

  • Page 45: Replacing The Door Hinge Cover

    Repair work at the outer door 6.2.2 Replacing the door hinge cover Spare parts: Door hinge cover (order no. 6002-0007) Necessary tools: Crosstip screwdriver, size 2 1. Remove the screws (B) of the door hinge covers (A). 2. Remove the door hinge cover. 3.

  • Page 46: Checking And Replacing The Interior Side Of The Outer Door

    Repair work at the outer door 6.2.3 Checking and replacing the interior side of the outer door Spare parts: Inner door (interior side of the outer door) KBF 115 order no. 8003-0181 Inner door (interior side of the outer door) KBF 240 order no.
  • Page 47 Repair work at the outer door T (°C) -10 96.086 96.478 96.870 97.262 97.653 98.045 98.436 98.827 99.218 99.609 100.000 0 100.000 100.391 100.781 101.172 101.562 101.953 102.343 102.733 103.123 103.513 103.902 10 103.902 104.292 104.681 105.071 105.460 105.849 106.238 106.627 107.016 107.404 107.793 20 107.793 108.181 108.570 108.958 109.346 109.734 110.122 110.509 110.897 111.284 111.672 30 111.672 112.059 112.446 112.833 113.220 113.607 113.994 114.380 114.767 115.153 115.539 40 115.539 115.925 116.311 116.697 117.083 117.469 117.854 118.240 118.625 119.010 119.395...

  • Page 48: Replacing The Door

    Repair work at the outer door 6.2.4 Replacing the door Door 240 KBF/E5 (order no. 8002-0594) (complete door) Door 240 KBF/E5 (order no. 8002-0595) (door housing) Spare parts: Interior side of outer door 240 KB/E5 (order no. 8003-0182), complete, incl. heat conductor (order no.

  • Page 49: Replacing The Door Contact Switch (-3S1 )

    Repair work at the outer door 6.2.5 Replacing the door contact switch (-3S1 ) Spare parts: Door contact switch order no. 5019-0061 Necessary Small slotted screwdriver tools: Disconnect the unit from the power supply. Open the door and remove the interior side of the door (chap. 6.2.1) Prize up the clips of the door contact switch (A) and push them from inside out of the door frame (C).

  • Page 50: Replacing The Outer Door Gasket

    Repair work at the outer door 6.2.6 Replacing the outer door gasket Spare parts: Outer door gasket 240 KB/E5 (order no. 6005-0161) Carefully pull the outer door gasket (A) out of the slot between the interior side of the outer door (D) and the door frame (B).

  • Page 51: Replacing The Triangle Instrument Box

    Repair work at the outer door Replacing the triangle instrument box CAUTION! Danger of damaging the electronic. Circuit boards might be damaged by handling malpractices and touching of its components.  Prior to work at electronic components the technician must take appropriate protective measures against electrostatic discharge.

  • Page 52: Replacing Of Components Of The Triangle Instrument Box

    Repair work at the outer door 6.3.2 Replacing of components of the triangle instrument box Spare parts: Triangle instrument box complete (order no. 8008-0246) Housing instrument box (order no. 6002-0180) Switch mat 3-fold (order no. 6002-0196) Switch mat 5-fold (order no. 6002-0184) Filter pane of instrument box (order no.
  • Page 53 Repair work at the outer door Figure 15: Replacing the triangle instrument box Door frame Plug of controller cable Interior side of the outer door Switch mat 3-fold Covers Switch mat 5-fold Screws Filter pane Connection of the grounding cable Housing of instrument box Controller display Please note that demounting the interior side of the outer door is necessary only if, while demounting the tri-...

  • Page 54: Replacing The Closing Device Of The Outer Door

    Repair work at the outer door Replacing the closing device of the outer door Spare parts: Door handle 104 mm / 4.09 in right (order no. 6002-0104) Push rod guide (order no. 6002-0018) Screw (order no. 3001-0003) Push rod (order no. 4021-0365) O-ring (order no.
  • Page 55 Repair work at the outer door When installing the push rods, the open side of the profile must point in direction of the unit. During as- sembling push rod lever (G) and axle bearing (H), pay attention that the guiding hooks of the push rod lever are within the guiding nuts of the axle bearing and that the door handle (D) can be turned into door closed position (I) and door open position (II).

  • Page 56: Repair Work At The Inner And Outer Chamber

    Repair work at the inner and outer chamber Repair work at the inner and outer chamber Replacing the glass door Spare parts: Glass door 115 complete, (order no. 8010-0088) Glass door 240 complete, (order no. 8010-0143) Glass door 720 complete, (2x), (order no. 8010-0086) Distance plate (order no.

  • Page 57: Replacing The Closing Device Of The Glass Door

    Repair work at the inner and outer chamber Replacing the closing device of the glass door Spare parts: Turn-lock fastener KB/E5 complete (order no. 6002-0316) Disk spring DIN2093-C 12.5 x 6.2 x 0.35 (order no. 3003-0034) Washer DIN9021-A 3.2 A2 140 (order no. 3003-0025) Screw DIN7985-A M3x6-4.8 zinc coated (order no.

  • Page 58: Replacing The Glass Door Gasket

    Repair work at the inner and outer chamber Replacing the glass door gasket Glass door gasket KBF 115, (order no. 6005-0204) Glass door gasket KBF 240, (order no. 6005-0149) Spare parts: Glass door gasket KBF 720, (2x),(order no. 6005-0198) Intermediate door gasket KBF 720, (order no. 6005-0192) 1.

  • Page 59: Replacing The Fan (-4M1)

    Repair work at the inner and outer chamber Replacing the fan (-4M1) Radial fan complete with motor and fan wheel order no. 5013-0088 Fan sheet KBF 115 order no. 4020-0576 Fan sheet KBF 240, 720 order no. 4020-0597 Spare parts: Fan cover KBF 115 order no.
  • Page 60 Repair work at the inner and outer chamber Hold on to the fan wheel (L) at the driving sheet (I) with a 24 mm / 0.94 in fork wrench. With a 10 mm / 0.39 in wrench loosen the nut (M) by turning it anti-clockwise and remove it. Figure 21: Removing the fan wheel Fan drive shaft gasket Fan wheel...
  • Page 61 Repair work at the inner and outer chamber Pull the power plug and the grounding cable from the connections of the fan motor (E). Remove the screws (D) and the carrier (B) together with the overvoltage cutout board (C). You can now remove the fan motor (E) to the rear. Install the fan by following steps 1 to 10 in reverse order.

  • Page 62: Replacing The Frame Gasket

    Repair work at the inner and outer chamber Replacing the frame gasket Spare parts: Frame gasket KBF 115, (Art. Nr. 6005-0207) Frame gasket KBF 240, (Art. Nr. 6005-0147) Frame gasket KBF 720, (Art. Nr. 6005-0196 Carefully pull the frame gasket (B) off the inner chamber edges (A). Clean the inner chamber edges. Place the new frame gasket on the inner chamber edges in such a way that the seam where the gasket is glued to be situated at the right side in the middle between the door hinges.

  • Page 63: Checking And Replacing The Frame Heating Wire (-4E3 )

    Repair work at the inner and outer chamber Checking and replacing the frame heating wire (-4E3 ) Frame heating wire KBF 115, (order no. 5005-0185) Frame heating wire KBF 240, (order no. 5005-0168) Spare parts: Frame heating wire KBF 720, (order no. 5005-0177) Connector 6-poles (order no.

  • Page 64: Replacing The Inner Chamber And The Gaskets Between The Inner And The Outer Chamber

    Repair work at the inner and outer chamber Replacing the inner chamber and the gaskets between the inner and the outer chamber Spare parts: Stop ledge KBF 115 (order no. 4005-0402) Stop ledge KBF 240 (order no. 4005-0410) Stop ledge KBF 720 (order no. 4005-0376) Side plate left of inner chamber KBF 115 (order no.
  • Page 65 Repair work at the inner and outer chamber Die side plates (C, G) are screwed with cap nuts at the stud bolts at the inner chamber ceiling. Incline the side plates (C, G) with the lower edge to the inside, pull them forward and remove the parts.

  • Page 66: Testing And Replacing The Heating Element (-4E1)

    Repair work at the inner and outer chamber Testing and replacing the heating element (-4E1) Heating element 240 V / 600 W (order no. 5005-0183) Heating element spacer (order no. 4020-0003) PU foam (order no. 1004-0009) Spare parts: Shrink down silicon hose, length 160 mm / 6.3 in (order no. 6007-0023) Silicone, red (order no.
  • Page 67 Repair work at the inner and outer chamber Figure 28: Replacing the heating element Rear panel of the outer chamber Heating element Bottom plate Fixing screws Gasket Service Manual KBF (E5.2) 04-2015...
  • Page 68 Repair work at the inner and outer chamber Following installation, fill the open spot around the connections with insulating foam. Before mounting the inner chamber, check the distance between the heating element (D) and the rear panel of the outer chamber (A). The heating element spacer (F) must be oriented with its long side towards the rear panel of the outer chamber.

  • Page 69: Checking And Replacing The Inner Chamber Pt 100 Temperature Sensor (-3B1)

    Repair work at the inner and outer chamber Checking and replacing the inner chamber Pt 100 temperature sensor (-3B1) Spare parts: Temperature sensor, 2 x Pt100 order no. 5002-0050 Sensor holder order no. 4020-0643 Screwed cable fitting order no. 6002-0397 Cable access port order no.
  • Page 70 Repair work at the inner and outer chamber Remove with a cutter the insulating foam at the unit rear in the area of the temperature sensor. Detach all fixings (cable connector etc.) of the Pt100 temperature sensor cable in the machine room and at the unit rear.

  • Page 71: Checking And Replacing The Humidity Sensor And The Sensor Board (-3B2)

    Repair work at the inner and outer chamber 7.10 Checking and replacing the humidity sensor and the sensor board (-3B2) Spare parts: Humidity sensor long with sensor board F2CX (order no. 5002-0143) Cable access port (order no. 6005-0112) Screwed cable fitting (order no. 6002-0398) PU foam (order no.
  • Page 72 Repair work at the inner and outer chamber Remove with a cutter the insulating foam at the unit rear in the area of the humidity sensor. Unscrew the nut of the screwed cable fitting (C) on the inside of the outer chamber. Pull the humidity sensor (A) toward the rear out of the outer chamber.
  • Page 73 Repair work at the inner and outer chamber Meas- Meas- Meas- Meas- Meas- ured ured ured ured ured humidity humidity humidity humidity humidity current current current current current % r.H. % r.H. % r.H. % r.H. % r.H. 4.00 7.20 10.40 13.60 16.80...

  • Page 74: Replacing The Temperature Fuse 110°C / 230°F (-1F2)

    Repair work at the inner and outer chamber 7.11 Replacing the temperature fuse 110°C / 230°F (-1F2) Spare parts: Temperature fuse 110°C / 230°F (order no. 5006-0043) Cable sockets (order no. 5024-0007) PU foam (order no. 1004-0009) Silicone, red (order no. 1004-0007) Shrink down silicon hose D 16.0 x 1.0 Crosstip screwdriver, size 2 Wrench, size 10...

  • Page 75: Repair Work At Electric And Electronic Components

    Repair work at electric and electronic components Repair work at electric and electronic components DANGER! Danger of electric shock. Danger to life.  The unit must be switched off and disconnected from the power supply prior to perform- ing most of the described service tasks. ...

  • Page 76: Activating And Replacing The Miniature Circuit Breaker (-1F1)

    Repair work at electric and electronic components Activating and replacing the miniature circuit breaker (-1F1) Spare parts: Miniature circuit breaker (order no. 5006-0075) Necessary tools Flathead screwdriver, size 2 Disconnect the unit from the power supply. Remove the housing cover on the lower front (chap. 5.1). Check the miniature circuit breaker.

  • Page 77: Replacing The Power Cord With Plug

    Repair work at electric and electronic components Replacing the power cord with plug Spare parts: Power cord with power plug (order no. 8009-0483) Power cord with power plug Switzerland (order no. 8012-0583) Power cord with power plug England (order no. 8012-0220) Power cord with power plug UL (order no.

  • Page 78: Replacing The Line Filter (-1Z1)

    Repair work at electric and electronic components Replacing the line filter (-1Z1) Spare parts: Line filter (order no. 5026-0016) Necessary tools Crosstip screwdriver, size 2 Disconnect the unit from the power supply and remove the rear panel (chap. 5.3). Mark the position of the connections. Pull the contactors from the connections (A).

  • Page 79: Checking And Replacing The Main Switch (-1S1) And The Humidity Switch (-8S1)

    Repair work at electric and electronic components 8.4 Checking and replacing the main switch (-1S1) and the humidity switch (-8S1) Spare parts: Rocker switch (2W) 230VAC (order no. 5019-0010) Crosstip screwdriver, size 2 Necessary tools Continuity checker or multimeter measuring device Disconnect the unit from the power supply.

  • Page 80: Removing The Electric Mounting Plates From The Machine Room

    Repair work at electric and electronic components Removing the electric mounting plates from the machine room DANGER! Danger of electric shock. Danger to life.  The unit must be switched off and disconnected from the power supply prior to per- forming most of the described service tasks.
  • Page 81 Repair work at electric and electronic components Electric mounting plate, standard Spare parts: KBF 115, 240, 720, Electric mounting plate, complete (order no. 8007-0339) Crosstip screwdriver, size 2 Necessary tools Torx screwdriver, size T20 Disconnect the unit from the power supply. Remove the housing cover on the lower front (chap.

  • Page 82: Components Of The Electric Mounting Plate (Standard)

    Repair work at electric and electronic components Components of the electric mounting plate (standard) X50 X120 X90 X140 X70 X100 Figure 38: Components of the electric mounting plate (standard) Slow-release time relay Converter RS422 / Ethernet Controller MB1 I/O board 115/230 V AC Fuse terminal 6.3x32 mm 4-wire through terminals Cable clamp, white 35 mm / 1.38 in...

  • Page 83: Components Of The Electric Mounting Plate (Optional Plate)

    Repair work at electric and electronic components Components of the electric mounting plate (optional plate) Figure : Components of the electric mounting plate (optional) Controller mTRON 4025 analog output Controller mTRON 4030 logic relay Controller mTRON 4025 analog output Relay (2 W / 8 A) 24 VDC Controller mTRON 4015 relay Relay (1W / 10A) 230VAC + relay socket Connector socket 6-poles...

  • Page 84: Controller Mb1 I/O Board (-3N2)

    Repair work at electric and electronic components Controller MB1 I/O Board (-3N2) 1 2 3 4 5 6 7 8 PE N L1 grounding pin analog output 2 input 1 binary output 2 input 2 binary output 3 input 3 binary output 1 input 4 binary output 4...

  • Page 85: Replacing The Controller Mb1 I/O Board (-3N2)

    Repair work at electric and electronic components 8.8.1 Replacing the controller MB1 I/O Board (-3N2) Spare parts: Controller MB1 I/O Board 115/230V AC (order no. 5014-0117) Necessary tools Crosstip screwdriver, size 2 Disconnect the unit from the power supply. Remove the housing cover of the lower front (chap. 5.1). Pull the electric mounting plate with the controller out of the machine room.

  • Page 86: Replacing Individual Mtron Relay Modules

    Send the removed mTRON modules back to BINDER-Service. Prior to sending, inscribe on the modules the date and, if the order was issued by BINDER GmbH Tuttlingen, also the “SAB no.”. 8.10 Replacing individual mTRON relay modules mTRON relay module 4015 (-11N1), (order no.
  • Page 87 Repair work at electric and electronic components Disconnect the unit from the power supply and remove the housing cover of the lower front (chap. 5.1). Pull the electric mounting plate with the options out of the machine room (chap. 8.5). Remove the connector blocks from the corresponding mTRON module and pull the module off the top hat rail.

  • Page 88: Replacing The Rs422 / Ethernet Converter (-2U1)

    Repair work at electric and electronic components 8.11 Replacing the RS422 / Ethernet converter (-2U1) Spare parts: RS422 / Ethernet converter (order no. 5021-0021) Necessary tools: Crosstip screwdriver, size 2 Disconnect the unit from the power supply. Remove the housing cover of the lower front (chap. 5.1). Pull the electric mounting plate with the RS422 / Ethernet converter out of the machine room (chap.

  • Page 89: Replacing The 24 V Power Supply Unit (-2T1)

    Repair work at electric and electronic components 8.12 Replacing the 24 V power supply unit (-2T1) Spare parts: Power supply unit (order no. 5020-0032) Necessary tools: Crosstip screwdriver, size 2 Disconnect the unit from the power supply. Remove the rear panel (chap. 5.3). Mark and remove the electrical connections from the power supply unit (B).

  • Page 90: Humidifying And Dehumidifying System

    Repair work at the humidifying and dehumidifying system Humidifying and dehumidifying system General information DANGER! Danger of electric shock. Danger to life.  The unit must be switched off and disconnected from the power supply prior to perform- ing most of the described service tasks. ...
  • Page 91 Repair work at the humidifying and dehumidifying system Range A: Control range of temperature and relative humidity Range Discontinuous range (no continuous operation Figure 46: Temperature-humidity diagram KBF Entry of the humidity set-point 0 % in defined program sections permits completely switching off humidity in Program Mode and thus attaining faster temperature changes.
  • Page 92 Water intake temperature NOT below +5°C / 41°F and not exceeding 40°C / 104°F. BINDER GmbH is NOT responsible for the water quality at the customer. Any problems and malfunctions that might arise following use of water of deviating quality is excluded from liability by BINDER GmbH.

  • Page 93: Variant A

    BINDER Service. Humidifying system In a cylindrical steam boiler with a volume of about 2 liters there is an electrical resistance heating. The pro- duced steam is maintained on a stable pressure level and is thus available in sufficient quantity for rapid hu- midity increases or for compensation of humidity losses, e.g.
  • Page 94 System structure and all functions are identical for the freshwater and waste water piping connection (with and without the option “BINDER Pure Aqua Service”, order no. 8012-0625) and for the option “external freshwater and waste water cans (order no. 8012-0643). The parts of these options are not described in this service manual.
  • Page 95 Repair work at the humidifying and dehumidifying system 9.1.2 Flow chart humidity system Equipment Equipment Designation Designation code code (-3N2) (-9Y10) Controller MB1 I / O board Solenoid valve steam release Float switch for filling level and (-8M1) Evacuation pump (-10S1) overflow sensor Side mounted float switch outlet...
  • Page 96 Deionized water from a water treatment installation already existing at the customer's site. • Water treated by the optional water treatment system BINDER Pure Aqua Service. BINDER GmbH is not responsible for the water quality at the customer. Any problems and malfunctions that might arise following use of water of deviating quality are excluded from liability by BINDER GmbH.
  • Page 97 Repair work at the humidifying and dehumidifying system 9.1.4 Function of the freshwater control Level control in the inlet tank: Water supply is effected by the solenoid valve (-10Y1) until the float switch (-10S3) opens. During filling the relay (-10K3) is switched. It switches off the entire humidification module (-9A1) for the duration of the filling and closes binary input 3 of the controller MB1 I/O board.
  • Page 98 Repair work at the humidifying and dehumidifying system 9.1.5 Humidification module (-9A1 ) structure 22/23 Figure 48: Humidification module (-9A1) Service Manual KBF (E5.2) 04-2015...
  • Page 99 Repair work at the humidifying and dehumidifying system • Steam hose (tissue), 1200 mm / 47.24 in • Pressure hose with metal braiding • Reflux valve • Water pump for steam boiler (-9M10) • Valve block pressure controller complete - Valve block with safety valve - Manometric switch with relay (-9F30) - Solenoid valve steam outlet (-9Y10) - Screw nut for valve block...
  • Page 100 Repair work at the humidifying and dehumidifying system • Freshwater connection • Waste water connection • Waste-water hose evacuation pump: Silicon hose, transparent Ø 20, length: 130 mm • Hose clamp 20-32 mm / 0.79 x 1.26 in • Boiler insulation complete Boiler insulation upper...
  • Page 101 Repair work at the humidifying and dehumidifying system 9.1.6 Dismantling the humidification module (-9A1) exchange module from variant variant refer " Replacement guide, humidification module ", order no.: 7001-0276 • Crosstip screwdriver, size 2 Necessary tools: • Torx screwdriver, size T 20 Disconnect the unit from the power supply.
  • Page 102 Repair work at the humidifying and dehumidifying system 9.1.7 Piping of the humidification module Figure 50: Piping of the humidification module Steam hose (tissue) (1200 mm / 47.24 in) Suction hose for water pump (800 mm / 31.49 in) Air relief hose of reflux valve (700 mm / 27.56 in) Pressure hose with metal braiding Wastewater hose of evacuation pump (130 mm / 5.12 in) Freshwater inlet hose (450 mm / 17.72 in)
  • Page 103 With option temperature safety device class 3.3 TEMP ALARM Exceeding the maximum or mini- mum temperature immediately With option locking of the keyboard (BINDER Individual) Locked keyboard KEY LOCK immediately The indicated intervals refer to the time after occurrence of the error or indicated condition.

  • Page 104: Variant B

    Fehler! Es ist nicht möglich, durch die BINDER GmbH is not responsible for the water quality at the customer. Bearbei- Any problems and malfunctions that might arise following use of water of deviating tung von quality is excluded from liability by BINDER GmbH.
  • Page 105 Repair work at the humidifying and dehumidifying system 9.2.2 Hydraulic scheme humidification module (-9A1) Service Manual KBF (E5.2) 04-2015...
  • Page 106 Repair work at the humidifying and dehumidifying system 9.2.3 Components of the humidification module (-9A1) Figure 51: Components of the humidification module Steam valve (-Y2) Connection water inlet Controller board Drain tap Riser hose Drain pump (-M1) Safety level sensors Boiler Condensate drain hose Safety thermostat (130 °C)
  • Page 107 Repair work at the humidifying and dehumidifying system 9.2.4 Replacing the complete humidification module (-9A1) • Humidification module Spare part: order no. 8009-0789 • Slotted and crosstip screwdrivers • Torx screwdriver, T 20 • Cutter Necessary tools: • Side cutter •...
  • Page 108 Repair work at the humidifying and dehumidifying system 7. Remove the condensate drain hose (E, Figure 51) from the drain tank (J, Figure 51). 8. Remove the hose clamp at the steam valve (A, Figure 51) of the steam hose (O, Figure 51). 9.
  • Page 109 Repair work at the humidifying and dehumidifying system 9.2.5 Checking the steam boiler DANGER! Danger by hot water. Danger of scalding.  Prior to work, make sure that the steam boiler has cooled down. To put out of action the humidification module, e.g. for maintenance proceed as follows: 1.
  • Page 110 Repair work at the humidifying and dehumidifying system 7. Open blue fastener holding band (steam boiler fixation). 8. The insulation of the steam cylinder can now be pushed over the lid, and the cables. Make sure that the cable of the capillary tube sensor is carefully passed through the opening.
  • Page 111 Repair work at the humidifying and dehumidifying system 9.2.6 Reassembling the steam boiler Assemble the steam bolier in reverse order. Please observe the following instructions: Check the capillary tube to correct resting on the heating elements and the correct fitting of the clamp. Before installing the steam boiler cover place the o-ring carefully into the edge of the steam cylinder.
  • Page 112 Repair work at the humidifying and dehumidifying system 9.2.7 Alarm system overview Malfunctions are detected by the system and displayed on the display of the MB1 controller. The internal buzzer of the device is activated. The alarm can be reset with the RESET key. On the control board of the humidification module, the red LED (ERROR) flashes.
  • Page 113 Repair work at the humidifying and dehumidifying system CAUTION! Overflow of the internal wastewater tank due to condensate. Emergence of water at the unit. Following high humidity operation, do NOT directly switch off the unit. Pump off the condensate before shut-down: •...

  • Page 114: Repair Work At The Cooling System

    Repair work at the cooling system Repair work at the cooling system 10.1 General information WARNING! If the KBF is maintained or repaired incorrectly, there is a risk of malfunction which could cause harm to human beings and material damage to the equipment and samples. CAUTION! If the KBF is calibrated or adjusted incorrectly, there is a risk of malfunction which could cause material damage to the samples and false test results.

  • Page 115: Replacing The Condenser Fan

    Repair work at the cooling system 10.3 Replacing the condenser fan Condenser complete KBF 115 Art.-Nr. 5013-0163 KBF 115 UL Art. Nr. 5013-0163 KBF 240 Art.-Nr. 5013-0165 KBF 240 Art.-Nr. 5013-0165 KBF 720 Art.-Nr. 5013-0163 KBF 720 UL Art. Nr. 5013-0163 Spare parts: Condenser fan KBF 115...

  • Page 116: Replacing The Capillary Tubes

    Repair work at the cooling system 10.4 Replacing the capillary tubes When replacing the capillary tubes mind their tightness. The capillary tubes should protrude by at least 40-50 mm / 1.57 x 1.97 in into the copper pipe. Figure 57: Replacing the capillary tubes Copper pipe Soldering joint Capillary tube...

  • Page 117: Checking The Step Motor Valve (-7Y3)

    Repair work at the cooling system 10.5 Checking the step motor valve (-7Y3) • Step motor valve (order no. 5025-0023) Spare parts: • Crosstip screwdriver, size 2 Necessary tools • Multimeter measuring device Disconnect the unit from the power supply. Remove the rear housing panel (chap.

  • Page 118: Interface Board Ib3 (-7N1) For Step Motor Valve

    Repair work at the cooling system 10.6 Interface board IB3 (-7N1) for step motor valve Jumper CN3 always placed 24 V - 24 V + green white black - 4-20 + 4-20 Jumper CN4 never placed Jumper CN2 Outside position: Normal operation Middle position: step motor valve open Figure : Interface board IB3 (-7N1 ) for step motor valve...

  • Page 119: Overview Cooling Cycle

    Repair work at the cooling system 10.7 Overview cooling cycle Solenoid valve (-7Y2) Solenoid valve (-7Y1) Filter dryer (-1J1) Compressor (-6M1) Condenser (-6M2) Solenoid valve (-7Y3) Filter (-1J6) Reflux valve (-1J7) Capillary tube (-1J3) Capillary tube (-1J2) Evaporator plate, small (-1J5) Evaporator plate, large (-1J5) Capillary tube (-1J4) Injection point cooling...

  • Page 120: Calibrating And Adjusting The Temperature And Humidity Control

    Calibrating and adjusting the temperature and humidity control Calibrating and adjusting the temperature and humidity control The temperature and humidity control of the unit have to be calibrated and if necessary ad- justed annually and after the following repair works: Replacing the inner chamber Pt100 temperature sensor (-3B1) (chap.

  • Page 121: Calibrating And Adjusting Points

    Calibrating and adjusting the temperature and humidity control 11.2 Calibrating and adjusting points 11.2.1 Calibrating and adjusting point of the temperature control The adjustment of the temperature control is carried out as a single point adjustment. Choose the most common operating temperature or a temperature situated in the middle of the most com- mon used temperature range as calibrating and adjusting point.

  • Page 122: Resetting The Temperature Controller Adjustment

    Calibrating and adjusting the temperature and humidity control 11.3.1 Resetting the temperature controller adjustment Before the unit can be re-adjusted the current adjustment has to be reset and the input value correction has to be switched off. Starting from Normal Display push <CONFIG>. ↓...
  • Page 123 Calibrating and adjusting the temperature and humidity control Use the buttons  or  to select the menu item “Inp.Val. correct.” and confirm with <ENTER>. Configuration 2 Analogue inputs Service Level Analogue outputs Inp.Val. correct. Limit comperators Analogue Inputs Donor-functions Analogue Outputs Controller Bin.
  • Page 124 Calibrating and adjusting the temperature and humidity control Use the buttons  or  to select a menu item and confirm with <ENTER>. Configuration 2 Analogue inputs For each menu item a submenu will be opened. Service Level Analogue outputs Inp.Val.

  • Page 125: Calibrating The Temperature Controller

    Calibrating and adjusting the temperature and humidity control 11.3.2 Calibrating the temperature controller Enter the “Service Level” (see steps 1 to 0, chap. 11.3.1). Configuration 2 Analogue inputs Analogue outputs Limit comperators Donor-functions Controller Service Level ↓ Use the buttons  or  to select the menu item “Analogue Inputs”...
  • Page 126 Calibrating and adjusting the temperature and humidity control Use the buttons  or  to select the menu “User-Settings” and confirm with <ENTER>. User-Settings Configuration 2 Configuration 1 Parameters Choose variation ↓ Note down the actual value of “Safety control.Act” (e.g. +22.7). User-Settings Instrument data Contrast...

  • Page 127: Adjusting The Temperature Controller

    Calibrating and adjusting the temperature and humidity control 11.3.3 Adjusting the temperature controller Enter the menu “Inp.Val. correct.“ (see steps 1 to 0, chap. 11.3.1). Configuration 2 Analogue inputs Service Level Analogue outputs Inp.Val. correct. Limit comperators Analogue Inputs Donor-functions Analogue Outputs Controller Bin.
  • Page 128 Calibrating and adjusting the temperature and humidity control Use the buttons  or  to select a menu item and confirm with <ENTER>. For each menu item a submenu will be Configuration 2 Analogue inputs opened. Service Level Analogue outputs Inp.Val.

  • Page 129: Setting The Door Heating Correction

    Calibrating and adjusting the temperature and humidity control 11.4 Setting the door heating correction Enter the menu “Inp.Val. correct.“ (see steps 1 to 0, chap. 11.3.1). Configuration 2 Analogue inputs Service Level Analogue outputs Inp.Val. correct. Limit comperators Analogue Inputs Donor-functions Analogue Outputs Controller...

  • Page 130: Calibrating And Adjusting The Humidity Controller

    Calibrating and adjusting the temperature and humidity control 11.5 Calibrating and adjusting the humidity controller Set the temperature set-point to that value the calibration of the temperature control is performed at (chap. 11.3). Set the humidity set-point to that value the calibration of the temperature control is performed at (chap. 11.3).

  • Page 131: Calibrating The Humidity Controller

    Calibrating and adjusting the temperature and humidity control ↓ Push <EXIT> four times to return to the basic display. 11.5.2 Calibrating the humidity controller Enter the “Service Level” (see steps 1 to 0, chap. 11.3.1). Configuration 2 Analogue inputs Analogue outputs Limit comperators Donor-functions Controller...
  • Page 132 Calibrating and adjusting the temperature and humidity control Push <EXIT> four times to return to the basic display. Push <CONFIG>. Set the set humidity to the other of the desired values for the humidity calibration and adjustment (chap. 11.2.2). Wait until the steady-state condition is reached (chap. 11.1). ↓...

  • Page 133: Adjusting The Humidity Controller

    Calibrating and adjusting the temperature and humidity control 11.5.3 Adjusting the humidity controller Enter the menu “Inp.Val. correct.“ (see steps 1 to 0, chap. 11.3.1). Configuration 2 Analogue inputs Service Level Analogue outputs Inp.Val. correct. Limit comperators Analogue Inputs Donor-functions Analogue Outputs Controller Bin.

  • Page 134: Spare Parts

    Spare parts Spare parts Name of spare part order no. Installation Housing cover standard KBF 115 4001-0726 KBF 240 4001-0745 KBF 720 8001-0256 chap. 5 Housing cover for option temperature safety device class 3.3 KBF 115 4001-0727 KBF 240 4001-0747 KBF 720 8001-0255 Lateral control panel, right...
  • Page 135 Spare parts Name of spare part order no. Installation Door handle KBF 115, 240, right 104 mm 6002-0104 KBF 720, right 77,5 mm 6002-0121 chap. 6.4 KBF 720, left 77,5 mm 6002-0122 Screw 3001-0003 Push rod guide KBF 115, 240 6002-0018 KBF 720 6002-0202...
  • Page 136 Spare parts Name of spare part order no. Installation Fan sheet KBF 115 4020-0576 KBF 240, 720 4020-0597 chap. 7.4 Fan cover KBF 115 4020-0949 KBF 240, 720 4020-0918 Frame gasket KBF 115 6005-0207 chap. 7.5 KBF 240 6005-0147 KBF 720 6005-0196 Frame heating wire KBF 115 (-4E3)
  • Page 137 Spare parts Name of spare part order no. Installation Power cord with plug 8009-0483 Power cord with plug UL 8009-0436 Power cord with plug Switzerland 8012-0583 chap. 8.2 Power cord with plug England 8012-0220 Power connection board 4001-0269 Line filter (-1Z1) 5026-0016 chap.

  • Page 138: Parts Subject To Wear

    Revision history Parts subject to wear Equipment Name of spare part order no. code Heating Door heating wire KBF 115 5005-0101 (-4E2) KBF 240 5005-0169 (-4E2) KBF 720 5005-0169 (-4E3, -4E4) Frame heating wire KBF 115 5005-0185 (-4E3) KBF 240 5005-0168 (-4E3) KBF 720...

This manual is also suitable for:

Kbf 115Kbf 115-ulKbf 240Kbf 240-ulKbf 720Kbf 720-ul ... Show all

Table of Contents

Save PDF