Binder KBF Series User manual

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)
9020-0108, 9120-0108
KBF 720-UL (E5.2)
9020-0168, 9120-0168
Issue 04-2015 order no. 7001-0203

Service Manual

Imprint
Imprint
Manufacturer:
BINDER GmbH
Address Post office box 102
D-78502 Tuttlingen
Tel. [phone]
Fax [phone]
Internet http://www.binder-world.com
E-mail [e-mail]
Service Hotline [phone]
Service Fax [phone]
Service E-Mail [e-mail]
Service Hotline USA [phone] or [phone] x3
Service Hotline Asia Pacific [phone] or [phone]
Service Hotline Russia and CIS [phone]
The reproduction, distribution and utilization of this document as well as the communication of its content to
others without explicit authorization are prohibited. 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 3

Table of content
Table of content
1Preface ...............................................................................................................................................6
1.1 General guidelines ..............................................................................................................................6
1.2 Syntax..................................................................................................................................................6
1.3 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 .............................................................................................................................8
1.3.6 Information symbol..............................................................................................................................8
2General safety instructions..............................................................................................................9
2.1 Qualification of service personnel.......................................................................................................9
2.2 Dangers.............................................................................................................................................10
3Maintenance.....................................................................................................................................12
3.1 Safety check acc. to DIN VDE 0701-0702........................................................................................17
4Troubleshooting..............................................................................................................................18
4.1 General electrical faults.....................................................................................................................19
4.2 Faults of the heating system .............................................................................................................21
4.3 Faults of the cooling system..............................................................................................................23
4.4 Functional check of the cooling system ............................................................................................25
4.5 Errors in the humidification module...................................................................................................27
5Repair work at the housing............................................................................................................34
5.1 Replacing the housing cover at the lower front.................................................................................34
5.2 Replacing the pen recorder (-14P1)..................................................................................................35
5.3 Replacing the rear panel...................................................................................................................36
5.4 Replacing the silicone access port....................................................................................................37
5.5 Replacing the castors........................................................................................................................39
6Repair work at the outer door........................................................................................................41
6.1 Aligning the outer door......................................................................................................................41
6.1.1 Aligning the door hinges....................................................................................................................41
6.1.2 Aligning the adjustable door holder lug with pulley...........................................................................42
6.2 Checking and replacing outer door components ..............................................................................43
6.2.1 Dismounting the interior side of the outer door.................................................................................43
6.2.2 Replacing the door hinge cover ........................................................................................................45
6.2.3 Checking and replacing the interior side of the outer door ...............................................................46
6.2.4 Replacing the door............................................................................................................................48
6.2.5 Replacing the door contact switch (-3S1 ) ........................................................................................49
6.2.6 Replacing the outer door gasket.......................................................................................................50
6.3 Replacing the triangle instrument box...............................................................................................51
6.3.1 Dismantling the instrument box.........................................................................................................51
6.3.2 Replacing of components of the triangle instrument box..................................................................52
6.4 Replacing the closing device of the outer door.................................................................................54
7Repair work at the inner and outer chamber................................................................................56
7.1 Replacing the glass door...................................................................................................................56
7.2 Replacing the closing device of the glass door.................................................................................57
7.3 Replacing the glass door gasket.......................................................................................................58
7.4 Replacing the fan (-4M1)...................................................................................................................59
7.5 Replacing the frame gasket ..............................................................................................................62
7.6 Checking and replacing the frame heating wire (-4E3 )....................................................................63
7.7 Replacing the inner chamber and the gaskets between the inner and the outer chamber ..............64
7.8 Testing and replacing the heating element (-4E1) ............................................................................66
7.9 Checking and replacing the inner chamber Pt 100 temperature sensor (-3B1)................................69
7.10 Checking and replacing the humidity sensor and the sensor board (-3B2)......................................71
7.11 Replacing the temperature fuse 110°C / 230°F (-1F2)......................................................................74
8Repair work at electric and electronic components....................................................................75
8.1 Activating and replacing the miniature circuit breaker (-1F1) ...........................................................76
4 Service Manual KBF (E5.2) 04-2015

Table of content
8.2 Replacing the power cord with plug..................................................................................................77
8.3 Replacing the line filter (-1Z1)...........................................................................................................78
8.4 Checking and replacing the main switch (-1S1) and the humidity switch (-8S1)..............................79
8.5 Removing the electric mounting plates from the machine room.......................................................80
8.6 Components of the electric mounting plate (standard) .....................................................................82
8.7 Components of the electric mounting plate (optional plate)..............................................................83
8.8 Controller MB1 I/O Board (-3N2).......................................................................................................84
8.8.1 Replacing the controller MB1 I/O Board (-3N2) ................................................................................85
8.9 Replacing the controller display (-3N1).............................................................................................85
8.10 Replacing individual mTRON relay modules ....................................................................................86
8.11 Replacing the RS422 / Ethernet converter (-2U1) ............................................................................88
8.12 Replacing the 24 V power supply unit (-2T1)....................................................................................89
9Humidifying and dehumidifying system.......................................................................................90
9.1 Variant A............................................................................................................................................93
9.2 Variant B..........................................................................................................................................104
10 Repair work at the cooling system..............................................................................................114
10.1 General information.........................................................................................................................114
10.2 Required tools for repairing the cooling system..............................................................................114
10.3 Replacing the condenser fan ..........................................................................................................115
10.4 Replacing the capillary tubes ..........................................................................................................116
10.5 Checking the step motor valve (-7Y3).............................................................................................117
10.6 Interface board IB3 (-7N1) for step motor valve..............................................................................118
10.7 Overview cooling cycle....................................................................................................................119
11 Calibrating and adjusting the temperature and humidity control............................................120
11.1 General execution of the calibration................................................................................................120
11.2 Calibrating and adjusting points......................................................................................................121
11.2.1 Calibrating and adjusting point of the temperature control .............................................................121
11.2.2 Calibrating and adjusting points of the humidity control..................................................................121
11.3 Calibrating and adjusting the temperature control..........................................................................121
11.3.1 Resetting the temperature controller adjustment............................................................................122
11.3.2 Calibrating the temperature controller.............................................................................................125
11.3.3 Adjusting the temperature controller ...............................................................................................127
11.4 Setting the door heating correction.................................................................................................129
11.5 Calibrating and adjusting the humidity controller ............................................................................130
11.5.1 Resetting the humidity controller adjustment..................................................................................130
11.5.2 Calibrating the humidity controller...................................................................................................131
11.5.3 Adjusting the humidity controller .....................................................................................................133
12 Spare parts.....................................................................................................................................134
13 Parts subject to wear ....................................................................................................................138
14 Revision history ............................................................................................................................138
Service Manual KBF (E5.2) 04-2015 5

Preface
1 Preface
1.1 General guidelines
This service manual describes the maintenance, the trouble shooting, the repair, the calibration and the ad-
justment of the KBF 115, 240 and 720 (E5.2). It is aimed at service personnel who should maintain, repair,
calibrate and adjust the KBF
The repair of the cooling system must only be performed by service personnel having specialized training as
cooling technician and special tools must be available.
References about the required qualification of the service personnel can be found in chap. 2.1.
Before starting the service work at a KBF, compare order and serial number of the unit with the validity note
on the front page of this service manual.
The marking of electrical equipment and electric contacts refers to the circuit diagram of the KBF 240 (E5.2),
57121004.PRO.
The marking relates to the designation in the circuit diagram and the labeling of the components into the
device. With other sizes of the device the marking can deviate. Therefore use always the appropriated circuit
diagram of the device.
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).
All information about initial operation, normal operation, cleaning, alarm and error messages can be found in
the relevant operating manual delivered with the KBF.
1.2 Syntax
Syntax
Meaning
(-1A1)
Marking of electrical equipment and electric contacts (Equipment code)
<button>
Button to be pushed
"text"
Displayed text or text to be keyed in
6 Service Manual KBF (E5.2) 04-2015

Preface
1.3 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
∅Instruction how to avoid the hazard: prohibition
1.3.2 Warning levels
Dangers are indicated, according to the severity and likelihood of their consequences, by a word to attract
attention, with the associated warning color and any appropriate safety symbol:
DANGER!
Indicates an imminently hazardous situation that, if not avoided, will result in death or seri-
ous (irreversible) injury.
WARNING!
Indicates a potentially hazardous situation which, if not avoided, could result in death or se-
rious (irreversible) injury.
CAUTION!
Indicates a potentially hazardous situation which, if not avoided, may result in moderate or
minor (reversible) injury.
CAUTION!
Indicates a potentially hazardous situation which, if not avoided, may result in damage of the product
and/or its functions or of a property in its ambiance.
Service Manual KBF (E5.2) 04-2015 7

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
1.3.5 Imperative symbols
Pull out the power plug
Wear protective goggles
Wear protective gloves
1.3.6 Information symbol
Important information
8 Service Manual KBF (E5.2) 04-2015

General safety instructions
2 General safety instructions
2.1 Qualification of service personnel
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.
The KBF should only be maintained, repaired, calibrated and adjusted by qualified persons.
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
Experience in servicing environmental simulation chambers for constant climates
Maintenance, repair and inspection of the cooling system must be performed by trained personnel,
that has a certification in accordance with EC Regulation 303/2008 and expert knowledge in accordance
with EN 13313:2010.
All work on the cooling system (repairs, inspections) must be recorded in the associated plant log book.
The KBF units are operated with R 134a refrigerant.
The amount of refrigerant may differ due to technical reasons.
The amount of refrigerant for a unit is specified on its type plate and the flow chart of the
refrigeration cycle.
Refrigerant R 134a must not enter the environment.
Before opening the cooling cycle, have the refrigerant sucked off in a professional
way and disposed of according to the international regulations.
Service Manual KBF (E5.2) 04-2015 9

General safety instructions
2.2 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.
The unit must be live to perform some of the service tasks.
In this case, a second person must be present who is able to switch off the unit in case
of emergency.
DANGER!
Danger of electric shock.
Danger to life.
The humidification module is supplied with electrical tension event if the humidity switch is
switched off.
∅Any service tasks at the humidification module must only be performed
if the KBF is disconnected from the power supply.
Disconnect the unit from the power supply, prior to performing repairs at the humidifica-
tion module.
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.
10 Service Manual KBF (E5.2) 04-2015

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.
Before opening the triangle instrument box the technician should at least electrostati-
cally discharge by touching grounded metallic objects.
CAUTION!
Danger of mechanical damages.
∅Never let mechanical components hang at electric cables. Electric cables are not appropriate to hold
bigger components and will be damaged if you do so.
CAUTION!
Danger of water running out.
Disconnect the waste water hose from the unit only if the main switch is switched off.
∅Never disconnect the waste water hose from the unit if only the humidity switch is switched off. Even if
the humidity switch is switched off, water may be pumped off the unit.
CAUTION!
Danger of malfunction and damaging the electronics.
Prior to work at the electrical equipment check identity of the components with the aid of the wiring dia-
gram. The order of the electrical equipment may differ from the description in this service manual.
Electrical connection
The climatic test chamber has a fixed power connection cable 1800 mm in length.
Power plug Tension
+/-10 %
Current
type
Power
frequency
Unit fuse
KMF 115;
KMF 240,
KMF 720 Shock-proof plug 200 V to 240 V 1N~ 50/60 Hz 16 Amp
KMF 115-UL
KMF 240-UL
KMF 720-UL NEMA 6-20P 200 V to 240 V 2~ 50/60 Hz 16 Amp
Service Manual KBF (E5.2) 04-2015 11

Maintenance
3 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
Housing
Sheet metal components Check the housing and the inner chamber for mechanical damages and corro-
sion.
If necessary, replace the damaged sheet metal components
(chap. 7.7, page 64).
Silicone access port Check the silicone access port for damages, tight fit in the housing
wall and leakproofness.
If necessary, replace the silicone access port (chap. 5.4, page 37).
Outer door
Outer door,
door hinges,
lugs
Check the outer door for alignment and tight fit.
Check the door hinges for well running.
If necessary, align the adjustable door holder lug with pulley
(chap. 6.1.2, page 42).
Instrument box Check the triangle instrument box for tight fit and fractures.
If necessary, fix or replace the instrument box (chap. 6.3, page 51).
Buttons on the instrument box
Check the function of the buttons on the instrument box by various entries (see
operating manual).
If necessary, replace the corresponding switch mat (chap. 6.3.2, page 52).
Outer door Check the door for mechanical damages and corrosion.
If necessary, replace the door (chap. 6.2.4 page 48).
Outer door gasket Check the outer door gasket for wear, tight fit, and damages.
If necessary, replace the outer door gasket or the frame gasket (chap. 6.2.6,
page 50 and chap. 7.5, page 62).
Door contact switch (-3S1) Check the door contact switch for tight fit and mechanical function.
If necessary, replace the door contact switch (chap. 6.2.5, page 49).
Interior side of the outer door
Check the interior side of the door for damages by
deformation and corrosion.
If necessary, replace the interior side of the door (chap. 6.2.3, page 46).
Closure Check the closure for function and well running.
If necessary, replace the closure (chap. 6.4, page 54).
12 Service Manual KBF (E5.2) 04-2015

Maintenance
Component Check step / Actions
Inner chamber and outer enclosure
- Glass door
- Closure of glass door
- Glass door supports at the sides
of the inner chamber
Check the glass door and the door hinges for damages.
Check the door hinges for well running.
Check the glass door for alignment and tight fit.
If necessary, align the glass door.
Check the glass door gasket.
If necessary, replace the glass door gasket.
Check the glass door closure.
If necessary, replace the glass door closure (chap. 7.2, page 57).
Check the solidity of the conglutination of the door handle and the glass door
hinges.
If necessary, replace the glass door (chap. 7.1, page 56).
Fan (-4M1) Check the fan for damages, corrosion, function and bearing noises.
If necessary, replace the entire fan (chap. 7.4, page 59).
Gaskets between the inner cham-
ber and the outer enclosure Check the gaskets between inner chamber and outer enclosure
If necessary, replace the gaskets between the inner chamber and the outer en-
closure (chap. 7.5, page 62).
Heating element (-4E1) Check the resistance of the heating element.
If necessary, replace the heating element (chap. 7.8, page 66).
Humidity sensor (-3B2) If necessary with dirt load inside the KBF, replace the filter cap of the humidity
sensor (chap. 7.10, page 71).
Machine room
Machine room Check the machine room for soiling, mechanical damages and corrosion.
Clean the machine room from dust and similar dirt.
Electric and electronic components
Mains plug
power cord Check the mains plug and power cord for damages.
If necessary, replace the mains plug and power cord (chap. 8.2, page 77).
Main switch (-1S1) and
Humidity switch (-8S1) Check the main switch and humidity switch for mechanical damages and corro-
sion.
If neces
sary, replace the main switch or the humidity switch
(chap. 8.4, page 79).
RJ45 socket (-2U1)
Interface RS 422 Check the RJ45 socket for mechanical damages and corrosion.
If necessary, replace the RJ45 socket (chap. 8.11, page 88).
Electric mounting plate
Check the electric mounting plate and the components on it for soiling, damages
and corrosion.
If necessary, clean the electric mounting plate and the components.
If necessary, replace the components on the electric mounting plate (chap. 8.6 ff,
page 82).
Check the components and the cables of the components on the electric mount-
ing plate for sufficient fixing.
Fix loose cables and components and replace any damaged cables.
Electronic components in the
machine room
Check the electronic components in the machine room for sufficient fixing, soiling,
damage, and corrosion.
If necessary, replace the electronic components in the machine room (chap. 8ff,
page 75).
Check the cables of the electronic components in the machine room for sufficient
fixing and for damages.
Fix loose cables and replace any damaged cables.
Service Manual KBF (E5.2) 04-2015 13

Maintenance
Component Check step / Actions
Humidification module variant A
Freshwater hose,
waste water hose
Check the freshwater and waste water hoses for wear, damag
e and
leakproofness.
⇒
If necessary, replace the humidification module, chap. 9.1.6
Inlet tank and outlet tank Check the inlet tank and outlet tank for soiling, damage and leakproof-
ness.
⇒
If necessary, replace the humidification module, chap. 9.1.6
Steam hose,
hoses of the ventilation,
reflux valve
Check the steam hose and the hoses of the ventilation for wear, damag-
es and leakproofness.
Check the reflux valve for wear, damages and leakproofness.
⇒
If necessary, replace the humidification module, chap. 9.1.6
Evacuation pump (-8M1)
Check the evacuation pump for damages.
Check the evacuation pump for function (float switch -10S2),
Clean the evacuation pump and replace the gaskets if necessary.
⇒
If necessary, replace the humidification module, chap. 9.1.6
Water pump for steam boiler
(-9M10) Check the water pump for damage and soiling.
⇒
If necessary, replace the humidification module, chap. 9.1.6
Freshwater inlet valve
(-10Y1)
Unscrew the freshwater hose and clean the connecting branch of the
freshwater inlet valve.
Check the freshwater inlet valve for damages.
Check the freshwater inlet valve for function (float switch -10S3)
⇒
If necessary, replace the humidification module, chap. 9.1.6
Float switches
(-10S1), (-10S2), (-10S3)
Check all float switches for smooth running.
Check the float switches for function
⇒
If necessary, replace the humidification module, chap. 9.1.6
Steam boiler (-9A10)
Check the electrical connections for sufficient fixing, soiling, damage, and
corrosion.
Check the steam boiler from outside for leakages, wear, and
damages.
If necessary, replace the humidification module, chap. 9.1.6
14 Service Manual KBF (E5.2) 04-2015

Maintenance
Component Check step / Actions
Humidification module variant B
Freshwater hose,
waste water hose
Check the freshwater and waste water hoses for wear
, damage and
leakproofness.
⇒If necessary, replace the freshwater and waste water hoses.
Drain tank Check the inlet tank and outlet tank for soiling, damage and leakproof-
ness.
Steam hose Check the steam hose and the hoses of the ventilation for wear, damag-
es and leakproofness.
Freshwater inlet valve
(-Y1)
Unscrew the freshwater hose and clean the connecting branch of the
freshwater inlet valve.
Check the freshwater inlet valve for damages.
Steam boiler
Check the electrical connections for sufficient fixing, soiling, damage, and
corrosion.
Check the steam boiler from outside for leakages, wear, and
damages.
⇒In case of lime decalcify the boiler following the instructions included
in the cleaning kit.
Service Manual KBF (E5.2) 04-2015 15

Maintenance
Component Check step / Actions
Cooling system
Piping,
dryer (-J1, -J2),
step motor valve (-7Y3)
Check the tubes, especially the soldering joints, and the components of the cool-
ing system for damages and corrosion.
If necessary, have repaired the cooling system (chap. 10ff, page 114).
Insulation Check the insulation of the cooling system for damages
If necessary, seal damages of the insulation with appropriate insulating material
Compressor,
condenser + fan Check the condenser for soiling and damages.
Check the compressor and the condenser and the fan for unusual noises.
Clean the condenser and the fan
If necessary, replace the condenser fan (chap. 10.3, page 115).
If necessary, have replaced the compressor and/or condenser.
Solenoid valves (-7Y1, -7Y2) Check the solenoid valves for damages and corrosion.
If necessary, replace the solenoid valve coils.
Check the electrical function of the solenoid valve coils according to the descrip-
tion in chap. 4.3, page 23.
Step motor valve (-7Y3)Check the Step motor valve for function (chap. 4.4)
Safety check*
(acc. to DIN VDE 0701-0702) Check the unit for visible damages and defects. Check the protective conductor resistance and the insulation resistance as well
as the protective conductor current (chap. 3.1, page 17).
Operating manual Check if the operating manual is available (e. g. for safety instructions)
Controller
Controller display Check the function of the controller display by entering different menus (see op-
erating manual).
If necessary, replace the controller (chap. 8.9, page 85).
Set point setting Key in several set points for temperature and humidity and check if the unit starts
approaching this values (see operating manual).
Execute a troubleshooting, if the unit does not start approaching the set points
(chap. 4, page 18).
Temperature control Calibrate the temperature controller (chap. 11, page 120).
If necessary, adjust the temperature controller.
If necessary, replace the Pt100 temperature sensor
(chap. 7.9, page 69).
Humidity control Calibrate the humidity controller (chap. 11, page 120).
If necessary, adjust the humidity controller.
If necessary, replace the humidit
y sensor incl. board
(chap. 7.10, page 71).
* According to general technical rules, conduct a safety check acc. to DIN VDE 0701-0702 after every repair
or modification of a unit.
Alternatively you can perform the safety check also with similar national standards if they contain the tests
described in chap. 3.1, page 17.
Independent of the standard used for the safety check, the measurement values indicated in chap. 3.1,
page 17 must be reached.
16 Service Manual KBF (E5.2) 04-2015

Maintenance
3.1 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.
2. Measuring the protective conductor resistance
The protective conductor resistance is measured between the grounding contacts of the
mains plug and several different, electrically conductive spots of the housing.
The measuring current for measuring the resistance must be at least 0.2 Amp.
The protective conductor resistance must not exceed the value 0.3 Ω.
Possible causes of error: corroded connections, no electrically conductive measuring spots
due to lacquer or dirt.
Cause removal: Clean connections or make the measuring spots metallically bare.
3. Measuring the insulation resistance
The insulation resistance is measured between one conduct and several different, electrical-
ly conductive spots of the housing. All switches must be closed during the measurement.
The resistance must not fall below the value 0.3 MΩ.
When measuring, make sure that the unit is not dirty or wet. If the measured resistance val-
ue is too low, we recommend drying thoroughly the unit and repeating the measurement.
4. Measuring the protective conductor current
The protective conductor current is the current that flows through the protective conductor
when the unit is switched on. All switches must be closed during the measurement.
Set the following set-point values:
•Temperature +90°C / 194°F
•Humidity 90% RH
The measurement is effected at all possible plugging positions of the mains plug. The pro-
tective conductor current must not exceed 3.5 mAmp. If the current is exceeded, a possible
cause may be bad insulation or short-circuit of a coil. Coils exist e.g. in fans, mains supply
units, motors, solenoid valves, and relays. By temporary electrical uncoupling of the corre-
sponding parts, you can identify and localize possible sources of error.
Service Manual KBF (E5.2) 04-2015 17

Troubleshooting
4 Troubleshooting
Alarm and error messages as well as basic measures the operator himself may take to
clear them are described in the KBF 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 Yes Remedial measure
No
Possible error cause Yes Remedial measure
Faults should be found by replacing components of the unit. Usually that will be the fastest method of trou-
bleshooting.
The sequence of the columns describing potential causes for errors, and the remedial actions to clear the
described error patterns, is mainly intended to facilitate basic error diagnosis and clearance.
So it is recommended to work your way from top to bottom of the diagrams.
Notations between brackets and in italics, e.g. (-1S1), behind a component refer to the respective equipment
codes for this component, as specified in the wiring diagram, and in labels on some parts inside the appa-
ratus.
Observe the safety instructions during service diagnosis!
When repairing the unit,
switch it off and disconnect it from the power supply.
18 Service Manual KBF (E5.2) 04-2015

Troubleshooting
4.1 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? No
Connect power plug
Yes
Main switch (-1S1) set to ON? No
Set main switch to ON
Yes
Facility-side power supply available? No Ensure facility-side power supply.
Yes
The miniature circuit breaker (-1F1) on the
electric mounting plate has responded?
Yes
Look for cause of the response and re-
move it:
if contaminated with conductive dust:
clean the apparatus carefully
if the cables are mechanically damaged:
replace or insulate the cable in a profes-
sional manner
if cables or components are burned:
replace cable or component
if the facility-side power supply is defec-
tive: have the power supply repaired
if the heater is defective: replace the
heater (chap. 7.8)
if the heating cable of the door is defec-
tive: replace the inside of o
uter door
(chap. 6.2.4)
if the frame heating wire is defective: re-
place the frame heating wire (chap. 7.6)
Activate the miniature circuit breaker
(-1F1) (chap. 8.1).
No
Service Manual KBF (E5.2) 04-2015 19

Troubleshooting
Plug at the main switch (-1S1) connected? No Connect plug at the main switch
(chap. 8.4, page 79)
Yes
Main switch (-1S1) defective? Yes Replace main switch
(chap. 8.4, page 79)
No
Power cord with mains plug (-X1) defective? Yes Replace power cord with mains plug
(chap. 8.2, page 77)
No
Plug of the controller cable connected to the
socket Interface Screen Board of the controller
MB1 I/O-board (-3N2)?
No Connect the plug of the controller cable to
the socket Interface Screen Board of the
controller MB1 I/O-board (chap. 8.8,
page 84)
Yes
Plug of the controller cable connected to the
controller display (-3N1)? No Connect the plug of the controller cable to
the controller display (chap. 8.9, page 85)
Yes
Temperature fuse (-1F2) is blown because of a
controller error?
Yes Find and remove the cause of overtempera-
ture
Replace temperature fuse
(chap. 7.11, page 74)
No
Controller MB1 I/O-board (-3N2) and/or
controller display (-3N1) defective?
Yes Replace controller MB1 I/O-board
(chap. 8.8.1, page 85)
and/or
controller display (chap. 8.9, page 85)
No
Line filter (-1Z1) defective? Yes Replace line filter (chap. 8.3, page 78)
20 Service Manual KBF (E5.2) 04-2015