User Manual

2.0

BOD INCUBATOR
OPERATION & MAINTENANCE MANUAL

Model Number

: NLBI7SI

Serial Number

: BOD/14-012U

The name you can trust

Newtronic Lifecare Equipment Private Limited
108-ABCD, Kandivli Co-Op. Industrial Estate, Mumbai 400067, India.
Phone: +91 22 28679326
Fax: +91 22 28676059
Email: sales@newtronic.in, service@newtronic.in
Web: www.newtronic.in

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Table of Content
1.
2.
3.

Company Information and Assistance ............................................................................... 3

Safety Warnings ................................................................................................................ 4
Receiving of BOD Incubator .............................................................................................. 6
3.1. Transportation ............................................................................................................. 6
4. Installation Instructions ...................................................................................................... 6
4.1. Location and Installation of Unit................................................................................... 6
4.2. Power Connection ....................................................................................................... 7
5. Product Description ........................................................................................................... 9
5.1. Heating System ........................................................................................................... 9
5.2. Air Circulation ............................................................................................................ 10
5.3. Cooling System ......................................................................................................... 11
6. Technical Specifications .................................................................................................. 12
6.1. Specification Summary .............................................................................................. 12
6.2. Technical Specifications of Components ................................................................... 13
7. Incubator Operations ....................................................................................................... 14
7.1. Installation checks ..................................................................................................... 14
7.2. General Safety Features on the Machine: Interlocks ................................................. 15
7.3. Controller ................................................................................................................... 15
8. Operations ....................................................................................................................... 16
8.1. Power ON .................................................................................................................. 16
8.2. Controller Settings ..................................................................................................... 16
8.3. Set Parameters.......................................................................................................... 16
9. Troubleshooting ............................................................................................................... 29
10. Maintenance ................................................................................................................. 30
10.1. Interior/Exterior surfaces ........................................................................................ 30
10.2. Door Gasket ........................................................................................................... 30
10.3. General Electrical Connections .............................................................................. 30
10.4. Electric Heater(s).................................................................................................... 31
10.5. Controller / Calibration............................................................................................ 31
10.6. Preventative Maintenance Schedule / Log ............................................................. 31
11. Supporting Documents ................................................................................................. 32

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1. Company Information and Assistance

Congratulations on purchasing a BOD Incubator from NEWTRONIC. You probably already
know us as NEWTRONIC Lifecare Equipment Private Limited. Weve changed expanded our
vision with the intent to provide you with more diversified solutions to your study and testing.
We truly hope that every aspect of BOD Incubator design and quality will measure up to your
strictest standards. Your BOD Incubator has been designed to operate with the reliability you
expect for the demands you impose on your product and research testing.
NEWTRONIC has head office in Mumbai which is located in western part of India. The
company has sales and servicing center in many parts of India and in other countries also.
Contact sales department to get latest information on sales offices around the world. For
servicing of equipment and support; contact servicing department.
Parts and service inquiries for equipment within each division should be directed to
NEWTRONIC by any of the following methods.
Important! Please mention the Model and Serial Numbers of your unit while communicating
with us.

Newtronic Lifecare Equipment Private Limited

108-ABCD, Kandivli Co-Op. Industrial Estate,
Near Hindustan Naka, Charkop, Kandivli (West)
Mumbai 400067, India.
Phone

: +91 22 28679326

Fax

: +91 22 28676059

Email

: sales@newtronic.in, service@newtronic.in

Web

: www.newtronic.in

Parts Replacement
Your BOD Incubator has been designed and manufactured to provide years of reliable service.
In the event a component should fail, it is recommended that only OEM approved parts be
used as replacements. Please contact the Service Department for component replacement,
or repair.

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2. Safety Warnings
o Read this entire Operation Manual, as well as the vendor manuals and cut-sheets
provided before operating this equipment! Failure to adhere to any Safety Warning, or
failure to follow the proper operating procedures listed throughout any of the information
provided, could cause damage to your equipment, personal injury, or death.
o Operators and service personnel must be familiar with the location and function of all
controls and the inherent dangers of the equipment before operating or maintaining it.
o Only qualified service personnel should ever be permitted to perform any service-related
procedure on this equipment
o This is not an explosion resistant chamber. Do not install test articles that may release
explosive or flammable vapors in the chamber.
o Do not place the unit near combustible materials or hazardous fumes or vapors.
o Do not install unit in a corrosive environment. A corrosive environment may lead to poor
performance and deterioration of unit.
o Make sure the chamber and any remote equipment provided are leveled when installed.
The chamber door may swing shut on personnel if it is tilted.
o A main power disconnect may not be provided with your unit. If not provided, we
recommend that a fused disconnect switch on a separate branch circuit be installed as the
power source in accordance with all National and Local Electrical Codes. If your unit is
equipped with a power cord and plug, you must utilize a receptacle with the appropriate
rating, which is on a branch circuit of its own.
o Do not position the equipment in a manner that would make it difficult to operate your main
power disconnect switch.
o Your power supply line voltage may be too low or too high to properly and safely operate
your equipment. Before making the power supply connection to your equipment, you must
follow the specific directions stated under Electric Supply in the Installation Instructions
section. Failing to perform the directions stated may damage your equipment and void
your warranty!
o Control panels, gauge boxes, etc., contain exposed electrical connections. Keep panels in
place properly when the unit is in operation. Disconnect and Lock-Out /Tag-Out all
electrical power from the unit at its source before servicing or cleaning.
o Do not modify any component on this unit. Use only original equipment manufactured
(OEM) parts as replacement parts. Modifications to any component, or the use of a nonOEM replacement part could cause damage to your equipment, personal injury, or death.
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INTERNATIONAL WARNING / SAFETY SYMBOL DEFINITIONS

Obey all DANGER, WARNING, and CAUTION labels shown in the manual and mounted
on the equipment. Do not remove any labels mounted on the equipment.
WARNING OF HAZARDOUS AREA

WARNING OF DANGEROUS ELECTRIC VOLTAGE

WARNING OF HOT SURFACE

DANGER ROTATING FAN

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3. Receiving of BOD Incubator

3.1. Transportation
All NEWTRONIC BOD Incubators are factory tested and certified free from defects,
when shipped.
Inspect BOD Incubator and shipping crate immediately upon receipt. If any damage is
apparent, you should discuss it with the trucking delivery person and contact the
transportation company immediately. Make notes of any damage on the Bill Of Lading.
Retain all shipping materials for inspection. Any claims for damage must start at the
receiving point. Check packing slip carefully and make sure all materials have been
received as indicated on the packing ticket. Unless otherwise noted, YOUR ORDER
HAS BEEN SHIPPED COMPLETE.

4. Installation Instructions
Read this section completely before attempting to install, or operate the equipment.
4.1. Location and Installation of Unit
Your equipment has been fully operated, tested, and balanced in our plant prior to
shipment, unless notified otherwise. Follow the installation requirements below.
Do not place the unit near combustible materials or hazardous fumes or vapors.

Do not locate unit in areas of wide ambient temperature variation such as near
vents or outdoor entrances.

Do not install unit in a corrosive environment. A corrosive environment may lead to

poor performance and deterioration of unit.

Do not position the unit in a manner that would make it difficult to operate
your main power disconnect switch.

Make sure the unit is leveled when set up.

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4.2. Power Connection

Warning! Before making the power supply connection to your unit, you must
perform the following procedure:

1. Verify the power supply voltage rating established for your chamber (listed above). The
voltage rating is also found on the serial tag on the side of the oven.
Note the rated value here:

2. Measure and record the intended voltage source.

Note the measured value here:
3. Reference the Line Voltage Min/Max Tables below. Verify that the power supply
voltage source you measured and recorded is within the minimum and maximum
allowable operating voltages for your chamber rating. If it is not within this operating
range, do not make the power connection! Otherwise, erratic operation and damage
may occur to your equipment, which may void your warranty. If you have any questions,
please call the NEWTRONIC Service Department.

Important! One of the most common causes of equipment malfunction is low line voltage as
the power source to the unit. Ordinarily in this condition, the heat output would be reduced
and the system's motors would operate erratically, eventually overheat, and shut down. You
must be certain that your equipment is connected to a circuit with an adequate voltage and
current source. An oversupply voltage would also cause erratic operation and eventual
shutdown, or damage to your equipment.

Supply Voltage should remain 23010Volts at all-time having 50Hz

frequency Operation outside this limits can results in damage to
controller.

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Making the Power Supply Connection to the Chamber:

A main power disconnect switch is normally provided with your small chamber. We
recommend that a fused disconnect switch on a separate branch circuit be installed as the
power source to your chamber, in accordance with all national and local electrical codes.
Reference your Electrical or Power Schematic for all electrical requirements.
The power connection is made via a cord and plug for standard units. Connect the plug to a
receptacle that has the appropriate power supply on a branch circuit of its own.
Warning! High Accessible Current An Earth connection is essential before
connecting the power supply. Make sure equipment is properly grounded in
accordance with all codes.

Application of Power
Before energizing any equipment, make a visual inspection for loose components,
electrical connections, fittings, etc. Shut all operating switches to the OFF position before
energizing.
Have trained personnel start and check out the equipment before its first cycle.

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5. Product Description
System Overview: NEWTRONICs BOD Incubators are engineered with precise control
action. Heaters are mounted on the right side of chamber. Air circulation system provides
maximum uniformity. The air circulation system sucks air from chamber; allows it to pass
trough heater and back in the chamber. Accurate Temperature PID controller ensures tight
control without over shoots of temperatures. Over temperature safety device provides
protection against overshoots of temperature.

5.1. Heating System

Heating is done by long lasting stainless steel tubular heaters. Heating system controls
temperature in the BOD Incubator using PID function. Supply to heaters is controlled
by solid state relay.
Safety relay prevents excessive temperatures and possible damage to samples or
equipment.

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5.2. Air Circulation

Air circulation system is provided for maximum uniformity of temperature. The
circulation motor is mounted on the back side of equipment. It remains continuously
ON for uniformity of temperature.
Process air is conditioned as it is drawn through the chamber by fan/blower wheel. It is
than passed through heaters and the refrigeration coil. The conditioned air is
discharged down and then enters the workspace through semi-pierced openings over
the entire width of plenum of the working chamber. Air flows horizontally across the
working space and then gets distributed on both side of the chamber. It is then passes
through product vertically/horizontally and exits the workspace through circular semipierced openings at the top of plenum. Processed air flows from bottom and returns to
the plenum for reconditioning. A inbuilt Temperature sensor is used to measurement of
temperature inside the chamber. The control sensor is placed in the discharge air in
the right side duct wall for better accuracy and control.
Adjustable ventilation is provided for air changes in the Incubator.

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5.3. Cooling System

CFC free (Refrigerant 134A) cooling system consists of hermitically sealed compressor
coupled with evaporation coil and condenser provides required cooling. Compressor is
been safe guarded by time delay programmed in the controller and by using a robust
electromagnetic relay circuit. The condenser unit is mounted in the top compartment of
the chamber. Temperature will raise minimum 5C above ambient in case of Cooling
System OFF/ not working
Low temperature safety thermostat prevents excessive cooling.

Condenser
Motor and
Condenser

Drier

Compressor

Compressor relay / Capacitor

It is recommended to keep Cooling ON for set temperature of 10C to 35C. For

temperature above 35C cooling should be kept OFF.

Note: 1. The ambient/ environment room condition where chamber is going to be

placed/kept must be between 25C to 30

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6. Technical Specifications
6.1. Specification Summary
Model
Internal Size
External Size
Power Supply
Temperature Range
Accuracy from set
Temperature
Temperature Uniformity
Inner Chamber(MOC)
Outer Chamber(MOC)
Insulation
Trays
Tray Size
Scanner
Door
Control System
Heating System
Chamber Cooling
Display panel
Control panel
Alarms
Safety

NLBI7SI
800(H) 500(W) 500(D) mm
1350(H) 630(W) 945(D) mm
230 Volts AC and 50HZ mains supply
+5C to 60C
0.5 C.
1C
Made of Stainless Steel Graded 304
Made of Stainless Steel Graded 304
PUF insulation between outer chamber and inner chamber.
Rod Type Trays 3 Nos.
430 x 460 mm
Four Point Temperature Scanner
Full length inner glass door and outside metal door with door seal gasket
and lock.
PID controller with Ethernet interface
Long lasting stainless steel tubular heaters with S.S. fins
Using Hermitically sealed compressor coupled with evaporation coil and
condenser, safe guarded by time delay. CFC Free Refrigerant.
Panel at front to view temperature, real time clock.
The front panel consists of Controller, ACK button and HT, LT indications.
Panel at top to consists of wiring, Safety thermostat and other standard
accessories.
Audio and Visual alarms generated for temperature variation
Safety relay for temperature.
Capillary Thermostate for temperature overshoots and undershoots in
case of malfunction.

Note: 1. Control Accuracy is of control sensor (Sensor 1) w.r.t set point.

2. Uniformity is the measure of variation in temperature at different, locations
within the working area of chamber w.r.t set value.

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6.2. Technical Specifications of Components

Component
PID Controller

Qt.

Make

Model/Type

Microcubs

NW 480

SMPS

OMRON

S8JC-Z05024CD

SSR
Safety
Thermostat
MCB

UNISON

Elcon

801ZDA 33 25 00
_

Hager

NCN116N C16

Hager

NCN202N C2

Relays

Allen Bradley

700-HC22A2-4L

Temperature
Sensor

Radix

PT 100

Temp Range - -30 to 65C

Circulation Motor

ELTEK

T.E.F.C. Type

1/12HP ,230 Volt, 50Hz,

1440 RPM

Blower

----

Alluminium blower

7 * 3 * 3/8 Bore

Dry Heaters

Rishina Electricals

14 U Type

S.S. Fin heaters 500 W , 230V

Condensing Unit

EMERSON

KCN 372LAG

Sumo lamps on
front control panel

SUMO

Panel LED 16 mm

BOD Incubator

Specification
Input 24VDC,
Output - 240VAC/30VDC
Input -200 240VAC,
50/60Hz, 0.5 Amp
Output 24VDC,1.5Amp
24 330VAC, 25 Amp
2C 85C, 15 Amps,
230/250 V
16 Amps, 240/415 V, 1 Pole
2 Amps, 240/415 V,2 Pole
240V , 50/60 HZ,
10 Amps/240VAC

Refrigerant-134A,
Drier- EK-032
Motor CF 01-01
240V AC LEDs in Red for HT
& LT indication

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7. Incubator Operations
Note: Before starting the chamber cross check all the requirements are satisfied for smooth
running of the Incubator/equipment.
7.1. Installation checks
Warning! Before switching ON the Incubator all the requirement should match.
Failing to do so will hamper chambers performance or damage its components. In
such case, Warranty will be void.

Description

Required for installation

Required Power Supply

UPS Power Supply

Single Phase, 230 V 10 %, 50Hz

UPS supply Single Phase, 220 V 10 %,
50Hz to the control and display unit,
1.5KVA
3 Core
25 Amps

Cable Specs.
Metal clad Socket with
MCB
Distance between power
socket & chamber
Proper Grounding
Drainage
Surrounding Temp
Area
Level
Clearance
Side
Space
Back Side
Front

BOD Incubator

Actual
Available
YES
NO
YES
NO

YES
YES

NO
NO

Less than 3 Meters

YES

NO

Must
At the backside bottom of the Equipment.
25C ~ 30C
Clean & free from dust
Horizontally leveled
Minimum 450mm
Minimum 500mm
Minimum 1000mm

YES
YES
YES
YES
YES
YES
YES
YES

NO
NO
NO
NO
NO
NO
NO
NO

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7.2. General Safety Features on the Machine: Interlocks

Following are the list of safety devices and interlocks. Cross checking of those safety devices
at regular interval is very essential for its operations
Safety Device
Low Temperature safety
thermostat (LT) & Indicator

Function
Cuts off the supply of cooling system and LT
indicator will be illuminated if chamber temperature
falls below temperature set on the dial of Low
Temperature Thermostat.
Operator has to set the dial on 10C below the actual
set temperature.
Auto Reset, once the temperature is above dial set
temperature.

High Temperature safety

thermostat (HT) & Indicator

Cuts off the supply of heating, humidity system and

HT indicator will be illuminated if chamber
temperature rises more than temperature set on the
dial of High Temperature Thermostat.
Operator has to set the dial on 10C above the
actual set temperature.
Auto Reset, once the temperature is below dial set
temperature

7.3. Controller
Accurate PID controller is used to control required temperature. The controller has
features like Auto Tuning, Temperature Deviation alarms, Over Temperature safety trip,
Soak timer.

Measured
Temperature in
C

Alarms
ENT /
Enter key

SET /
Select key

Keys: Change Set

Parameters

Compressor
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8. Operations
Following are the instructions and procedures to use BOD Incubator. Please read carefully
before operating.
8.1. Power ON
Turn ON the power switch. The motor will start rotating and controller display will be
ON.
8.2. Controller Settings
Temperature controller NW-480 is PID controller and Ethernet port with data logging
facility.
8.3. Set Parameters
Press SET key to scroll through parameters. Press ENT key to select parameter
to be change or register new value in memory. Use arrow keys to change
parameter value.
Note: This procedure is only for the chambers which does not have ICDAS software
connections. To change the set values using software please refer ICDAS operation manual.
Warning! Set the High Temperature safety thermostat at 10C above set
temperature and Low Temperature safety thermostat at 10C below the set
temperature. Improper setting of thermostat will affect functions of chamber.
Following parameters can be access by pressing SET key

Default Window >> Enter Lock Code .

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Set Temperature & Press Enter Key

Set PID Parameters & press Enter key

Set Date & Time Setting & Press Enter Key

Set Alarm Low & High Alarm limits

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Set Calibration Offset

Print Command

Erase Memory

Set IP Address

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Set lock code & Press Enter

SCANNER
It shows reading of Each Sensor. In One Display
it shows Temperature reading for 1 to 4 sensors
in degree C.
For remaining sensors press up arrow key.

It shows reading of Each Sensor. In One Display

it shows Temperature reading for 5 to 8 sensors
in degree C.

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To set parameters such as temperature, alarm limits, PID values, Real time clock, Calibration
Offset, Print Command, Erase Memory, and Set IP Address No & Set Pass Code use the
following procedure.
8.3.1. Set Temperature

Set Temperature & Press Enter Key

Set Temperature
Use arrow keys to change set temperature then
press ENT key to register new value in memory.

8.3.2. PID Parameters

Set PID Parameters & press Enter key
CAUTION:
These parameters affect accuracy of controller; do
not change if you are not a qualified engineer.

Press ENT key and following parameters will be displayed. Use arrow keys to
change parameter value; then press ENT to register it in memory and go to next
parameter.

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Proportional Band

Integral time

Derivative time

Cycle time

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Compressor Delay Time

Compressor Hystresis

Compressor ON

Compressor OFF

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8.3.3. Set Date & Time

Set Date & Time Setting & Press Enter Key

Press ENT key and following parameters will be
displayed. Use arrow keys to change parameter
value; then press ENT to register it in memory and
go to next parameter.

Set Minutes & press Enter

Set Hours & press Enter

Set Year & press Enter

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Set Month & press Enter

Set Date & press Enter

Set Print Interval Time

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8.3.4. Temperature Alarm Limits

Set Alarm Low & High Alarm limits
Press ENT key and following parameters will be
displayed. Use arrow keys to change parameter
value; then press ENT to register it in memory
and go to next parameter.

Temperature Deviation High Alarm

The controller will generate alarm if the
measured temperature is above this value with
respect to set temperature.

Temperature Deviation Low Alarm

The controller will generate alarm if the
measured temperature is below this value with
respect to set temperature.

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8.3.5. Calibration Offset

Set Calibration Offset

Press ENT key and following parameters will be

displayed. Use arrow keys to change parameter
value; then press ENT to register it in memory.
Add the calibration offset in C.

8.3.6. Print Command

Press ENT key and data will be printed on the

connected printer and following window will
appear.
CAUTION:
Before giving print command verify printer is
connected properly, powered ON and sufficient
papers are present.

Note:
The controller is compatible to a DOS base printer on Parallel port.

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8.3.7. Erase Memory

Pressing ENT key controller memory will be
erased and it will come to default window.

8.3.8. Set IP Address No.

Set IP Address

Setting for IP address:

Enter 192 and press enter

Again enter 168 and press enter

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Again enter 0 and press enter

And enter 139 and press enter

8.3.9. Set Lock Code

Set lock code & Press Enter

Set the password and press enter.

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9. Troubleshooting
Problem
No display on controller
Temperature
achieving
Temperature
decreasing.

is

not

not

Temperature is not rising

Temperature
is
overshooting
Temperature
is
not
controlled in 3C accuracy

BOD Incubator

Possible Cause and Rectification

Check electric supply, mains switch. If supply voltage less than
200V than rectify the supply.
Check the set temperature.
If the set temperature is below or near ambient temperature
turn ON cooling system.
Check cooling system is turned ON.
LT (Low temperature safety thermostat) is not illuminating. If
it is ON than check settings on Low temperature thermostat;
it should be 10C below set value.
Check the controller is not OFF.
Check the set value
Check controller output to Solid State Relay and to the
heater as the circuit diagram.
Check Over temperature Safety relay.
Check heater continuity.
Check Solid State Relay. It may have been shorted.
PID tuning may be disturbed.
Check Solid State Relay. It may have been shorted.
Check circulation motor. It is not running then may require
replacement.
PID tuning may be disturbed.

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10.

Maintenance
Only qualified service personnel should ever be permitted to perform any
service related procedure on this chamber!
Disconnect and Lock-Out / Tag-Out all electrical power from the facility at its
source before servicing or cleaning.

Frequency of preventive maintenance procedures depends upon how the facility is used and
upon other circumstances. Because of this, a hard and fast schedule of maintenance
operations is difficult to present. Indeed, an inflexible schedule might be suitable for one user,
but completely inadequate for another. Therefore, we have provided periodic figures when to
perform maintenance procedures, based on the average chamber use.
We suggest that you maintain a preventive maintenance log. In this log you will record
operating notes, pressures, temperatures, and electric readings. The log is valuable because
it will help maintenance and service people by documenting long term trends and by showing
parameter levels when the chamber is operating properly.
10.1.

Interior/Exterior surfaces
The interior and exterior surfaces of the chamber are best cleaned by using
warm water with mild soap and a clean soft cloth. For finger prints or other
stains, mild, non-abrasive cleaners may be used. On stainless steel outer body
with a satin finish, run strokes in the direction as the grain.
Inspection Period: 15Days

10.2.

Door Gasket
Door gaskets should be cleaned on a regular basis. To clean the gasket, use
baking soda and warm water, wiping dry with a soft cloth. The vinyl gasket from
around the inside door will assure an air tight seal if properly maintained and
inspected regularly. When inspecting, check that the gaskets are properly
seated in their retainers. A visual check for wear and tear is also required. If
gaskets should become torn or broken, they should be replaced immediately.
Inspection Period: 30Days

10.3.

General Electrical Connections

Warning! Remove All Power From Chamber!
Inspect inside the control panel and the machinery compartment for loose
electrical connections, frayed wires, loose components, or other potential
problems.
Inspection Period: 6 Months

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10.4.

Electric Heater(s)
Warning! Remove All Power From Chamber!
Inspect the electric heater(s) inside the chamber conditioning plenum and look
for defects.
Inspection Period: 6 Months

10.5.

Controller / Calibration
The controller, sensors should be rechecked for its accuracy and for the proper
activation of limit or alarm outputs.
Inspection Period: 1 Year

10.6.

Preventative Maintenance Schedule / Log

Important: For each of the items to be inspected, refer to item description
sections for details on maintenance and service.
Preventative Maintenance Schedule / Log

Item to be
Inspected
Interior/ Exterior
surfaces

Inspection
Period

Actual Date
Inspected /
Serviced

Actual Date
Inspected /
Serviced

Actual Date
Inspected /
Serviced

15Days

Door Gasket

30Days

General Electrical
Connections

6 Months

Electric Heaters

6 Months

Controller
Calibration

1 Year

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Actual Date
Inspected /
Serviced

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11.

Supporting Documents
As applicable to the chamber model and serial number, the following are included in
the Supplemental Instructions Section of this manual.

Document
Electrical Schematic Diagram
General Assembly Drawing
SOP
Test Certificates
Material of Construction test certificate
PID Controller Certificate
Circulation Motor test certificate
Condensing unit test certificate
Temperature sensors test certificate
Dry heaters test certificate

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