Salt-Spray-IP-Manual-Iss-W S120 ip

Salt Spray Test
Chamber
Models:
S120/450/1000/1300/2000/2600iP
Instruction Manual SSiP Issue - W
Ascott Analytical Equipment Limited,
Unit 6 Gerard, Lichfield Road Industrial Estate,
Tamworth, Staffs. B79 7UW Great Britain
Telephone: +44 (0) 1827 318040 Fax: +44 (0) 1827 318049
E-Mail: [email protected] Website: www.ascott-analytical.com
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Contents
Contents…………………………………………………... 3
Introduction ................................................................... 8
General Description of machine operation ................................ 8
Part 1 - Health & Safety ............................................... 9
1.1 Health and Safety Policy........................................................... 9
1.2 Declared Dual-Number Noise ................................................. 10
1.3 Training ......................................................................................... 11
1.4 Personal Protection Equipment Policy ................................... 11
1.5 Safety During Chamber Operation ........................................ 11
1.6 Modifications to Chamber. ...................................................... 11
1.7 Breakdown Policy ....................................................................... 11
1.8 Safety Labelling .......................................................................... 12
Transport and Lifting ......................................................................... 14
Part 2 – Installation ........................................................ 15
2.1 Operating Environment............................................................. 15
2.2 Positioning .................................................................................... 16
2.3 External Services ......................................................................... 17
2.3.1
Electrical Supply...................................................................................... 18
2.3.2 Compressed Air Supply ............................................................................... 19
2.3.3 De-ionised Water Supply ............................................................................. 20
2.3.4
Salt Solution Reservoir ............................................................................ 20
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2.3.5 Condensate Drain ........................................................................................ 22
2.3.6
Exhaust Vent to Atmosphere ................................................................ 24
2.3.7
Air Saturator Drain .................................................................................. 25
2.4 Atomiser Set up ........................................................................... 26
Part 3 – Operation ........................................................ 28
3.1 Human Machine Interface (HMI) Screen .............................. 28
3.2 Initial Power Up – Ascott Main Menu ...................................... 29
3.2.1 Contact Details............................................................................................. 29
3.3 Language .................................................................................... 30
3.4 User Access ................................................................................. 30
3.5 Help ............................................................................................... 32
3.6 Settings – Mode .......................................................................... 32
3.6.1 Set Password ................................................................................................. 33
3.6.2 Set Holdback ................................................................................................ 34
3.6.3 Set Air Saturator Temp ................................................................................. 35
3.6.4 Set Pump speeds .......................................................................................... 35
3.6.5 Set Purge Time .............................................................................................. 37
3.6.6 Disable Alarm Sounder ................................................................................ 37
3.6.7 Calibration..................................................................................................... 38
3.6.8 Set Ramping .................................................................................................. 39
3.6.9 Power Fail Recovery..................................................................................... 40
3.6.10 Set Test Type ................................................................................................ 41
3.6.11 Air Saturator Fill Method ............................................................................ 42
3.6.12 Set Background Colour ............................................................................. 44
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3.6.13 Set Chamber IP Address............................................................................ 45
3.6.14 Set Test Sample Test Agenda ................................................................... 46
3.6.15 PLC Monitor ................................................................................................. 47
3.7 Program Menu ............................................................................ 48
3.7.1 Program Delete ............................................................................................ 49
3.7.2 Program View ............................................................................................... 50
3.7.3 Program Edit.................................................................................................. 51
3.7.4 Saving/Cancelling an Edited Program ..................................................... 59
3.8 Running a Program .................................................................... 61
3.8.1 View Running Program ................................................................................ 63
3.8.2 Step Number ................................................................................................. 63
3.8.3 Step Function ................................................................................................ 64
3.8.4 Step Temperature ........................................................................................ 64
3.8.5 Step Time ....................................................................................................... 64
3.8.6 Humidity Value ............................................................................................. 64
3.8.7 Program Run Time ........................................................................................ 65
3.8.8 Canopy .......................................................................................................... 65
3.8.9 Program Load ............................................................................................... 67
3.8.10 Program Run ............................................................................................... 69
3.8.11 Program Stop .............................................................................................. 69
3.8.12 Program Pause ........................................................................................... 69
3.8.13 Program Fast Forward................................................................................ 70
3.8.14 Run Settings ................................................................................................. 70
3.8.15 Interior Illumination (Optional Accessory ref: ACC26) .......................... 71
3.8.16 Trending ....................................................................................................... 71
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3.8.17 Total Chamber Hours Run ......................................................................... 72
3.8.18 Air Saturator Mode ..................................................................................... 73
3.8.19 Message Bar................................................................................................ 74
3.8.20 Alarm Status ................................................................................................ 74
3.9 Control.......................................................................................... 76
3.9.1 Emergency Stop ........................................................................................... 76
3.9.2 Mains Isolator ................................................................................................ 76
3.9.3 Air Pressure Gauge & Regulator................................................................. 76
3.9.4 Flow Meter(s) & Peristaltic Pump(s) ............................................................ 77
3.9.5 Ethernet Communications Port .................................................................. 78
3.10 .......................................................................................................................................... Setting
up Procedure .................................................................................... 78
3.10.1 Determine the test parameters ................................................................ 78
3.10.2 Set up chamber.......................................................................................... 79
3.10.3 Set the Salt Fog Fallout Rate ..................................................................... 80
3.11 Shut down procedure: ............................................................ 81
Part 4 – Care & Maintenance .................................... 82
4.1 Routine Maintenance ............................................................... 82
4.1.1 Daily Checks ................................................................................................. 83
4.1.2 Weekly Maintenance .................................................................................. 83
4.1.4 Three–Monthly Maintenance ..................................................................... 89
4.1.5 After Use ........................................................................................................ 91
4.2 Unscheduled Maintenance ..................................................... 92
4.2.1 Storage & Contamination ........................................................................... 92
4.2.2 Deionised Water Inlet Filter.......................................................................... 92
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4.2.3
Clean or Unblock Salt Spray Atomiser ................................................. 93
4.3 Sample Daily Check Sheet ....................................................... 95
4.4 Fault Finding & problem solving .............................................. 96
4.5 Salt Spray Chamber Exploded view ....................................... 97
4.5.1 S120IP ............................................................................................................. 97
4.5.1 S120IP ............................................................................................................. 98
4.5.1 S120IP ............................................................................................................. 99
4.5.2 S450IP ............................................................................................................. 100
4.5.2 S450IP ............................................................................................................. 101
4.5.2 S450IP ............................................................................................................. 102
4.5.2 S450IP ............................................................................................................. 103
4.5.2 S450IP ............................................................................................................. 104
4.5.3 S1000IP ........................................................................................................... 105
4.5.3 S1000IP ........................................................................................................... 106
4.5.3 S1000IP ........................................................................................................... 107
4.5.3 S1000IP ........................................................................................................... 108
4.5.3 S1000IP ........................................................................................................... 109
4.5.4 S2000IP ........................................................................................................... 110
4.5.4 S2000IP ........................................................................................................... 111
4.5.4 S2000IP ........................................................................................................... 112
4.5.4 S2000IP ........................................................................................................... 113
4.5.4 S2000IP ........................................................................................................... 114
4.6 Chamber Air Saturator (Welded fabrication) ....................... 115
4.6.1 S120ip ............................................................................................................. 115
115
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4.6.2 S450ip, S1000ip and S1300ip ....................................................................... 118
4.6.3 S2000ip and S2600ip..................................................................................... 121
4.7 Chamber Air Saturator (Glass fabrication) ............................ 124
4.7.1 S120ip, S450ip and S1000ip ......................................................................... 124
4.7.2 S1300ip ........................................................................................................... 127
4.7.2 S2000ip and S2600ip..................................................................................... 130
5 Optional Accessories Manual ................................. 133
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Introduction
General Description of machine operation
The Salt Spray test (also known as a salt fog or salt mist) has been the
benchmark corrosion test in many industries for decades. The Ascott Salt
Spray chambers (iS) meet the requirements of basic, continuous salt spray
tests conducted at a single temperature only, such as ASTM B117 and similar
international test standards, and may be used with pH neutral salt solutions
(NSS) or those acidified by the addition of Acetic Acid (ASS) or Cupric Acid
(CASS).
Ascott Premium Salt Spray models (iP) can perform the same basic salt spray
tests, but in addition are equipped with extra features which enable them to
undertake ‘modified’ tests such as those defined in ASTM G85. Here
conventional salt spray is often combined with one other climate, in a twopart cycle, to accelerate the test. For example: salt spray and condensation
humidity (SWAAT) or salt spray and drying (PROHESION) or salt spray and SO2
testing.
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Part 1 - Health & Safety
1.1 Health and Safety Policy
The manufacturer is required to ensure, for reasons of Health and Safety at
Work that, as far as is reasonably practicable, the articles which we design,
produce and supply are as safe as possible and of minimal risk to health.
We are required to provide information on the safety and handling
precautions to be observed when installing, operating and maintaining our
product. Such advice is contained in this manual.
We should also like to point out, however that you as users have an important
responsibility in the provision and maintenance of safe working practices and
conditions.
Accordingly we draw to your attention the following matters:
i.
This apparatus should only be used as intended and within its design
parameters by suitably qualified and trained personnel who have read and
understood the relevant sections of this manual.
ii
This manual should be readily available to such personnel at all times.
iii
In addition to that which is written in the manual, normal commonsense safety precautions must be taken at all times to avoid the possibility of
accidents.
iv
Installation, maintenance and connection to electrical supplies should
only be carried out by suitably trained personnel.
We would recommend that users produce their own risk assessment for the
entire testing process for which this apparatus will be used.
The normal operation noise levels for the chamber are shown below and if
they exceed these parameters then there is a problem with the chamber.
Please obtain advise from your local agent / distributor or Ascott themselves
to ascertain problem. Some accessories may deviate from these levels.
Warning! - connecting an Ascott chamber to poor quality external service
utilities (ie; water and compressed air) and/or a failure to maintain Ascott
products regularly in accordance with Ascott recommended maintenance
procedures, could lead to a catastrophic and potentially dangerous failure of
the product safety systems.
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1.2 Declared Dual-Number Noise
Declared Dual-Number Noise Declaration
Manufacturer
Ascott Analytical Equipment Ltd
Type
Cyclic Corrosion Test Chambers (CC1000iP)
Declared Dual Number Noise Emission Values according to EN
ISO 4871
A-Weighted Emission Sound Pressure Level at the Work Station
Measured value Lpa in
decibels
51.59
Uncertainty Kpa in
decibels
1.50
A-Weighted Emission Sound Power Level
Measured Value Lwa in
Decibels
69.02
Uncertainty Kwa in
decibels
1.50
The determination, declaration and verification of air Bourne
noise emission have been carried out in accordance with EN
14462 as required within clause 5.5.2 (Noise reduction at
source at the design stage) of EN12921-1:2005+A1:2010.
Values determined according to the noise test code EN 14462
using the basic standards EN ISO 11201 (Grade 2) and EN ISO
3744.
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1.3 Training
Training is available if required. Please contact Ascott or your Agent /
Distributor for more details.
1.4 Personal Protection Equipment Policy
No specific PPE is required during standard operation of the chamber as the
chamber is designed to purge the atmosphere before opening the canopy
to the chamber working area. Some accessories may require PPE to be worn.
All accessories that utilise sub-zero temperatures will require gloves to be worn
when handling anything inside the chamber. Accessory ACC46 – SO2 testing
facility must follow the instructions for the accessory as the atmosphere and bi
products can be extremely hazardous.
1.5 Safety During Chamber Operation
Under no circumstances should anyone be inside the chamber during
operation or exposed to the corrosive atmosphere of the chamber. All leaks
must be reported and repaired. Chamber must be isolated immediately if
any atmosphere or water leaks are detected.
1.6 Modifications to Chamber.
No structural changes or fitting of customers own tools / accessories without
first contacting Ascott or its associates.
1.7 Breakdown Policy
In the event of a breakdown consult Ascott or its associates immediately as
further damage to the chamber and / or personnel may occur.
11
1.8 Safety Labelling
Ascott chambers will have the following safety labels attached to the side
panel work.
Warning people of potential electric
shock.
Warning people of hot water,
confined space and sharp edges.
The control panel also has two labels to identify the Air Pressure Gauge for the
chamber and the regulator for the air supply.
12
Denotes Pressure Gauge
Denotes Pressure Regulator
Inside the control compartment the earth point of the chamber is clearly
identified with the following symbol
13
Transport and Lifting
Lifting of the chamber should only be done with a fork truck and lifted using
the designated lifting points at the rear of the chamber. The lifting points are
identified with the following logo.
When transporting the chamber ensure it is locked and strapped into position
preferably chocked up off the castors using the chassis frame. No loads are to
be put on the top. Drains must be emptied before loading.
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Part 2 – Installation
CAUTION
THE EQUIPMENT SHOULD ONLY BE INSTALLED BY
SUITABLY QUALIFIED PERSONNEL. DAMAGE
CAUSED DUE TO INCORRECT INSTALLATION WILL
NOT BE COVERED BY THE WARRANTY.
2.1 Operating Environment
Ascott chambers are designed to minimise the risk of an uncontrolled
escape of the corrosive conditions they generate. However, this risk
remains and if there is an uncontrolled escape this is likely to
contaminate the local surroundings and may in some cases be
hazardous to human health. When choosing a location for the
installation of an Ascott chamber, a risk assessment should be
undertaken to identify the most appropriate location and minimise the
risks arising.
This equipment is designed for internal use only, in an environment controlled
to within the following limits:Storage
Ambient Temperature:
+5 to +23°C (no icing)
Ambient Humidity:
Maximum 85% RH (no condensation)
Operation
Ambient Temperature:
Ambient Humidity:
+18 to +23°C (no icing)
<50% RH (no condensation)
Note: The minimum operating temperature achievable inside a basic
chamber (without accessories) will depend directly upon the actual ambient
temperature of the environment in which it is located
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2.2 Positioning
Move the Cyclic Corrosion Test Chamber into position on a clear, clean
stable, level floor as shown:
Chamber
The rear castors can be locked
when the chamber has been
positioned.
(Not fitted to 120L chambers)
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2.3 External Services
Note: All hoses and pipes up to 3 metres (10ft) in length, and the power
cable are supplied with the chamber.
Air Saturator Automatic Water Inlet
(De-ionised Water) 12.5 mm (½”)
bore hose
Air Saturator Drain (No connection)
Compressed air inlet 12.5 mm (½”)
bore hose
If optional SO2 gas dosing facility (ACC46) has been ordered, the following
external service utility connection will also be provided.
SO2 gas inlet – 6 mm OD hose for
connection to separate SO2 gas
cylinder (not supplied).
Resettable Thermal Over current trip
switches
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WARNING: THIS APPARATUS MUST BE EARTHED
2.3.1 Electrical Supply
We recommend this equipment is connected to an electrical supply
protected by a residual current device (earth leakage circuit breaker).
Before connecting this equipment to an electrical supply, check the
information given on the equipment rating plate and ensure that:
Your supply voltage is of the correct frequency.
Your supply voltage is the correct type (three phase or Single phase
depending on model)
Your supply voltage is within the stated range.
The current rating is within the capacity of your supply outlet.
Your plug or outlet circuit is suitably fused.
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A rotary electrical isolator switch is
mounted in a prominent position on
the chamber. This isolates the
chamber from the incoming
electrical supply (live and neutral)
when the switch is rotated to the '0'
position, and can be padlocked in
this position if required. The electrical
supply is connected when this switch
is rotated to the '1' position.
2.3.2 Compressed Air Supply
Note: The compressed air supply must be clean, dry (a cohesive dryer of
grade 2 which will give 3 microns cleanliness) and oil free. It must have a
minimum pressure of 4.0 bar (57 psi) and a maximum pressure of 6.0 bar (87
psi). Between these pressures, the flow rate should be at least 75 litres per
minute (2.6 cubic feet per minute) equating to a free flow at atmospheric
pressure of approximately 102 standard litres per minute (3.6 standard cubic
feet per minute).
Connect the 12.5 mm bore air hose supplied, between the air inlet at the rear
of the chamber and the compressed air supply. (See above).
19
2.3.3 De-ionised Water Supply
Note: The de-ionised water supply must have a minimum pressure of 0.5 bar
(7PSI) and a maximum of 5 bar (72PSI).
Connect the 12.5 mm bore water hose supplied, between the two water inlet
hose connections at the rear of the chamber and the de-ionised water
supply. (See above).
2.3.4 Salt Solution Reservoir
Position the Salt Solution Reservoir to the left of the chamber.
Salt Solution Reservoir – The side wall
has a hole to allow the salt solution
hose to pass through.
Salt solution inlet hose
20
120L
Feed the end of the 6 mm salt solution hose
that is fitted with a filter, into the Salt Solution
Reservoir ensuring that the filter unit lies at the
bottom of the reservoir.
For 120 Litre chambers, an external reservoir
can be used in place of the internal reservoir
Locate existing salt solution hose at back of
cabinet
21
Disconnect bottom of hose from grey fitting
and salvage compression fittings from end of
hose.
Use salvaged compression fittings to attach a
new length of salt solution hose (internal
diameter 4mm external diameter 6mm) of
sufficient length (3m) to reach the auxiliary
salt solution reservoir, and attach primary filter
unit.
Drop primary filter unit into auxiliary salt
solution reservoir so that it rests at the bottom.
The chamber is now ready for use.
2.3.5 Condensate Drain
Drain – 22 mm (7/8”) diameter pipe
22
Connect the 22 mm diameter push-fit pipe to the rear of the chamber
Connect the other end to the service drain.
Figure 1Ensure drainage flows down and away from the chamber
to ensure consistent performance.
2.3.5.1 Manual Base Drain
Drains the chamber completely.
With the tap handle in the vertical
(closed) position, salt fog
condensate will accumulate in the
chamber base to a predetermined
level, before draining to waste. This
assists in maintaining a high humidity
during testing, and is the correct
23
position for most continuous salt
spray tests.
With the tap handle in the horizontal
(open) position, salt fog condensate
will drain away. This drains the
chamber interior for cleaning.
2.3.6 Exhaust Vent to Atmosphere
Exhaust –55mm (2”) diameter pipe
for all S chambers.
Connect the exhaust pipe provided to the exhaust outlet to the rear of the
chamber.
If the length of the vent pipe route is greater than 5 metres, a larger diameter
pipe may be
required.
Route the other end
to outside
atmosphere,
maintaining a
straight run-up or
run-down to avoid
sags where
condensate may
collect and cause
backpressure.
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2.3.7 Air Saturator Drain
Air Saturator Drain
Do not connect anything to the Air
Saturator Drain; it is provided for
maintenance purposes only.
(See section- Running a program / Air saturator mode)
Note: If chambers are left unused for any length of time it is recommended
that the air saturator is drained to prevent the build-up of algae which could
cause system blockages or of bacteria which might present a potential
health risk.
25
To drain when required:
Reduce the air pressure on the
control panel to zero. Then use a flat
blade screwdriver to open the drain
tap.
2.4 Atomiser Set up
On 450L/1000L & 2000L chambers, the atomiser is mounted in a PVC holder
located on the rear wall of the chamber. It is locked into position using plastic
thumbscrews. Position and lock the atomiser so that when atomising, the
spray impacts in the centre of the inside of the canopy viewing window when
26
the canopy is closed. This position can be adjusted to achieve even fallout
results during salt spray testing.
On 120L chambers, the atomiser is mounted in a PVC holder located on a
sideways moveable mount. Position the atomiser so that when atomising, the
spray impacts in the sealing gasket between the canopy and the GRP
chamber, when the canopy is closed. This position can be adjusted left to
right to achieve even fallout results during salt spray testing.
Note: Please see the care and maintenance section for details of how to
remove and maintain the atomiser.
27
Part 3 – Operation
3.1 Human Machine Interface (HMI) Screen
The chamber control system utilises a Human Machine Interface (HMI) screen
mounted in the chamber control panel. This operates in conjunction with a
Programmable Logic Controller (PLC) mounted within the chamber. The HMI
screen is touch sensitive and uses ‘virtual’ push buttons for the selection of
various functions.
Run Indicator
Illuminates green while the HMI
is powered and operating
correctly.
(Orange/red illumination
indicates a problem).
Display
Full colour VGA LCD screen
with backlight.
Screen Saver Mode
If the HMI is not touched for 10
minutes it will enter screen saver
mode to preserve the life of the
HMI, the chamber will continue
to function as normal. To
illuminate the HMI, simply touch
the roaming screen switch.
The HMI screen uses a menu driven format, where functions are selected from
a variety of ‘pop-up’ pages. Most ‘pop-up’ pages usually have an
(escape) button, located in the top right hand corner.
Touching
will return the HMI display to the previous page.
28
3.2 Initial Power Up – Ascott Main Menu
When the chamber is first switched on, after a few moments, the following
page will be displayed.
Ascott Main Menu Page:
When operating the chamber,
repeatedly touch the
button to return to the Ascott
Main Menu page.
3.2.1 Contact Details
To access the chamber serial number, PLC/ HMI software revision numbers
and for Ascott contact details; touch the touch the
logo.
29
This page displays three pieces of
information required by an Ascott
engineer if contact with Ascott is
to be made. They are:
Chamber serial number, PLC
software revision number and
HMI software revision number.
Touch the
button to return
to the Main Menu page shown
above.
3.3 Language
The chamber can be operated using a number of languages.
At the Ascott Main Menu Page, touching
displays the following page:
Language Page:
Touch any of the flags to change
the screen language.
(Note: some terms may remain in
English)
Touch the
button to return
to the Main Menu page
3.4 User Access
The chamber has two operating modes, ‘Operator’ and ‘Settings’.
‘Supervisor’ mode allows access to an additional chamber settings menu.
30
At the Ascott Main Menu Page, touching
displays the following page:
To enter the settings menu
available in ‘Supervisor’ mode
a 4 digit code will need to be
entered. This is default set to
1234 but can be changed
within the Settings Menu.
Entering the 4 digit code displays the following page:
In the Settings Menu, all of the
test chamber settable
parameters can be viewed
and adjusted.
See ‘Settings- Mode’ below for
details of these parameters.
31
3.5 Help
Touching
screen.
opens up the help pages. Follow the guidance on the
3.6 Settings – Mode
The
button will only be visible if the correct access code has been
input. See Access, above.
Note: In each Settings page touch
the supervisor ‘Settings Menu’.
to save the setting and exit back to
Note: The settings that appear within this menu depend upon the optional
accessories (if any) ordered with the chamber.
At the Ascott ‘Main Menu’ Page, touching
brings up a series of pages
giving access to chamber settings and control parameters:
32
Settings Menu, Page 1
Touch
to display page 2.
Settings Menu, Page 2
Touch
to display page 1 settings.
Touch
on.
to display page 3 and so
These pages include global settings that apply to all programs and therefore
need only be set once. Additional settings buttons may appear depending
upon optional accessories fitted to the chamber. Details for these will be
included in the Optional Accessories section of the manual as required.
Descriptions for typical settings follows:
3.6.1 Set Password
Touching
brings up the following page:
33
Touch the
button to
display a numeric keypad which will
enable a new password to be
entered and saved.
The current password is displayed in the left-hand window (factory set to
1234).
3.6.2 Set Holdback
Touching
brings up the following page:
Touch the
button to
activate/ deactivate the holdback
facility. To adjust the holdback
tolerance setting, touch current
value displayed on the
button to reveal a numeric keypad,
the new setting can then be
entered and saved.
Holdback creates a ‘tolerance band’ around the set value for temperature.
With holdback on, the program step timer will not start until the temperature
inside the chamber is within the tolerance band. A HOLDBACK ON message
will appear within the main run page and the chamber will continue to
function normally in this holdback state.
This function can be useful in providing a ‘guaranteed soak time’ at a
particular set temperature. However, if an unrealistically small tolerance
band is set, especially when the chamber has been programmed for
34
automatic temperature cycling, then the programmed step times might
easily be exceeded due to the effect of holdback.
3.6.3 Set Air Saturator Temp
This is the target set temperature for the air saturator.
Touching the
button brings up the following page:
To adjust the set value of the air
saturator, touch the current value
displayed in the
button to
display a numeric keypad, the new
setting can then be entered and
saved. Refer to the test standard
being run for the air saturator set
value.
The maximum permitted set value is
63C.
3.6.4 Set Pump speeds
35
This sets the speed of rotation of the peristaltic pump(s) in the usual salt spray
mode of operation. It is adjustable from 0-99%. Increasing pump speed will
increase the salt spray fallout rates collected inside the chamber and vice
versa.
Depending on the size of test chamber, touching the
button will bring up one of the two following pages:
If a single pump is fitted:
To adjust the pump speed, press the
current value displayed in the
button, this will display a numeric
keypad where the new pump speed
can be entered and saved.
If two pumps are fitted (2000L) the
following page will be displayed.
Adjusting the pump speeds is the
same process as described above.
Each pump speed can be
individually set.
36
3.6.5 Set Purge Time
Touching the
button will bring up the following page:
‘Normal’ purge time is the number of
seconds of air purging of the
chamber interior that will take place
automatically, if salt spray or SO2
testing has occurred, before the
chamber canopy can be opened. It
is factory set to 450 seconds and
cannot be set to less than this. Adjust
by touching the value to show a
numeric touch pad, and then a new
value can be entered.
Purge before function ‘3/7’ is the number of seconds of air purging of
the chamber interior that will take place automatically at the beginning of
function 3 (Wetting
)and function 7, Cooling
(Not applicable). It is
factory set to 0 seconds and can be adjusted by using the numeric key pad.
Touch
Menu’.
to save the settings and exit back to the supervisor ‘Settings
Note: Users may decide that if a Wetting or drying phase is
programmed to follow a salt spray or SO2 phase, it may be desirable to
incorporate a period of air purging to minimise the salt spray/SO2 remaining in
the chamber atmosphere, before a Wetting or drying phase begins.
3.6.6 Disable Alarm Sounder
Touching the
button will bring up the following page:
37
If a chamber alarm condition arises,
a visual alarm indicator on the
control panel illuminates and an
audible alarm sounds. Touching the
‘SOUNDER ENABLED’ button will
enable/disable the alarm sounder.
The sounder is factory set to on.
Touch
to save the settings and
exit back to the supervisor ‘Settings
Menu’.
Note: If the alarm sounder is switched off, the audible alarm will still
sound when the canopy is opened or closed. For safety reasons this cannot
be disabled.
3.6.7 Calibration
Touching the
button will bring up the following page:
Note: Warning message and touch
to access Calibration pages.
By reference to independent, calibrated temperature/humidity
measuring sensors, users can cross check and adjust chamber values for the
following parameters. One parameter is displayed on each page and these
can be scrolled to by touching the
buttons:
38
Chamber temperature can be offset
by adding or subtracting °C to the
displayed value (result) by touching
the
buttons to display a
numeric key pad.
Air saturator temperature can be
offset by adding or subtracting °C to
the displayed value (result) by
touching the
buttons to display
a numeric key pad.
Chamber humidity can be offset by
adding or subtracting %RH to the
displayed value (result) by touching
the
buttons to display a
numeric key pad.
3.6.8 Set Ramping
Touching the
button will bring up the following page:
39
Touching the
button
will enable/disable the program
ramping facility within ‘main
programs’.
With ramping set to on, when a main program is run, programmed changes
in temperature and/or humidity set values will occur linearly over the duration
of the programmed step time (for all step times greater than 1 minute) i.e.;
the temperature/humidity will ramp to the new set value(s). With ramping set
to off, when a main program is run, programmed changes in temperature set
values will occur as quickly as the chamber is capable of achieving, over the
duration of the programmed step time.
Note: If any program step changes are required to occur linearly over time,
then ramping must be set to on. If all program step changes are required to
occur as quickly as possible, then ramping should be set to off as this will
simplify programming and maximise the number of function steps available
per program.
3.6.9 Power Fail Recovery
Touching the
button will bring up either of the following
pages, depending on how the chamber has been set up:
40
With power fail recovery mode set to
; following an
interruption to the chamber
electrical supply, the chamber will
automatically continue any running
program from exactly the same point
in the program that it was at when
the electrical supply was first
interrupted. The total hours counter
will not have reset, and will therefore
accurately reflect the total run time.
If power fail recovery mode is set to
; following an
interruption to the chamber
electrical supply, the chamber will
automatically pause any running
program. The operator then has the
choice of continuing or stopping the
test.
Touching either of these buttons toggles the power fail recover mode
between
and
mode. Set as required.
3.6.10 Set Test Type
WARNING!
It is important that the following procedure is
complied with to prevent damage to the humidity
sensor.
41
The chamber is fitted with an automatic ‘air
curtain’ which will protect the humidity
sensor with a jet of compressed air during
salt spray testing with acidic solutions.
The humidity sensor does not function when
this is operational.
Touching
choices;
brings up a menu with the following 4
Select the most appropriate choice
for the type of testing to be
undertaken. This will trigger a
reminder that the humidity sensor
may need to be further protected.
(Fitting the solid cap)
The humidity display icon changes
to show when this is active.
The ‘Air Curtain’ is automatically operated whenever salt spray testing is used.
3.6.11 Air Saturator Fill Method
Note:This setting only applies to chambers fitted with the Manual
Filling Air Saturator Option (optional accessory ref.: ACC66).
Touching the
button will bring up the following page.
42
If the chamber is not connected to a
permanent supply of mains pressure,
de-ionised water and the manual fill
optional accessory has been fitted,
set to ‘manual’. This will allow manual
filling of the air saturator.
If pre-humidification of the atomiser air is required, and the chamber is not
connected to a pressurised supply of deionised water for automatic filling of
the Air Saturator, and a manual fill facility has been provided instead
(optional accessory), then fill the Air Saturator manually as follows:
Ensure that the air saturator is de-pressurised by selecting dry air at the HMI.
Open the hand operated ball valve at the manual filler port by rotating it fully
anti-clockwise.
Insert a funnel into the open orifice of the manual filler port and slowly fill with
deionised or distilled water.
43
Stop filling when the Air Saturator Full indicator illuminates.
Remove the funnel and close the ball valve
Reselect moist air testing at the HMI.
3.6.12 Set Background Colour
Touching the
button will bring up the following page.
Adjust the background colour of the
HMI to your preference:
Press the
buttons to scroll
through the palette of colours in
sequence. A reference number is
displayed for each colour.
Alternatively, match the screen
background to one of the more
commonly used canopy colours by
touching one of the coloured
buttons.
Touching
will save the settings
and exit back to the supervisor
settings menu.
44
3.6.13 Set Chamber IP Address
There are optional accessories that can be connected to the chamber using
a Local Area Network (LAN) or by a direct link to a computer that may
require the chamber IP address to be known or altered. Please refer to the
instructions for these accessories for details.
Touching the
button will bring up the following page.
The chamber is factory set with the IP
Address 198.168.250.200
Touching each value brings up a
numeric key pad where new values
can be entered.
Touching
will save the settings
and exit back to the supervisor
settings menu.
Note: The PLC NODE NUMBER relates to the last three digits of the IP address. If
this changes from ‘200’ the PLC Node number will also change.
If The PLC NODE Number changes from the default value of C8, you will need
to alter two small dials on the chamber PLC.
To do this you will need to access the chamber control system by removing
the right hand access panel.
Locate the PLC module.
Two, very small dials will need to be
adjusted using a small screwdriver.
The bottom two dials should be
adjusted. NOTE – THE CHAMBER
POWER MUST BE SWITCHED OFF TO
MAKE ADJUSTMENTS
(left dial for 1st digit, right dial for 2nd
digit)
45
As changes are made, the display above will also change. Adjust this to suit
your PLC NODE Number.
3.6.14 Set Test Sample Test Agenda
This function allows up to 10 timers to be set that will operate when switched
on and a test is running. When each timer reaches the set value, a saved
message will be displayed and at the same time an alarm will sound. This
allows the chamber to display a message when batches of samples
complete timed test periods in the chamber.
Touching the
button will bring up the following page.
Touching the SV numeric value
brings up a numeric
key pad where timer Set Values can
be entered. Type in the test duration
for your batch of samples. Set hours,
then set minutes.
Touching the empty ‘message box’ will open a large alpha numeric keypad.
Use this to enter a message to be displayed when the timer Process Value
(PV) reaches the set value.
46
Touching
will exit back to the supervisor settings menu.
Each of the timers can be set to ON or OFF by pressing the
current status of the timer will be displayed.
button. The
3.6.15 PLC Monitor
Touching the
will access the screen shown below. This
is a pictorial view of the Programmable Logic Controller (PLC).
This page can be useful for determining what the chamber is ‘doing’ and
may be used by service engineers.
Touching any of the modules will
bring up a screen specific to that
module.
47
Inputs and outputs will illuminate with
an orange background when they
are active.
3.7 Program Menu
Please note that at the end of this programming section, an example
program has been included, with step by step instructions on how to create it.
Touching
brings up the following Program Menu page:
Touching
allows the user to
edit an existing program, or create a
new program.
Touching
allows the user to
view all the steps of an existing
program and their operating
sequence.
Touching
allows the user to
delete an existing program.
48
3.7.1 Program Delete
Touching
opens up the following page:
From this page the user can
choose whether to delete a
main or single line program.
Touching
brings up the following page:
From this page redundant programs
can be deleted to make space for
creating new programs.
Scroll through the list of programs
using the
buttons.
49
Highlight the program to be deleted
by touching the corresponding
button. I.E.;
.
This will cause the program number to
flash.
Touch
shown below;
to display the page
The selected program number and
title will be highlighted at the top of
the page.
Touch
program.
to delete the highlighted
Touch
to cancel program
delete and return to the Program
Menu page.
Sub programs and Single programs can be selected and deleted in the same
way as detailed above.
3.7.2 Program View
This allows the operator to view a written program in full without risk of making
any changes. Here the operator can view all of the programmable
parameters and number of cycle repeats.
Touching
in the Program Menu page brings up the following page.
50
From this page the user can choose
whether to view a main or single line
program.
The selected program number and
title will be highlighted at the top of
the page.
This page shows the program steps: 1
step for single programs and up to 30
steps for main programs. For main
programs, the view is spread over
more than 1 page, which can be
scrolled through by touching the
buttons.
3.7.3 Program Edit
Touching
opens up the following page:
From this page the user can choose
to edit a main or single line
program.
The differences between the
program types are detailed below.
51
i) Programs Main
A main program can comprise of a number of step functions or sub
programs, linked together in a sequence to form a test cycle. Each step can
have independent settings for temperature, time and where applicable,
relative humidity.
Up to 9 main programs, each comprising of up to 30 separate steps
can be stored.
Touching
brings up the following page:
Scroll through the list of programs
using the
buttons.
Highlight the program to be edited
by touching the corresponding
button. i.e.
. This
will cause the program number to
flash confirming that it has been
selected.
ii) Programs Single
A single program is used for operating a single function, at a single steady
state temperature, for a programmed period of time.
Up to 5 single programs, each comprising of 1 step can be stored.
Touching
opens the following page:
52
Highlight the program to be edited
by touching the corresponding
button. i.e.
. This
will cause the program number to
flash confirming that it has been
selected.
3.7.3.1 Open Program
Once a program type has been selected, touching
program edit page opens the following page:
in any
This is the ‘program edit’ page,
where from here the complete
program can be written, the
following steps will guide an operator
through the process.
The actual buttons displayed will
depend upon the function selected.
Touching
opens the following page:
53
This page allows the program title to
be entered or amended.
Using letters and numbers the user
can name programs using up to 16
characters, including spaces.
The
button must be
touched to confirm the new title.
Touching the
button opens the following page:
The new title will be displayed in the
and
windows.
To generate a program, follow the steps detailed below.
3.7.3.2 Step Number
A step is an individual programmable segment of a program. A main
program can be made of up to 30 steps. A single program is made from a
single step.
All programs start at step number 1.
54
Scroll through the program steps
using the
buttons located
beneath the current step number
until the required step number is
displayed.
3.7.3.3 Mode
The function required to be run in each program step is displayed inside the
button.
Touching the
page:
button within the
button brings up the following
If editing
or
are the step function choices.
these
Note: The page displayed in this table
represents a chamber with various
optional accessories fitted. The actual
buttons displayed will depend upon
which options have been fitted to the
chamber.
55
The above functions are described in detail below. Functions not described
will be detailed in the corresponding section of the manual for the optional
accessories.
Once a function is selected, it will be active during the entire program step.
Once selected, the screen will automatically return the ‘program edit’ page.
3.7.3.4 Program Functions
i) Function Off
If selected, no function will be active during this step of the program; however
a time can still be entered for the step. This can be used to operate as a
‘delayed’ start to a test commencing.
ii) Conventional Salt Spray
During this mode of operation salt fog is sprayed directly at the canopy
window and deflected around the test area. The chamber relative humidity is
not controlled during this mode of operation.
Conventional Salt Spray has a maximum operating temperature of
+50C.
56
iii) Temperature Controlled Air Flushing
During this mode of operation fresh air drawn from outside the
chamber is continuously blown into the chamber via an air heater. Relative
humidity is uncontrolled and will depend largely upon the ambient humidity
of the room in which the chamber is located.
The chamber air temperature is adjustable from ambient up to +50C.
iv) Condensation Humidity / Wetting
At the start of this function, the chamber automatically fills the small
tank located in the bottom of the chamber with fresh water. Heat is
generated using the immersion heater positioned in the small tank in the
bottom of the chamber. Set temperatures being 10~15C above ambient
ensure that high relative humidity levels are achieved, between 95~100%
during this mode.
Note: 120L chambers will fill the entire base and heat is applied using ‘wrap
around heating elements.
The chamber air temperature is adjustable from ambient up to +50C.
iv) Salt Spray and Sulphur Dioxide (Optional Accessory ref: ACC46)
57
During this mode of operation; Sulphur dioxide (SO2) gas is introduced into
the chamber interior at the same time as salt fog is created at the salt spray
atomiser(s).
Chamber air temperature is adjustable from ambient up to +50C.
Note: Refer to the separate optional accessory instructions at the back of this
manual for details on how to adjust the SO2 flow rate.
v) Sulphur Dioxide (Optional Accessory ref: ACC46)
During this mode of operation; Sulphur dioxide (SO2) gas is introduced into
the chamber interior. Relative Humidity is uncontrolled, the actual %RH
achieved being dependent on the quantity of any retained moisture inside
the chamber and the temperature setting.
The chamber air temperature is adjustable from ambient up to +50C.
Note: Refer to the separate optional accessory instructions at the back of this
manual for details on how to adjust the SO2 flow rate.
3.7.3.5 Step Temperature Set Value
This is the target set value for temperature to be achieved at the end of the
step time, for this particular step.
Touching the
buttons within the
button increases/ decreases the
set temperature by 0.1C each time a button is touched. Alternatively, for
large value changes, touching
brings up a numeric key pad where
larger values can be entered and saved.
58
3.7.3.6 Step Time Set Value
Step time is the duration of a program step. It can be set from 1
minute, (Rapid Step) to 99 hours 59 minutes (Ramp/Dwell).
Touching the
buttons of the
button increases/ decreases
the step time by 1 minute each time a button is touched. Alternatively, for
large value changes, touching the
button brings up a numeric key
pad where larger values can be entered and saved.
Note; A rapid step is a step that will take the actual chamber values of
temperature and humidity to the set values programmed within each step as
quickly as the chamber can physically manage. To program a rapid step the
time within that step must be set to 1 minute. This type of step should be used
when rapid conditional changes within the test space are required.
3.7.4 Saving/Cancelling an Edited Program
Once a program has been edited, pressing
following page:
brings up the
On this page, the number of required
program repeats (see below) can be
set, and the program can be saved
or cancelled.
59
3.7.4.1 Program Repeats
This is used to set the number of times a program is repeated. A setting
of 0 means the program will run once only with no repeats. A setting of 99
means the program will repeat continuously. Any other setting means the
program will be repeated the set number of times.
For main programs, this is used to select the number of times an entire
program is to be repeated. For single programs this can be used to extend
the maximum duration of the program, which would otherwise be limited to
the 99 hours & 59 minutes maximum step time. For example, if a single
program duration of 250 hours is required; this could be achieved by setting a
step time of 25 hours and setting the number of program repeats to 9. ((1 x
25) + (9 x 25) = 250).
Touching
entered.
brings up a numeric key pad where values can be
3.7.4.2 Save
Touching
number.
saves an edited program under its current program
3.7.4.3 Save as
Touching
gives the user the opportunity to save a previously saved
program under another program number, by bringing up the following page:
The current program number will be
flashing. Touch the new program
number as required, which will then
60
start to flash confirming its selection; touch
under this program number.
to save the program
3.7.4.4 Cancel
Touching the
button will display the following page;
Touching
‘SAVE AS’.
will cancel the
Touching
‘SAVE AS’ page.
will return to the
3.8 Running a Program
Touch the
button to return to the ‘Main Menu’ page
61
‘Main Menu’ Page.
Touching
opens the ‘Run’ page:
This is the page from which programs
are loaded, started, monitored and
paused/stopped.
The page has a ‘Message bar’,
above the row of buttons.
The page has an ‘Alarm Status
button’ below the row of buttons.
The page display mimics the programming page and is laid out in a similar
way. The actual page display may differ slightly from the page shown above,
depending upon the chamber model, its optional accessories, and the type
of program loaded.
62
Note: ‘XXXXXXXXX’ as shown above in the program number and title boxes
will be replaced by the number and name of the program when loaded.
As usual, touching the
button will escape to the previous page.
3.8.1 View Running Program
Touching the screen in this area
that is currently loaded.
allows the user to view the program
Scroll through the program using the
buttons.
Touch
to return to the ‘Run’ page.
3.8.2 Step Number
This shows the step number for the program step about to be run - if the
program has yet to be started, or the current step - if the program is running.
63
3.8.3 Step Function
This shows the step function for the program step about to be run - if the
program has yet to be started, or the current step - if the program is running.
3.8.4 Step Temperature
This shows the temperature set value (SV) and the temperature actual
value (PV) for the program step about to be run - if the program has yet
to be started, or the current step - if the program is running.
3.8.5 Step Time
This shows the step time set (SV) and the step time elapsed (PV) for the
program step about to be run - if the program has yet to be started, or the
current step - if the program is running.
3.8.6 Humidity Value
64
This shows the process value of relative humidity (PV) within the
chamber.
3.8.7 Program Run Time
This shows the total elapsed program run time in hours. Touching this
display will reveal any part hours elapsed as minutes, if required. Starting
a program will zero’s this timer.
3.8.8 Canopy
Touching the
button in any page opens one of the following pages:
If the canopy is closed and a
program is running, a warning
message is displayed advising the
user that the canopy cannot be
opened while a program is running.
Touch
to clear message.
65
If the canopy is closed with no
program running, touch
to
open. If no program with Salt spray or
SO2 has been run an alarm will sound
for a few seconds and then the
canopy will open automatically.
Pressing
page.
or
will close this
If the canopy is closed with no
program running but a program has
been run with salt spray or SO2 then
the chamber will automatically
purge itself for a minimum of 7
minutes
Once the purge is complete touch
to open; an alarm will sound
for a few seconds and then the
canopy will open automatically.
Pressing
page.
or
will close this
If the canopy is open touch and hold
to close. An alarm will sound
for a few seconds and then the
canopy will close. The
button
must be held until the canopy has
fully closed.
Pressing
page.
or
will close this
66
NOTE: When closing the canopy it is important to keep pressing the close
button until the HMI screen automatically reverts to the run page.
This may be a moment after the canopy has physically closed.
3.8.9 Program Load
Touching
opens the following page:
Here user first chooses the type of
program they wish to load; the
actual program can be selected
from the list previously created during
program edit.
67
If a program is running, a warning
message is displayed advising the
user that a program cannot be
loaded while a program is running.
Touch
to clear message.
Scroll through the available
programs using the
buttons.
Highlight the program to be loaded
by touching the corresponding
button. I.E.
. This
will cause the program number to
flash confirming that it has been
selected.
Once a program has been selected press
‘Run’ page.
the page will revert to the
If the loaded program contains a salt
spray or SO2 step, the Message Bar
will indicate;
This allows limited access to the
Supervisor settings page for
determining the test type. Select the
appropriate type from the choices
given. See the instruction manual
section which covers Supervisor
settings for further information.
68
3.8.10 Program Run
Touching
will start the loaded program running, either from the very
beginning, or from the beginning of a program step selected via the
button (see below). Touching the
Time counter.
button also zero’s the Program Run
Note: Programs should be run only with the canopy closed. However it is
possible to run a loaded program for up to 5 minutes with the canopy open,
for test purposes.
3.8.11 Program Stop
Touching
will stop the loaded program. Confirmation is required
because once a program is stopped it can only be restarted from the
beginning of the program. The program run time counter will also be reset to
zero.
3.8.12 Program Pause
69
Touching
will pause a running program. During program pause, the
button will flash continuously. Touching
or
once more will
allow the program to run again from the same point in the program from
when the pause button was first touched.
Note: During program pause, the step time counter and the program total run
time counter are also paused.
3.8.13 Program Fast Forward
This button will only appear if a program is stopped and not running. Touching
enables the user to fast forward to the program step of their choice
and start the program from there, rather than the very beginning, if required.
3.8.14 Run Settings
Touching the
button brings up the ‘Run Settings’ page.
70
This is the page from which some
chamber settings can be checked or
altered.
The page has a ‘Message bar’,
above the row of buttons.
The page has an ‘Alarm Status
button’ below the row of buttons.
Press
or
to return to the ‘Run’ page.
3.8.15 Interior Illumination (Optional Accessory ref:
ACC26)
Touching
switches the chamber interior illumination on (if fitted).
Touching this button again will switch off the interior illumination. The
illumination will also switch off automatically after a period of approximately
10 minutes.
3.8.16 Trending
This facility allows the user to monitor the chamber temperature and relative
humidity against time, graphically.
71
Touching the
button brings up the following page:
Touch
view the temperature profile.
to
Touch
to
view the relative humidity profile.
Touch
to scroll the display
back/forward in 30 minute steps.
Touch
to go to the
previous/next page of display data.
This is a graphical representation of the set temperature/humidity (dashed
line) and actual temperature/humidity (solid line) against time.
Each page displays data logged over a 300 minute period of time.
The page displayed on first entering the Trending facility relates to the current
time. Previous pages of data can be viewed covering a total time of 72
hours. Data over 72 hours old is continually discarded as new data is logged.
Press
to return to the ‘Run Settings’ page.
3.8.17 Total Chamber Hours Run
Touching the
button brings up the following display.
72
This will display the total number of
hours the chamber has run and can
not be reset.
3.8.18 Air Saturator Mode
Touching the
button brings up the following page:
This page allows the user to select if
they wish the chamber air saturator
to be active or inactive.
Touch the required button to select.
Press
to return to the ‘Run Settings’ page.
In the
mode of operation, compressed air for the salt spray atomiser is
bubbled through the chamber air saturator. This is the factory set condition,
since this is a requirement of most salt spray test standards.
73
Note: the chamber will automatically revert to this mode whenever the
chamber power is switched off and back on again.
In
air mode the air saturator is bypassed. This is the correct mode for
testing to ASTM G85, annex A5.
The run settings page button will display
and will display
when the air saturator is active
when it is inactive.
3.8.19 Message Bar
A message bar is provided where shown, this is used to display a range of
messages to the user, including alarms. In the context of running a program,
the message bar will display the message ‘Program Completed’ when the
running program and any repeats have been completed.
For certain program types the
Message bar will also flash:
See the ‘Set Test Type’ section of the
manual for details.
3.8.20 Alarm Status
74
Touching
brings up the following page:
Touch
warning
to silence audible
Touch
to reset any alarms
that are no longer active
Touch
to review alarms
history (see below).
This page will list any active alarms. Note that active alarms will sound an
audible warning unless this has been disabled (within supervisor settings). A
list of all possible alarm conditions and their meaning is given in the care and
maintenance section of this instruction manual.
Touching
brings up the following page:
This page lists all of the alarm
conditions that have
occurred, together with their
frequency of occurrence.
Press
to return to the previous page.
75
3.9 Control
3.9.1 Emergency Stop
Pressing the chamber emergency
stop button during canopy opening
or closing will ‘freeze’ the canopy in
its current position.
An audible alarm sounds. When the emergency stop button is returned to its
normal position, the HMI screen will return to the canopy Open/Close screen.
3.9.2 Mains Isolator
Isolates the chamber from the
electricity supply
3.9.3 Air Pressure Gauge & Regulator
76
Air Pressure Gauge and Regulator
These indicate and control the pressure
of the compressed air supply to the
atomiser(s).
To adjust the air pressure:
Pull out the regulator knob to unlock.
Rotate anticlockwise to decrease the pressure and clockwise to increase it.
Push in the regulator knob to lock.
3.9.4 Flow Meter(s) & Peristaltic Pump(s)
Flow meters and Peristaltic
pumps
(2000L- pictured)
77
450L and 1000L chambers are fitted with one flow meter and one
peristaltic pump. 2000L chambers are fitted with two flow meters, and two
peristaltic pumps, one of each for each atomiser. The flow meter(s) monitor
the flow rate of salt solution from the reservoir to the atomiser(s). The
peristaltic pump(s) draw salt solution from the reservoir and pass it to the
atomiser(s).
3.9.5 Ethernet Communications Port
RJ45 Connection
This enables remote data logging of the chamber process variables via a
suitable computer (utilising optional programming software ref.: ACC120).
3.10 Setting up Procedure
3.10.1 Determine the test parameters
Corrosion Test to be performed.
Composition of the salt solution.
Atomiser air, dry/moist, heated/unheated.
Salt fog fall out rate.
78
Test duration/number of cycles.
3.10.2 Set up chamber
Ensure mains isolator is ON.
Load the test samples into the chamber.
Prepare the salt solution and transfer it to the salt solution reservoir.
Ensure that the salt solution reservoir is connected to the chamber.
Ensure that the drain and exhaust are connected and not blocked.
Load required test program.
If pre-humidification of the atomiser air is required and the chamber is not
connected to a pressurised supply of deionised water for automatic filling of
the Air Saturator, and a manual fill facility has been provided instead
(optional accessory), then fill the Air Saturator manually as follows:
Depressurise the air saturator by selecting dry air within the global settings
page.
79
Open the hand operated ball valve at the manual filler port by rotating it fully
anti-clockwise.
Insert a funnel into the open orifice of the manual filler port and slowly fill with
deionised or distilled water.
Stop filling when high water lamp on the side of the chamber illuminates.
Remove the funnel and close the ball valve
Reselect moist air within the global settings page.
Run the loaded test program.
Adjust the pressure regulator and/or the salt solution flow rate to give the
required salt fog fall-out rate.
3.10.3 Set the Salt Fog Fallout Rate
(Refer to Optional accessories section of this manual if ACC116 – Electronic
Catchpots is fitted)
(Usually carried out in advance of testing of components)
The method for measuring the Salt Fog Fallout Rate is specified as being a 100
mm-diameter funnel in conjunction with a measuring cylinder graduated in
80
millilitres. This procedure is used to collect salt fog fallout at various points
across the chamber workspace (no closer than 100 mm from the chamber
walls or atomiser) for set periods of time.
From these measurements the average fog fallout rate and the spread of the
fog throughout the chamber can be determined.
Generally, the spread of the fog within the chamber is controlled by the air
pressure, and the density of the fog is controlled by the salt solution flow rate.
With the atomiser positioned centrally in the chamber, increasing the air
pressure will tend to increase the salt fog fallout at the extremes of the
chamber, whilst decreasing the air pressure will tend to increase the fallout in
the centre of the chamber.
Increasing the salt solution flow rate will increase the salt fog fallout at any
point in the chamber, whilst decreasing the flow rate will reduce the fallout at
any point.
Only very small adjustments to the air pressure and flow rate should be made
at any one time, before rechecking the results.
Set the air pressure to be between 12 and 18psi
Set the initial flow rate so that the peak flow is approximately 10 to 15 ml/min.
The ball in the flow meter will fluctuate up and down with every half revolution
of the peristaltic pump.
Adjust the air pressure to obtain an even spread of fog within the chamber,
regardless of the actual amount of fallout collected.
Adjust the flow rate to bring the fallout within the limits specified in the test
standard.
Recheck the spread of the fog and repeat operations iii and iv above until
satisfactory.
3.11 Shut down procedure:
Stop any running programs.
Clean humidity sensor
Clean chamber
81
Switch electrical isolator to OFF.
Turn off water supply
Turn off air supply
Part 4 – Care & Maintenance
4.1 Routine Maintenance
Routine maintenance is essential to keep the chamber in good working order.
82
The following maintenance is recommended for a chamber that is in regular
use.
4.1.1 Daily Checks
Record chamber variable parameters on the Daily Check Sheet. A sample
Daily Check Sheet is provided at the end of this manual.
Ensure that corrosion waste or small samples are not gathering in the base of
the chamber. This can lead to blockages within the drain/humidity system
and will affect chamber performance.
Contamination may also lead to changes in corrosivity within the chamber
that could affect test results!
Ensure that the drain is clear.
Ensure that the chamber exhaust is clear and is not restricted.
Check that deionised water supply is within specification.
4.1.2 Weekly Maintenance
4.1.2.1 Consumables kit
Ascott Ref. No.: ACC12/1
83
A kit of consumables parts is available for Ascott salt spray and cyclic
corrosion test chambers. These contain user replaceable items sufficient for
up to 1 year.
1m x PERC012 – Silicone Tube
2pk x SALC010 - Salt Filter Wadding
1pk x ELEC690 - Cable Ties
ATOA110 - Atomiser air in luer fitting
assembly
ATOA120 - Atomiser salt in luer fitting
assembly
SALC012 - Salt Filter Housing Tube
4.1.2.2 Maintenance of Atomiser
Atomiser ‘salt in’
Luer fitting
assembly
Atomiser Body & filter
spacer
Compressed Air Inlet
Hose & Atomiser ‘air in’
Luer fitting assembly
Atomiser Cap
84
Salt Solution Inlet
Hose
Salt solution Filter
Housing (filter fitted)
Plastic spacer
Atomiser Nozzle
1) Check that the chamber service connections are secure and are not
leaking.
2) Switch off the power supply to the chamber.
3) Withdraw the atomiser and filter assembly from its support, taking care not
to damage the two hose connections.
4) Check the salt solution filter material for discoloration.
5) Disconnect the compressed air inlet hose (BLACK) by rotating the collar of
the ‘air in’ fitting assembly anti clockwise.
6) Unscrew the atomiser body and cap as a complete assembly, from the salt
solution filter housing. If the atomiser and cap are dirty or have been giving
poor fallout
7) Withdraw the salt solution filter material from the salt solution filter housing
using tweezers.
8) Wash the filter material in warm water and mild detergent.
9) If the filter material is badly contaminated or damaged, discard it and
replace it with new filter material.
10) Reassemble the salt solution filter.
85
Roll the filter material into a cylindrical shape
and insert into the filter housing (1&2).
(1)
(2)
Screw the atomiser body, nozzle and cap
onto the filter housing ensuring Re-attach the
compressed air inlet hose (3).
Refit the atomiser and filter assembly onto its
mount.
Switch on the power supply to the chamber.
3)
4.1.2.3 Maintenance of Float Switch
Corrosion contamination, salt accumulation and poor water quality can all
lead to the build-up of deposits on the float switch, located within the floor of
the chamber.
This can in turn lead to the float switch failing to operate correctly! This is a
safety hazard!
Remove corrosion waste and any dropped components from the base of the
chamber by scooping out. Do not flush down the drain as this will lead to
blockages.
86
Check that the float switch is clean and operates freely.
Cleaning with a soft brush can be carried out carefully.
4.1.2.4 Maintenance of Humidity sensor
A well maintained humidity sensor is vital for continued chamber
performance!
Sensor in normal position, within protective plastic
sheath, revealing only the tip of the sensor, to
minimise the number of water droplets running over
the sensor.
The hose attachment supplies compressed air forming
an air curtain during acidic salt spray tests.
It is important to protect the sensor from salt
accumulation. Selecting an acidified option when
starting the test will ensure that the air curtain is used
Filter cap – MUST BE KEPT CLEAN to ensure good
chamber performance and reliability.
WEEKLY PROCEDURE For cleaning the humidity sensor
cap:
Protective plastic sheath removed to reveal entire
humidity sensor probe.
87
Filter cap unscrews from sensor to reveal electronic
sensing element inside.
This filter can be removed for cleaning or
replacement. In either case, the chamber must not
be operated until the filter has been correctly
screwed back into position (finger tight only).
Rinse the cap in warm water to dissolve any salt
deposits.
Dry with clean, compressed air before replacing.
Take care not to lose the small ‘o’ ring!
4.1.2.5 Fitting a Humidity Sensor Cover
(Protects humidity sensor from exposure to acidic solutions, eg; ASS, CASS,
SO2)
Note: In salt spray chambers, the humidity sensor is only used as an indicator
and has no effect on chamber performance. Therefore the protective cover
can be left in place unless a humidity reading is required.
In cyclic corrosion chambers, the humidity sensor is used as a part of the
mechanism for controlled humidity, the sensor cover should only be fitted
when SO2, ASS, CASS testing or similar. For all other modes of operation the
humidity sensor MUST be free to operate normally.
Isolate the chamber from its electrical supply
88
Carefully remove the blue humidity sensor
cap by unscrewing clockwise, ensuring the
little black ring is inside it.
The humidity sensor has an o ring that should
be used whenever this solid cap is fitted.
Do Not Use The Chamber With This Cap
Removed.
Carefully screw on the grey protective sensor
cover anti-clockwise as shown by the
directional arrow.
(no picture)
The blue humidity sensor cap and o ring
should be kept in a safe place. These should
be replaced in the chamber when the
humidity probe is required for use.
The delicate sensor element should only ever be cleaned using a can of dry
compressed air such as ‘duster gases. Under no circumstances should it be
scratched or rubbed. Avoid contact with finger tips.
If the sensor element is seen to be corroded or damaged in any way it should
be considered for replacement.
4.1.2.6 Gasket Check
The canopy gasket may occasionally stick to the
surface of the chamber body. This may happen if
high temperatures are used or if the chamber is left
closed for long periods.
Apply a thin smear of petroleum jelly or silicone
grease to the surface of the gasket material to
prevent this. Repeat as required.
4.1.4 Three–Monthly Maintenance
89
Change the silicone rubber tube of the peristaltic pump every three months
or earlier if it splits or becomes deformed with usage.
Replace the tube as follows:
Switch off the chamber.
Release the two clamps that hold the silicone rubber
tube in the pump body (1).
(1)
Pull gently on end of silicone rubber tube, whilst
turning the pump roller clockwise by hand, to
withdraw the tube from the pump (2).
Unscrew the cap of the plastic compression fitting
on both ends of the silicone tube (3).
Pull the two silicone tube ends out of the
compression fittings and retain the olive and cap for
re-use.
(2)
Cut a length of new silicone rubber tubing to exactly
the same length as the original tubing and fit the
compression fitting cap and olive to each end.
Reconnect one end of the new tube to the left
compression fitting.
Place the tube into the left clamp (4)
(3)
Whilst turning the pump roller clockwise by hand,
feed the pipe under the pump roller mechanism
until the whole length has been drawn correctly into
the pump. Ensure that the tube is not twisted or
stretched, and lies naturally in the pump.
Clamp the other end of the new tube into the right
clamp (5).
(4)
Reconnect the remaining end of the new tube to
the right compression fitting (6).
Restart pump, and release right clamp for a few
minutes to allow the silicone rubber tubing to find its
natural position.
(5)
90
(6)
4.1.5 After Use
Remove corrosion waste and any dropped components by scooping out. Do
not flush down the drain as this will lead to blockages.
Clean the chamber interior and canopy by washing with warm water and
mild detergent.
If the chamber is not going to be used for a period of one week or longer,
refer to ‘unscheduled maintenance’ section of this manual.
91
4.2 Unscheduled Maintenance
4.2.1 Storage & Contamination
If the chamber is to stand unused for a period of more than one week, or if
contamination by algae growth is detected in the salt solution reservoir, the
following procedure is recommended:
Switch off the chamber.
Drain the air saturator (refer to section 3.7).
Discard any salt solution remaining in the reservoir.
Clean the reservoir thoroughly.
Partly fill the reservoir with a biocidal sterilising agent solution and replace the
salt filter housing in the reservoir.
Switch on the chamber and run it in the Salt Spray mode of operation for
approximately five minutes, with the canopy closed. This will flush all the salt
solution hoses and fittings with the sterilising agent.
Switch off the chamber and leave to stand until required for use.
Discard the sterilising agent and clean the tank thoroughly.
Refill the reservoir with salt water and run for approximately five minutes to
flush any remaining sterilising agent.
4.2.2 Deionised Water Inlet Filter
Detach deionised water supply hose from the bulkhead fitting at the rear of
the chamber.
Withdraw the wire mesh filter from inside the bulkhead fitting.
Scrub the filter clean with a brush under running water, or replace the filter.
Re-insert the filter into the bulkhead fitting.
Reconnect the deionised water supply.
92
4.2.3 Clean or Unblock Salt Spray Atomiser
Atomiser ‘salt in’
Luer fitting
assembly
Atomiser Body & filter
spacer
Salt Solution Inlet
Hose
Salt solution Filter
Housing (filter fitted)
Compressed Air Inlet
Hose & Atomiser ‘air in’
Luer fitting assembly
Atomiser Cap
Plastic spacer
Atomiser Nozzle
Open the chamber canopy
Switch off the power supply to the chamber.
Withdraw the atomiser and filter assembly
from its support, taking care not to damage
the two hoses.
Detach the compressed air inlet Hose (1).
Unscrew the atomiser cap (2).
Wash the atomiser cap in warm running
water.
Unscrew the atomiser body, nozzle and cap
from the salt solution filter housing.
(1)
Wash the atomiser body and nozzle in warm
running water.
If the nozzle is blocked, clear the obstruction
by operating the chamber (canopy open)
and place atomiser assembly, without the
filter attached, into a cup of clean water (3).
93
Water should be drawn through the atomiser
to create a spray.
Place finger over atomiser outlet to blow
air/water back through the atomiser,
clearing any obstruction (4).
(2)
Only if this does not work should the atomiser
cone be cleaned with a fine wire.
Take care not to damage the cone!
Reassemble the Salt Spray Atomiser and test
once again (5).
(3)
(4)
(5)
94
Day
% Concentration
of Salt Solution
/Specific Gravity
(µs)
Water
Conductivity
of Fallout
pH
/hour)
(ml/80cm²
Fallout
(Bar)
Pressure
Daily Checks for Month:
Air
Temp (°C)
Air Saturator
Temp (°C)
Chamber
4.3 Sample Daily Check Sheet
……………………………
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
95
4.4 Fault Finding & problem solving
Technical Support and solutions to
common faults or problems can be found
by logging on line to Ascott’s Chamber
Doctor Application. Access is free for the
first 12 months from receiving the
chamber. Further access can be obtained
by contacting Ascott Technical Support.
Silver and Gold Technical support
packages, where direct access to an
Ascott engineer after warranty periods
expire can also be purchased. Please
contact Ascott Technical Support for
assistance on Tel: +44 1827 318040 or Fax
+44 1827 318049
96
4.5 Salt Spray Chamber Exploded view
4.5.1 S120IP
Control Compartment
97
4.5.1 S120IP
98
4.5.1 S120IP
Rear Ascott Chamber
99
4.5.2 S450IP
Control Compartment (Base Plate)
100
4.5.2 S450IP
Front Ascott Chamber
101
4.5.2 S450IP
Rear Ascott Chamber
102
4.5.2 S450IP
Services Panels (Rear External)
103
4.5.2 S450IP
Services Panels (Rear Internal)
104
4.5.3 S1000IP
Control Compartment (Base Plate)
105
4.5.3 S1000IP
Front Ascott Chamber
106
4.5.3 S1000IP
Service Panels (Rear External)
107
4.5.3 S1000IP
Service Panels (Rear Internal)
108
4.5.3 S1000IP
Rear Ascott Chamber
109
4.5.4 S2000IP
Control Compartment (Base Plate)
110
4.5.4 S2000IP
Front Ascott Chamber
111
4.5.4 S2000IP
Service Panels (Rear External)
112
4.5.4 S2000IP
Service Panel (Rear Internal)
113
4.5.4 S2000IP
Rear Ascott Chamber
114
4.6 Chamber Air Saturator (Welded fabrication)
4.6.1 S120ip
115
116
117
4.6.2 S450ip, S1000ip and S1300ip
118
119
120
4.6.3 S2000ip and S2600ip
121
122
123
4.7 Chamber Air Saturator (Glass fabrication)
4.7.1 S120ip, S450ip and S1000ip
124
125
126
4.7.2 S1300ip
127
128
129
4.7.2 S2000ip and S2600ip
130
131
132
5 Optional Accessories Manual
133
Issue
Date First
Issued
Description Of Amendments
I
Jan 2014
Added Navigation, updated Maintenance and Improved
layout.
J
March 2014
Refined layout, new pictures and header.
K
March 2014
Refined layout further, new pictures and tables
L
April 2014
Moved humidity sensor maintenance & unified layout
M
June 2014
Refined layout, updated photos and table borders.
N
July 2014
Hungarian Added to language picture, updates to tables,
typeface consistency and colour.
O
October 2014
Added Additional direction for humidity sensor cap O-ring
placement.
P
November
2014
Moved humidity sensor cap and filter to weekly
maintenance
Q
March 2015
Updated Layout & services quality warning added
R
June 2015
Exploded views added
S
Nov 2015
Gasket check added
T
March 2016
Part numbers updated
U
May 2016
Pressure settings corrected for chamber setup
V
June 2016
Air saturator top plate parts changed s2000ip,PNEA078
and PNEC752 removed and replaced
W
July 2017
Air saturator parts change and glass air saturators added
134