Salt Spray Test Chamber Models: S120/450/1000/2000iS 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 1 FILE NOTE A COPY OF THIS INSTRUCTION MANUAL HAS BEEN SENT WITH THE CHAMBER Instruction Manual iS Issue - L Issue Date First Issued - March 2015 Description Of Amendments A Nov 2009 Original Issue ( Draft) B Aug 2010 Change to H&S Statement C June 2011 Multiple updates to specification D June 2011 Test mode reference added F June 2012 CE updates G October 2013 General Updates H February 2014 Updated contents page, layout. I March 2014 Updated Layout, pictures and Headers J March 2014 Updated Layout, Pictures and tables. K June 2014 Updated Atomiser Pictures, tables and Air saturator drain. L March 2015 Updated Layout & services quality warning added 2 Contents Contents ......................................................................................................................................... 3 Introduction - General Description of machine operation..................................................... 7 Part 1 - Health & Safety ........................................................................................................... 8 1.1 Health and Safety Policy ................................................................................................8 1.2 Transport and Lifting ......................................................................................................13 Part 2 - Installation .................................................................................................................. 14 2.1 Operating Environment ................................................................................................14 2.2 Positioning .......................................................................................................................15 2.3 External Services ............................................................................................................16 2.4 Part 3 - 2.3.1 Electrical Supply............................................................................................. 17 2.3.2 Compressed Air Supply ................................................................................. 18 2.3.3 De-ionised Water Supply .............................................................................. 18 2.3.4 Salt Solution Reservoir .................................................................................... 19 2.3.5 Condensate Drain ......................................................................................... 20 2.3.6 Exhaust Vent to Atmosphere ....................................................................... 22 2.3.7 Air Saturator Drain.......................................................................................... 23 Atomiser Set up ..............................................................................................................24 Operation .................................................................................................................. 26 3.1 Human Machine Interface (HMI) Screen ...................................................................26 3.2 Initial Power Up...............................................................................................................27 3.3 3.2.1 Contact Details .............................................................................................. 27 3.2.2 Chamber Information ................................................................................... 28 3.2.3 Run Screen...................................................................................................... 28 Run Screen......................................................................................................................29 3 3.4 3.5 3.3.1 Stopped / Running ........................................................................................ 29 3.3.2 Starting/Stopping a test ................................................................................ 30 3.3.3 Test Mode ....................................................................................................... 30 3.3.4 Canopy ........................................................................................................... 31 Run Mode .......................................................................................................................34 3.4.1 Chamber Temperature Display ................................................................... 34 3.4.2 Air Saturator Temperature Display .............................................................. 35 3.4.3 Hours Run Display........................................................................................... 35 Setup Mode ....................................................................................................................36 3.5.1 Time to stop .................................................................................................... 36 3.5.2 Hours Run – Reset ........................................................................................... 38 3.5.3 Air Saturator (Moist air / Dry Air) ................................................................... 38 3.5.4 Pump Speed(s) .............................................................................................. 39 3.5.5 Chamber Temperature Set point ................................................................ 42 3.5.6 Air Saturator Temperature Setpoint ............................................................ 43 3.6 Alarm Status....................................................................................................................44 3.7 Control ............................................................................................................................45 3.8 3.9 3.7.1 Emergency Stop ............................................................................................ 45 3.7.2 Mains Isolator .................................................................................................. 45 3.7.3 Air Pressure Gauge & Regulator .................................................................. 46 3.7.4 Flow Meter(s) & Peristaltic Pump(s) ............................................................. 47 Setting Up Procedure ....................................................................................................48 3.8.1 Determine the test parameters ................................................................... 48 3.8.2 Set up chamber ............................................................................................. 49 3.8.3 Set the Salt Fog Fallout Rate ........................................................................ 51 Shut down procedure: ..................................................................................................52 4 Part 4 4.1 4.2 Care & Maintenance............................................................................................... 53 Routine Maintenance ...................................................................................................53 4.1.1 Daily Checks................................................................................................... 53 4.1.2 Weekly Maintenance.................................................................................... 54 4.1.3 Three–Monthly Maintenance ....................................................................... 57 4.1.4 After Use .......................................................................................................... 58 Unscheduled Maintenance .........................................................................................59 4.2.1 Storage & Contamination ............................................................................ 59 4.2.2 Deionised Water Inlet Filter ........................................................................... 59 4.2.3 Clean or Unblock Salt Spray Atomiser ........................................................ 60 4.3 Sample Daily Check Sheet...........................................................................................62 4.4 Fault Finding ...................................................................................................................63 Part 5 - Optional Accessories Manual (If Ordered) ........................................................... 64 5 Attention! Please read the enclosed instruction manual before connecting this chamber to its external service utilities and attempting to use it. This chamber has been despatched with its air saturator emptied of water in order to reduce weight. As a consequence, when power is first applied, the HMI display will default to an alarm condition, with an audible alarm sounding: Whilst the HMI is displaying the above, pressing; MUTE - mutes the audible alarm. RESET - resets the alarm* * Note: The alarm can be silenced, but it will not be possible to reset the alarm until the actual alarm condition has been cleared. This will require the air saturator to be filled with water; this will happen automatically if the chamber is connected to a de-ionised water supply. 6 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). 7 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 common-sense safety precautions must be taken at all times to avoid the possibility of accidents. ivInstallation, 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. 8 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 airborne 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 EN129211:2005+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. 9 Training is available if required. Please contact Ascott or your Agent / Distributor for more details. 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. 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. No structural changes or fitting of customers own tools / accessories without first contacting Ascott or its associates. In the event of a breakdown consult Ascott or its associates immediately as further damage to the chamber and / or personnel may occur. 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. 10 The control panel also has two labels to identify the Air Pressure Gauge for the chamber and the regulator for the air Supply. Denotes Pressure Gauge Denotes Pressure Regulator 11 Inside the control compartment the earthing point of the chamber is clearly identified with the following symbol 12 1.2 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 logos. 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. 13 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 This equipment is designed for internal use only, in an environment controlled to within the following limits:- Ambient Temperature:+18 to +23°C (no icing) Note: The minimum operating temperature of the chamber will depend directly upon the actual ambient temperature of the environment in which it is located . Ambient Humidity:45 to 85% RH (no condensation) 14 2.2 Positioning Move the Salt Spray Test Chamber into position as shown: Chamber The rear castors can be locked when the chamber has been positioned. 15 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. Electricity – single phase with neutral & earth. Compressed air – 12.5 mm (½”) bore hose Salt Water – 3 mm (1/8”) bore hose (to separate salt solution reservoir) Water – 12.5 mm (½”) bore hose 16 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. WARNING: THIS APPARATUS MUST BE EARTHED 17 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). 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). 18 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 120L Only 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. 19 2.3.5 Condensate Drain Drain – 22 mm (7/8”) diameter pipe Connect the 22 mm diameter push-fit pipe to the rear of the chamber Connect the other end to the service drain. 20 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 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. 21 2.3.6 Exhaust Vent to Atmosphere Exhaust –50mm (2”) diameter pipe for all iS 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. 22 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. To drain when required: Set the chamber to salt spray mode with the air saturator ‘switched off’. Then use a flat bladed screwdriver to open the drain tap. (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. 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. 23 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 the canopy is closed. This position can be adjusted to achieve even fallout results during salt spray testing. 24 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. 25 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. Display LCD screen with backlight. The HMI screen uses a menu driven format, where functions are selected from a variety of ‘pop-up’ screens. The through the screens. buttons are used to navigate 26 3.2 Initial Power Up When the chamber is first switched on; after a few moments, the following screens will be displayed in sequence. 3.2.1 Contact Details Ascott Main Menu Page: Press the buttons to scroll between screens. After a few moments the screen will display the chamber information screen. 27 3.2.2 Chamber Information This screen 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. Press the buttons to scroll between screens. After a few moments the screen will display the Run screen. 3.2.3 Run Screen After a few moments the screen will move on to display the Run Screen. Press the buttons to scroll between screens. 28 3.3 Run Screen Once the start sequence has completed the screen will display the Run Screen. The Run Screen displays the current status of the chamber. The canopy can also be opened from this page. 3.3.1 Stopped / Running The Run Screen displays the current status of the chamber. The chamber will be either STOPPED or RUNNING. The canopy can also be opened from this page. 29 3.3.2 Starting/Stopping a test Press to start a test. (Hours run counter starts) Press to stop a test. (Hours run counter pauses) 3.3.3 Test Mode If you start a test with the canopy open, the chamber will enter ‘test mode’. It will start spraying but will not apply any heat to the chamber. It will stop automatically after 5 minutes. The screen will revert to the normal run screen after a short time. 30 3.3.4 Canopy Chambers are fitted with a pneumatically operated canopy that opens and closes at the press of a button on the HMI. The chamber must be connected to a suitable compressed air supply before the canopy will open/close. To open the Canopy: From the Run Screen press If no test has been started the canopy can be opened immediately by pressing An alarm will sound for a few seconds and the canopy will open automatically. 31 If a test has been started the chamber will need to go through a purge cycle to remove salt fog. An alarm will sound for a few seconds and the canopy will open. Once the purge has completed the canopy can be opened by pressing An alarm will sound for a few seconds and the canopy will open automatically. Once the canopy is open, the chamber can be operated in ‘test mode’ for five minutes. No heat is applied. 32 If the chamber is RUNNING a test and you press , the screen will display this message and will continue testing. The screen will revert to the run screen after a few seconds. To close the Canopy: From the Run Screen, press Note: If you run a test with the canopy open, no heat is applied but the spray atomiser To close the canopy press and hold Keep pressing until the alarm stops. 33 3.4 Run Mode The chamber has two operating modes; Setup and Run: Run mode allows the user to view the current status of the chamber. When in Setup mode, the change to Run mode. button is displayed to allow you to When in Run mode, the button is displayed in many of the menu screens to allow you to change to Setup mode. When in Setup mode, press Press the to change to Run mode. buttons to scroll through the various Run screens. Note: Values cannot be adjusted when the chamber is in Run Mode 3.4.1 Chamber Temperature Display When in Run Mode the setpoint and actual values for chamber temperature are displayed. 34 No adjustment can be made 3.4.2 Air Saturator Temperature Display When in Run Mode the set point and actual values for air saturator temperature are displayed. No adjustment can be made 3.4.3 Hours Run Display When in Run Mode the hours set, run and remaining are 35 displayed. No adjustment can be made 3.5 Setup Mode Setup mode allows the user to change the chamber parameters. To enter the Setup mode press Press the screens. 3.5.1 buttons to scroll through the various settings Time to stop The chamber can be set to run a test for a predetermined length of time using the Time to Stop facility. The maximum value for this is 999.9 hrs. 36 If the value 999.9 hrs is selected, the chamber will continue to run without stopping and the hours run counter will rise accordingly. To adjust the value press A key pad will appear. Type in the number required. Press to confirm Press to escape without making changes. Once the test is started, the hours run timer will increase. Once the timer reaches the Time to Stop value the test will stop automatically. If you wish to start a new test you must reset the hours run counter. Press 37 to exit to the run screen immediately. After a short period the screen will revert to the run screen automatically. 3.5.2 Hours Run – Reset To reset the counter to 0000.0, press 3.5.3 Air Saturator (Moist air / Dry Air) In the ‘Moist air’ mode of operation, compressed air for the salt spray atomiser is bubbled through the chamber air saturator to apply heat and 38 moisture. This is the factory set condition, since this is a requirement of most salt spray test standards. Note: The chamber will automatically revert to this mode whenever the chamber power is switched off and back on again. The current selection is shown in the centre of the display. To change press 3.5.4 or Pump Speed(s) The peristaltic pump is used to control the flow of salt solution to the atomiser. 39 To adjust the value press A key pad will appear. Type in the number required. Press to confirm Press to escape without making changes. 2000L chambers have two peristaltic pump motors. Pump 1 on the left, pump 2 on the right. Press the button to scroll to the second pump setting. 40 To adjust the value press A key pad will appear. Type in the number required. Press to confirm Press to escape without making changes. 41 3.5.5 Chamber Temperature Set point To adjust the value press (Maximum 50C) A key pad will appear. Type in the number required. Press to confirm Press to escape without making changes. 42 3.5.6 Air Saturator Temperature Setpoint To adjust the value press (Maximum 63C) A key pad will appear. Type in the number required. Press to confirm Press to escape without making changes. 43 3.6 Alarm Status The chamber has a number of inbuilt alarms that will indicate the nature of a potential problem. An alarm buzzer will sound and the screen will be backlit with a red lamp. The nature of the alarm will be displayed. Press to silence the alarm. The screen will return to the run page. If the ‘fault’ is still present the alarm will re-occur after a few seconds. Press to reset the alarm condition once the cause of the alarm has been investigated and cleared. See section 5 regarding care and maintenance 44 3.7 Control 3.7.1 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. 3.7.2 Mains Isolator Isolates the chamber from the electricity supply. 45 3.7.3 Air Pressure Gauge & Regulator Air Pressure Gauge and Regulator These indicate and control the pressure of the compressed air supply to the atomiser(s). They will only operate when air is supplied to the atomisers. To adjust the air pressure: (i). Pull out the regulator knob to unlock. (ii). Rotate anticlockwise to decrease the pressure and clockwise to increase it. (iii). Push in the regulator knob to lock. 46 3.7.4 Flow Meter(s) & Peristaltic Pump(s) Flow meters and Peristaltic pumps (2000L- pictured) 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). 47 3.8 Setting Up Procedure 3.8.1 Determine the test parameters (i). Salt Spray Test to be performed. (ii). Composition of the salt solution. (iii). Atomiser air, dry/moist, heated/unheated. (iv). Salt fog fall out rate. (v). Test duration. 48 3.8.2 Set up chamber (i). Ensure mains isolator is ON. (ii). Load the test samples into the chamber. (iii). Prepare the salt solution and transfer it to the salt solution reservoir. (iv). Ensure that the salt solution reservoir is connected to the chamber. (v). For 120L chambers, fill the integral salt solution reservoir: (vi). Ensure that the drain and exhaust are connected and not blocked. (vii). Load required test program. (viii). 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: 49 (xi) Depressurise the air saturator by selecting dry air within the global settings page. (xii) Open the hand operated ball valve at the manual filler port by rotating it fully anti-clockwise. (xiii) Insert a funnel into the open orifice of the manual filler port and slowly fill with deionised or distilled water. (xiv) Stop filling when high water lamp on the side of the chamber illuminates. (xv)Remove the funnel and close the ball valve (xvi)Reselect moist air within the global settings page. (i). Run the loaded test program. (ii). Adjust the pressure regulator and/or the salt solution flow rate to give the required salt fog fall-out rate. 50 3.8.3 Set the Salt Fog Fallout Rate (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 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. 51 Only very small adjustments to the air pressure and flow rate should be made at any one time, before rechecking the results. (i). Set the air pressure to 1.4 bar (20 psi). (ii). 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. (iii). Adjust the air pressure to obtain an even spread of fog within the chamber, regardless of the actual amount of fallout collected. (iv). Adjust the flow rate to bring the fallout within the limits specified in the test standard. (v). Recheck the spread of the fog and repeat operations iii and iv above until satisfactory. 3.9 Shut down procedure: (i). Stop any running programs. (ii). Switch electrical isolator to OFF. 52 Part 4 - Care & Maintenance 4.1 Routine Maintenance Routine maintenance is essential to keep the chamber in good working order. 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 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. 53 4.1.2 4.1.2.1 Weekly Maintenance Consumables kit Ascott Ref. No.: ACC12/1 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 54 4.1.2.2 Maintenance of 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 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. 55 10) Reassemble the salt solution filter. 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) 56 4.1.3 Three–Monthly Maintenance 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. (3) Place the tube into the left clamp (4) 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. (4) Clamp the other end of the new tube into the right 57 clamp (5). Reconnect the remaining end of the new tube to the right compression fitting (6). (5) Restart pump, and release right clamp for a few minutes to allow the silicone rubber tubing to find its natural position. (6) 4.1.4 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. 58 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. 59 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). (1) Unscrew the atomiser cap (2). Wash the atomiser cap in warm running water. 60 Unscrew the atomiser body, nozzle and cap from the salt solution filter housing. Wash the atomiser body and nozzle in warm running water. (2) (3) 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). 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). Only if this does not work should the atomiser cone be cleaned with a fine wire. (4) Take care not to damage the cone! Reassemble the Salt Spray Atomiser and test once again (5). (5) 61 Day 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 62 Gravity /Specific of Salt Solution Concentration % (µs) Conductivity Water of Fallout /hour) pH (ml/80cm² (Bar) Fallout Pressure Air Temp (C) Air Saturator Temp (C) Chamber 4.3 Sample Daily Check Sheet Daily Checks for Month:…………………………… 4.4 Fault Finding We hope that the ownership of your Ascott corrosion chamber is problem free. But it should be noted that corrosion chambers do benefit form routine servicing and maintenance. Please contact your distributor for details. Additional Technical Support can be found by logging on line to Ascott’s Chamber Doctor Application. Access is free during the warranty period of the chamber. Further access can be obtained by contacting Ascott Technical Support. Access to Chamber Doctor is gained by entering the password & login details given on the technical support card, provided. http://www.ascottanalytical.com/support_card.htm Silver and Gold Technical support packages, can also be purchased for remote technical support, providing direct access to an Ascott engineer after the warranty period has expired. Please contact Ascott Technical Support for assistance on Tel: +44 1827 318040 or Fax +44 1827 318049 63 Part 5 - Optional Accessories Manual (If Ordered) 64
