Cyclic Corrosion Test Chamber Models:

Transcription

1 Cyclic Corrosion Test Chamber Models: CC450/1000/1300/2000/2600iP Instruction Manual CCiP Issue R Ascott Analytical Equipment Limited, 6-8 Gerard, Lichfield Road Industrial Estate, Tamworth, Staffs. B79 7UW Great Britain Telephone: +44 (0) Fax: +44 (0) info@ascott-analytical.com Website: 1

2 Contents Contents 2 Introduction - General Description of machine operation 5 Part 1 - Health & Safety 6 Health and Safety Policy 6 Transport and Lifting 10 Part 2- Installation Operating Environment Positioning External Services Electrical Supply Compressed Air Supply De-ionised Water Supply Salt Solution Reservoir Condensate Drain Exhaust Vent to Atmosphere Air Saturator Drain Atomiser Set up 18 Part 3 - Operation Human Machine Interface (HMI) Screen Initial Power Up Ascott Main Menu Contact Details Language User Access Help Settings Supervisor Mode Set Password Set Holdback Set Air Saturator Temp Set Pump speeds (Vertical) Liquid Immersion Manual Liquid Transfer Set Pump Speeds (Multi Solution Spray) Spot Cooler Setup Set Purge Time Disable Alarm Sounder Calibration Set Ramping Power Fail Recovery Set Test Type Air Saturator Fill Method Set Background Colour Set Chamber IP Address Set Test Sample Test Agenda 39 2

3 PLC Monitor Enable Ambient Air drying Program Menu Program Delete Program View Program Edit Saving/Cancelling an Edited Program Example CCT Program Running a Program View Running Program Step Number Step Function Step Temperature Step Time Step Humidity Program Run Time Canopy Program Load Program Run Program Stop Program Pause Program Fast Forward Run Settings Interior Illumination (Optional Accessory ref: ACC26) Trending Total Chamber Hours Run Base Drain Air Saturator Mode Message Bar Alarm Status Control Emergency Stop Mains Isolator Air Pressure Gauge & Regulator Flow Meter(s) & Peristaltic Pump(s) Ethernet Communications Port Setting up Procedure Determine the test parameters Set up chamber Set the Salt Fog Fallout Rate Shut down procedure: 92 Part 4 Care & Maintenance Routine Maintenance Daily Checks Weekly Maintenance Three Monthly Maintenance After Use Unscheduled Maintenance Storage & Contamination 100 3

4 4.2.2 Deionised Water Inlet Filter Clean or Unblock Salt Spray Atomiser Sample Daily Check Sheet Fault Finding & problem solving Cyclic Corrosion Chamber Exploded View CC450IP Control Compartment (Base Plate) CC450IP Control Compartment CC450IP Service Panels (Rear External) CC450IP Service Panel (Rear Internal) CC450IP Rear Ascott Chamber CC1000IP Control Compartment (Base Plate) CC1000IP Control Compartment CC1000IP Services Panels (Rear External) CC1000IP Services Panel (Rear Internal) CC1000IP Rear Ascott Chamber CC1300IP Control Compartment (Base Plate) CC1300IP Control compartment CC1300IP Service Panels (Rear External) CC1300IP Service Panels (Rear Internal) CC1300IP Rear Ascott Chamber CC2000IP Control Compartment (Base Plate) CC2000IP Control Compartment CC2000IP Service Panels (Rear External) CC2000IP Services Panels (Rear Internal) CC2000IP Rear Ascott Chamber CC2600IP Control Compartment CC2600IP Front Ascott Chamber CC2600IP Services Panels (Rear External) CC2600IP Service Panels (Rear Internal) CC2600IP Rear Ascott Chamber Air Saturators (Welded fabrication) CC450ip, CC1000ip and CC1300ip CC2000ip and CC2600ip Air Saturators (Glass fabrication) CC450ip, CC1000ip and CC1300ip CC2000ip and CC2600ip 139 Part 5 Optional Accessories 142 4

5 Introduction - General Description of machine operation The Ascott cyclic chamber is used for a means of recreating/accelerating a variety of corrosive climates within the convenience of an enclosed test facility. It is used for predicting the life expectancy of materials and components under simulated service life conditions. As standard it comes with the ability to create 4 distinct climates Salt Spray, Condensation Humidity (wetting), Air Drying and controlled humidity which may be programmed to occur in any sequence and repeated automatically. Programming and operation is done via a touch screen interface on the control panel. The chamber should only be used for its intended purpose any deviation from its standard use will require consultation with Ascott. 5

6 Part 1 - Health & Safety 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. 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. Training is available if required. Please contact Ascott or your Agent / Distributor for more details. 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. Declared Dual-Number Noise Declaration 6

7 Manufacturer Type Ascott Analytical Equipment Ltd 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 Uncertainty Kpa in decibels 1.50 A-Weighted Emission Sound Power Level Measured Value Lwa in Decibels Uncertainty Kwa in decibels 1.50 The determination, declaration and verification of air borne noise emission have been carried out in accordance with EN as required within clause (Noise reduction at source at the design stage) of EN :2005+A1:2010. Values determined according to the noise test code EN using the basic standards EN ISO (Grade 2) and EN ISO

8 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. water, confined space and sharp edges. Warning people of hot 8

9 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 Inside the control compartment the earth point of the chamber is clearly identified with the following symbol 9

10 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. 10

11 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:- 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) 2.2 Positioning Move the Cyclic Corrosion Test Chamber into position on a clear, clean stable, level floor as shown: 11

12 Chamber The rear castors can be locked when the chamber has been positioned. 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. Humidity Generator Water Inlet (De-ionised Water) 12.5 mm (½ ) bore hose 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 12

13 Resettable thermal over-current trip switches Salt solution inlet 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) Electrical Supply 13

14 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 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 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) De-ionised Water Supply 14

15 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) 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. 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 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. 15

16 Figure 1Ensure drainage flows down and away from the chamber to ensure consistent performance Exhaust Vent to Atmosphere Exhaust 110mm (4½ ) diameter pipe for all CCT 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 must be installed. 16

17 Route the other end to outside atmosphere, maintaining a straight run-up or rundown to avoid sags where condensate may collect and cause backpressure 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) 17

18 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 which is located on the rear left of the chamber. 2.4 Atomiser Set up Atomiser positioned in mounting holder 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 18

19 viewing window when the canopy is closed. This position can be adjusted 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. 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. 19

20 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. 3.2 Initial Power Up Ascott Main Menu Note: When power is first applied, the air inlet fan(s) may operate for a few minutes. This is a normal feature. When the chamber is first switched on, after a few moments, the following page will be displayed. 20

21 Ascott Main Menu Page: When operating the chamber, repeatedly touch the button to return to the Ascott Main Menu page Contact Details To access the chamber serial number, PLC/ HMI software revision numbers and for Ascott contact details; touch the touch the logo. 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: 21

22 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 Supervisor. Supervisor mode allows access to an additional chamber settings menu. 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: 22

23 In the Settings Menu, all of the test chamber settable parameters can be viewed and adjusted. See Settings-Supervisor Mode below for details of these parameters. 3.5 Help Touching opens up the help pages. Follow the guidance on the screen. 3.6 Settings Supervisor Mode The button will only be visible if the correct access code has been input. See Access, above. Note: In each Settings page touch supervisor Settings Menu. to save the setting and exit back to the 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: 23

24 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. 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 Descriptions for typical settings follow Set Password 24

25 Touching brings up the following page: 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) 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 automatic temperature cycling, then 25

26 the programmed step times might easily be exceeded due to the effect of holdback 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 Set Pump speeds (Vertical) 26

27 Note: If this chamber has been fitted with a Multi-Solution Salt Spray Facility (Optional accessory ref.: ACC86) then the instructions that follow for setting the Pump Speed(s) will change. Please refer to the supplementary instructions, which will have been provided in the optional accessories section at the back of this manual. 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 bring up one of the two following pages: button will 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 Liquid Immersion Manual Liquid Transfer 27

28 Note: This setting only applies to chambers fitted with the Liquid Immersion facility (optional accessory ref.: ACC34). These buttons are inactive when this mode of operation is running within a program. Please refer to the supplementary instructions, which will have been provided in the optional accessories section at the back of this manual. Touching the button will bring up the following page: Touching the button pumps the immersion liquid from the holding tank to the chamber. Touching the button pumps the immersion liquid from the chamber to the holding tank. Touching the button stops the pump from pumping the liquid to the chamber or to the tank Set Pump Speeds (Multi Solution Spray) Note: This setting only applies to chambers fitted with the Multi Solution Spray Facility (optional accessory ref; ACC86). Please refer to the supplementary instructions, which will have been provided in the optional accessories section at the back of this manual. Pump speed(s) are adjustable from 0-99%. Increasing pump speed will increase the salt spray fallout rates collected inside the chamber, Touching the button will bring up the following page: 28

29 Depending on the size of chamber and the optional accessory fitted, a page similar to the one shown here will be displayed. All the pumps fitted can be independently set by touching the set value to show a numeric touch pad, and then the new value can be entered. Touch to save the settings and exit back to the supervisor Settings Menu. Press the button to scroll down to settings page Spot Cooler Setup Note: This setting only applies to chambers fitted with the Output Signal to Remote Air cooling/dehumidification Unit facility (optional accessory ref.: ACC80). Please refer to the supplementary instructions, which will have been provided in the optional accessories section at the back of this manual. Touching the button displays the following page. The values for humidity and temperature below which the remote air cooling/ dehumidification unit is required to operate can be adjusted by the user. Set by touching the display value to open a numeric touch pad, and then a new value can be entered. Touch to save the settings and exit back to the supervisor Settings Menu. 29

30 3.6.8 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 (optional accessory). It is factory set to 0 seconds and can be adjusted by using the numeric key pad. Touch to save the settings and exit back to the supervisor Settings Menu. Note: Users may decide that if a Wetting or Cooling 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 Cooling phase begins. 30

31 3.6.9 Disable Alarm Sounder Touching the button will bring up the following page: 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 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: 31

32 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. Liquid Immersion (Fn6) temperature can be offset by adding or subtracting C to the displayed value (result) by touching the buttons to display a numeric key pad. 32

33 Set Ramping Touching the button will bring up the following page: 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 and/or humidity 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. 33

34 Power Fail Recovery Touching the button will bring up either of the following pages, depending on how the chamber has been set up: 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. 34

35 Set Test Type WARNING! It is important that the following procedure is complied with to prevent damage to the humidity sensor. 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 brings up a menu with the following 4 choices; Select the most appropriate choice for the type of testing to be undertaken. All but Neutral Salt Spray (NSS) testing will activate the air curtain. The humidity display icon changes to show when this is active. It is the manufacturer s recommendation that the Air Curtain is used whenever salt spray testing is used and the display of relative humidity value is not required. 35

36 Air Saturator Fill Method Note: This setting only applies to chambers fitted with the Manual Filling Air Saturator Option (optional accessory ref.: ACC66). Please refer to the supplementary instructions, which will have been provided in the optional accessories section at the back of this manual. Touching the button will bring up the following page. 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. 36

37 Open the hand operated ball valve at the manual filler port by rotating it fully anticlockwise. Insert a funnel into the open orifice of the manual filler port and slowly fill with deionised or distilled water. Stop filling when the Air Saturator Full indicator illuminates. Remove the funnel and close the ball valve Reselect moist air testing at the HMI 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. 37

38 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 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 1 st digit, right dial for 2 nd digit) As changes are made, the display above will also change. Adjust this to suit your PLC NODE Number. 38

39 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. 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 39

40 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. Inputs and outputs will illuminate with an orange background when they are active 40

41 Enable Ambient Air drying It is possible to program the chamber canopy to open automatically during a test profile. This allows the samples within the chamber to dry under laboratory ambient conditions. When this mode is selected, the user can determine the duration that the canopy will remain open. An automatic purge of 7 minutes will take place before the canopy opens. This is not included in the test duration. The movement of the canopy to OPEN is included in the duration set by the user. Canopy closing time is not included in the duration but only takes a few seconds to complete. CAUTION: It should be noted that during this mode the canopy will open and close without the user being present. Care must be taken to avoid any possibility of injury. For safety reasons, creating programs with this function can be disabled by the supervisor of the chamber within the settings menu. Pressing the button will reveal the following screen: Touching brings up a second grey screen AMBIENT DRYING WARNING. Touching the YES button will allow this function to operate. Touching the NO button will return to the previous screen. 41

42 Touching the YES button will allow this function to operate. Touching the NO button will return to the previous screen. When this function is disabled new programs cannot be created with this function, however any existing programs can be loaded and run. 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. 42

43 3.7.1 Program Delete Touching opens up the following page: From this page the user can choose whether to delete a main, sub 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. 43

44 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 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. 44

45 From this page the user can choose whether to view a main, sub or single line program. Touching brings up the following page: Scroll through the list of programs using the buttons. Highlight the program to be viewed by touching the corresponding button. i.e.. This will cause the program number to flash. Touch to display the page shown below. 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, up to 7 steps for sub programs, and up to 30 steps for main programs. For main and sub programs, the view is spread over more than 1 page, which can be scrolled through by touching the buttons. Main programs and Single programs can be selected and viewed in the same way as detailed above. 45

46 3.7.3 Program Edit Touching opens up the following page: From this page the user can choose to edit a main, sub or single line program. The differences between the program types are detailed below. 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: 46

47 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 Sub A sub program is constructed in exactly the same way as described for a main program but with fewer steps. The purpose of a sub program is to create a sub routine that can be incorporated into a main program. For example, a part of a main program might require a function to be repetitively cycled between 2 different temperatures many times. This cycle could be programmed separately as a sub program which is then incorporated into a main program. This will then simplify the programming of the main program. Up to 10 sub programs, each comprising of up to 7 separate steps can be stored. Touching opens 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. 47

48 These pages list the 10 sub programs, by number (S1-S10) and by name (if named), spread over 2 screen pages, which can be scrolled through by touching the page up/down arrows. Touching the program number (or name) of the program to be edited/viewed/deleted, will cause its program number to flash, confirming that it has been selected. iii) 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: 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. 48

49 Open Program Once a program type has been selected, touching edit page opens the following page: in any program 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: 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. 49

50 Step Number A step is an individual programmable segment of a program. A main program can be made of up to 30 steps. A sub program can be made of up to 7 steps. A single program is made from a single step. All programs start at step number 1. Scroll through the program steps using the buttons located beneath the current step number until the required step number is displayed Mode The function required to be run in each program step is displayed inside the button. Touching the button within the button brings up the following page: 50

51 If editing function choices. these are the step 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. If editing or these are the step function choices. Note: The page displayed in this table represents a chamber with various optional accessories fitted. The buttons actually displayed will depend upon which options have been fitted to the chamber. Note that is missing. (Sub programs cannot be inserted into a single program. 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. 51

52 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. Note: If this chamber has been fitted with a Multi-Solution Salt Spray Facility (Optional accessory ref.: ACC86) then these instructions for Salt Spray Vertically Up will change. Please refer to the supplementary instructions, which will have been provided at the back of this manual, if this facility has been fitted. 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. 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 +70C. 52

53 iv) Condensation Humidity / Wetting At the start of this function, the base drain automatically opens to allow any liquid accumulated to drain away. The chamber then 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. The chamber air temperature is adjustable from ambient up to +60C. v) Controlled Humidity At the start of this function, the base drain automatically opens to allow any liquid accumulated to drain away. The chamber then 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. Heat is also generated using external heaters bonded to the chamber walls. The temperature/ relative humidity envelope achievable in this mode is ambient up to +60C/90%RH. vi) Wall Wash (Optional Accessory ref: ACC42) If this optional accessory is fitted; during this mode of operation, the chamber walls are automatically washed down with fresh water, sprayed on to them by the water dispersion system located around the walls of the test space. The chamber air temperature and relative humidity are not controlled during this mode of operation. 53

54 vii) Salt Spray Vertically Down (Optional Accessory ref: ACC30) If this optional accessory is fitted; during this mode of operation, salt solution is sprayed vertically downwards from salt spray nozzles located at high level inside the chamber. The chamber air temperature and relative humidity are not controlled during this mode of operation. viii) Liquid Immersion (Optional Accessory ref: ACC34) If this optional accessory is fitted; during this mode of operation the chamber will be automatically filled with liquid pumped from a separate holding tank up to a predetermined level. Any test samples loaded inside the chamber below this level will be immersed in liquid. During this mode of operation, temperature control within the chamber changes from air temperature control, to control the temperature of the immersion liquid. The chamber relative humidity is not controlled during this mode of operation. The chamber temperature is adjustable from ambient up to +50C ix) Cooling with Humidity Control (Optional Accessory ref: ACC29/Special) If this accessory is fitted; during this mode of operation the chamber air is automatically circulated to and from a remote Air Temperature Conditioning Unit (ATCU). The ATCU can refrigerate the chamber air temperature to 20C/-40C (depending on specification) and it can heat the air up to +60C. Above +10C the relative humidity can be controlled between 25~98%RH. 54

55 Important Note ACC29 and ACC29/Special: Whilst the chamber is in the cooling mode of operation, certain precautions need to be taken due to the possibility of moisture/water freezing inside the chamber. Some precautions are taken care of automatically by the chamber control system; some are the responsibility of the user. A summary of these precautions follows: Automatic Precautions The chamber will automatically purge for a pre-set period of time before commencing a cooling cycle. The peristaltic pump will automatically run in reverse for a pre-set period of time before commencing a cooling cycle. The chamber base will automatically be drained of any water/condensate. For as long as the chamber actual temperature (PV) is below a temperature of 10ºC, the chamber will automatically ensure the following: The peristaltic pump will not run forwards. The chamber heating power will be limited. The chamber base will not fill with water. The Wall Wash function will not operate. The Salt Spray function will not operate. The Liquid Immersion function will not operate. Also, if any of the above funtions are programmed to occur whilst the chamber is below 10ºC, a warning will appear in the HMI and the program will be put on hold until the temperature exceeds 10ºC, when the program will resume running again. User Precautions: No attempt should be made to open the chamber below a temperature of 10ºC. No program should be written that would attempt to override any of the above automatic precautions. Program steps that are programmed to occur after a cooling cycle, should take into account the time the chamber will take to rise above the 10ºC safety threshold, below which many chamber functions are automatically inhibited. 55

56 x) Salt Spray and Sulphur Dioxide (Optional Accessory ref: ACC46) 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. xi) 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. xii) Ambient Air Drying (Automatic opening canopy) It is possible to program the chamber canopy to open automatically during a test profile. This allows the samples within the chamber to dry under laboratory ambient conditions. When this mode is selected, the user can determine the duration that the canopy will remain open. 56

57 An automatic purge of 7 minutes will take place before the canopy opens. This is not included in the test duration. The movement of the canopy to OPEN is included in the duration set by the user. Canopy closing time is not included in the duration but only takes a few seconds to complete. CAUTION: It should be noted that during this mode the canopy will open and close without the user being present. Care must be taken to avoid any possibility of injury. When the automatic canopy mode is selected warning screens will advise the user that if operated, the canopy will open and close automatically. This screen appears when the program is created and loaded. In each instance the user must accept by pressing When the program is started, a final warning screen appears: 57

58 Pressing acknowledges that the user has understood the warning and the test will start. Pressing will revert the page back to the run page. The chamber will give an audible alarm before and during the movement of the canopy. A warning screen will also be displayed on the HMI. ix) Sub Programs If selected, any 1 of the 10 available sub programs will be active (S1-S10) during this step of the program (applies to main programs only). 58

59 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 can be entered and saved. brings up a numeric key pad where larger values 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. 59

60 Step Relative Humidity Set Value (If Applicable) This is the target set value for relative humidity to be achieved at the end of the step time, for this particular step. Touching the buttons of the button increases/ decreases the set value for relative humidity by 1%, each time the button(s) are touched. Alternatively, for large value changes, touching the button will bring up a numeric keypad where larger values can be entered and saved Saving/Cancelling an Edited Program Once a program has been edited, pressing page: brings up the following On this page, the number of required program repeats (see below) can be set, and the program can be saved or cancelled 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. 60

61 For main programs, this is used to select the number of times an entire program is to be repeated. For sub programs, this will determine the number of times the sub program is repeated within a main program. 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 brings up a numeric key pad where values can be entered Save Touching saves an edited program under its current program number 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 start to flash confirming its selection; touch to save the program under this program number. 61

62 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 Example CCT Program This example program is provided to assist the user in understanding the programming technique. It is portrayed graphically, as follows, together with step by step programming instruction on how to create it. Note: Since some program step changes are required to occur linearly over time, then ramping must be set to on (within supervisor settings) for the following program. Humidity - % RH

63 Most of the time, touching the button in any page will usually escape back to the previously displayed page. At other times, it will save the entered information and index forward to the next page. The example program can be created using the following procedure: Touch the button. Enter system log-on password (originally set to 1234). Touch the button. Touch the button. Touch the button. Touch the program number to be programmed, so that it flashes, then touch the button to open the following page: This page shows individual program step settings. 63

64 Touch to open the program title edit page, enter the program title using the key pad, and press to save. Now you will be presented with the first program step to be edited. If this program has not been used before, the first step defaults to and a step time of 0 hours & 0 minutes. If this program has been used before, the first step will contain the previously programmed step data. At any time, before saving an edited programmed, it is possible to index through and edit each of the program steps (1-30 for main programs). To do this touch the buttons beneath the current step number display. For the creation of the example program we will start at step number 1. (Program Step 1:) Note: This phase of the example program requires the temperature to change as quickly as possible (within 30 minutes if possible), with no control over the rate of change of temperature, but with the total exposure time controlled. To do this, this phase is programmed as 2 separate steps. Each step is programmed with the Standard Salt Spray function selected. The first step changes the set temperature to 35C as quickly as possible. To do this, a step time of 1 minute is selected (1 minute step times are special rapid step, during which the temperature will change as quickly as possible). The second step maintains the set temperature at 35C for 1 hour & 59 minutes (to allow the actual chamber temperature to catch up and stabilise). The total exposure time will therefore be 2 hours. Touching within the button, which will take you to the Function / Sub program selection page. Touch the button to select standard Salt Spray. Touch within the button to enter the required value for 64

65 Temperature at the end of step 1. Alternatively, for small value changes touch the buttons instead. For the example program this is set to 35.0ºC. Touch within the button to enter the step time required for step 1. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 1 minute. (Program Step 2:) Index on to step 2 by touching the display. buttons beneath the current step number Touching within the button, which will take you to the Function / Sub program selection page. Touch the button to select standard Salt Spray. Touch within the button to enter the required value for temperature at the end of step 2. Alternatively, for small value changes touch the instead. buttons For the example program this is set to 35.0ºC. Touch within the button to enter the step time required for step 2. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 1 hour & 59 minutes. 65

66 (Program Step 3:) Note: The next phase of the example program requires the temperature and humidity to change at a controlled rate, with the total exposure time also controlled. To do this, this phase is programmed as 3 separate steps. Each step is programmed with the Controlled Humidity function selected. The first step changes the set temperature to 60C and the set humidity to 50% RH in 30 minutes. The second step maintains the set temperature at 60C, but further changes the set humidity to 20% RH in 30 minutes. The third step maintains the set temperature at 60C and maintains the set humidity at 20% RH for 3 hours. The total exposure time will therefore be 4 hours. Index on to step 3 by touching the display. buttons beneath the current step number Touching within the button, which will take you to the Function / Sub program selection page. Touch the button to select Controlled Humidity. Touch within the button to enter the required value for temperature at the end of step 3. Alternatively, for small value changes touch the instead. buttons For the example program this is set to 60.0ºC. Touch within the button to enter the step time required for step 3. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 30 minutes. 66

67 Touch within the button to enter the required value for relative humidity at the end of step 3. Alternatively, for small value changes, touch the buttons instead. For the example program this is set to 50% RH. (Program Step 4:) Index on to step 4 by touching the display. buttons beneath the current step number Touching within the button, which will take you to the Function / Sub program selection page. Touch the button to select Controlled Humidity. Touch within the button to enter the required value for temperature at the end of step 4. Alternatively, for small value changes touch the instead. buttons For the example program this is set to 60.0ºC. Touch within the button to enter the step time required for step 4. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 30 minutes. 67

68 Touch within the button to enter the required value for relative humidity at the end of step 4. Alternatively, for small value changes touch the buttons instead. For the example program this is set to 20% RH. (Program Step 5:) Index on to step 5 by touching the display. buttons beneath the current step number Touching within the button, which will take you to the Function / Sub program selection page. Touch the button to select Controlled Humidity. Touch within the button to enter the required value for temperature at the end of step 5. Alternatively, for small value changes touch the instead. buttons For the example program this is set to 60.0ºC. Touch within the button to enter the step time required for step 5. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 3 hours. 68

69 Touch within the button to enter the required value for relative humidity at the end of step 5. Alternatively, for small value changes touch the buttons instead. For the example program this is set to 20% RH. (Program Step 6:) Index on to step 6 by touching the display. buttons beneath the current step number Note: The next phase of the example program requires both the temperature and humidity to change as quickly as possible (within 30 minutes if possible), with no control over the rate of change of temperature, but with the total exposure time controlled. This is a special phase. To achieve a fast transition to 50C/95% RH from 60C/20% RH (the conditions at the end of the previous phase), it is necessary to use the Controlled Humidity function during the transition period, and then follow this with the Controlled Humidity function for the remaining steady state conditioning period at 50C/95% RH. (Note that this is an example program and that this may not be possible in some instances without a refrigeration accessory) To do this, this phase is programmed in 2 separate steps. The first step changes the set temperature to 50C and the set humidity to 95% RH in 1 minute (a quick step time). The second step maintains the set temperature at 50C and the set humidity at 95% RH for 1 hour and 59 minutes. Touching within the button, which will take you to the Function / Sub program selection page. Touch the button to select Controlled Humidity. 69

70 Touch within the button to enter the required value for temperature at the end of step 6. Alternatively, for small value changes touch the instead. buttons For the example program this is set to 50.0ºC. Touch within the button to enter the step time required for step 6. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 1 minute. Touch within the button to enter the required value for relative humidity at the end of step 6. Alternatively, for small value changes touch the buttons instead. For the example program this is set to 95% RH. (Program Step 7:) Index on to step 7 by touching the display. buttons beneath the current step number Touching within the button, which will take you to the Function / Sub program selection page. 70

71 Touch the button to select Controlled Humidity. Touch within the button to enter the required value for temperature at the end of step 7. Alternatively, for small value changes touch the instead. buttons For the example program this is set to 50.0ºC. Touch within the button to enter the step time required for step 7. Alternatively, for small value changes touch the buttons instead. For the example program, this is set to 1 hour & 59 minutes. Touch within the button to enter the required value for relative humidity at the end of step 7. Alternatively, for small value changes touch the buttons instead. For the example program this is set to 95% RH. (Program Steps 8-30:) The example program is now complete, apart from entering the number of times it is to be repeated. To ensure that the program ends at the end of step 7, index through steps 8-30 by touching the buttons beneath the current step number display, and check/change the functions to OFF and the step times to 0 hours & 0 minutes. Touch the button to escape from the program edit page, this takes you to the page for selecting the number of program repeats. 71

72 Touching brings up a numeric key pad where values can be entered. For the example program, this is set to 9 repeats. Touch the button to save the program under the current program number location. Touch the button if you have edited an existing program and want to save it under a new program number location. Note: Before running the above program, refer to the appropriate section in this instruction manual, and check/adjust the global Settings as required. These are accessed via the settings menu and run page. 72

73 3.9 Running a Program Touch the button to return to the Main Menu page 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. 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. 73

74 3.9.1 View Running Program Touching the screen in this area currently loaded. allows the user to view the program that is Scroll through the program using the buttons. Touch to return to the Run page 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 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 Step Temperature 74

75 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 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 Step Humidity This shows the humidity set value (SV) and the humidity 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. Note: This will only appear if the step function is a humidity step Program Run Time 75

76 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 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. 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 or will close this page. 76

77 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 or will close this page. 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 or will close this page. 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. 77

78 3.9.9 Program Load Touching opens the following page: Here the 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. 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. 78

79 Once a program has been selected press page. the page will revert to the Run 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 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 button also zero s the Program Run Time counter. 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. 79

80 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 Program Pause 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 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. 80

81 Run Settings Touching the button brings up the Run Settings page. 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. Touching this button will reveal the timings for the user programmable change over contact, if fitted. Note: If fitted, further instructions on programming this will be given in Part 5: Optional Accessories section at the back of this manual 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. 81

82 Trending This facility allows the user to monitor the chamber temperature and relative humidity against time, graphically. 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. 82

83 Total Chamber Hours Run Touching the button brings up the following display. This will display the total number of hours the chamber has run and cannot be reset Base Drain Touching the button brings up the following page: The current status of the drain is displayed. Touch to close the drain. Touch to open the drain. When is active, the chamber base will partially fill with condensate/water in certain modes of operation. This is the factory set condition, since this is used to generate high humidity conditions during certain modes of operation. 83

84 Setting the chamber base to allow the chamber to drain of any condensate for maintenance and cleaning purposes. This is also the correct mode for testing to ASTM G85 annex A5. If the chamber is left in the mode; the chamber will automatically close the drain if test functions require it. Once this function is complete, the drain will open once again. The should be set to ON for most tests. It should be set to OFF for SWAAT testing, where the base of the chamber should not empty between salt spray and humidity cycles 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 (Moist Air) or inactive (Dry Air). 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. 84

85 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 when the air saturator is active and will display when it is inactive 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. 85

86 Alarm Status 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). 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. 86

87 3.10 Control 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 Mains Isolator Isolates the chamber from the electricity supply Air Pressure Gauge & Regulator 87

88 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 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). 88

89 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) Setting up Procedure Determine the test parameters Cyclic Corrosion Test to be performed. Composition of the salt solution. Atomiser air, dry/moist, heated/unheated. Salt fog fall out rate. Test duration/number of cycles Set up chamber 89

90 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. 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. 90

91 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 mmdiameter 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. 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 between 12 18psi 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. 91

92 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. Recheck the spread of the fog and repeat operations iii and iv above until satisfactory Shut down procedure: Stop any running programs. Switch electrical isolator to OFF. Turn off water supply Turn off air supply 92

93 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 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 Weekly Maintenance Consumables kit Ascott Ref. No.: ACC12/1 93

94 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 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 Salt Solution Inlet Hose Salt solution Filter Housing (filter fitted) Plastic spacer Atomiser Nozzle 94

95 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. (1) Roll the filter material into a cylindrical shape and insert into the filter housing (1&2). (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) 95

96 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. Check that the float switch is clean and operates freely. Cleaning with a soft brush can be carried out carefully 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. 96

97 WEEKLY PROCEDURE For cleaning the humidity sensor cap: Protective plastic sheath removed to reveal entire humidity sensor probe. 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! 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 97

98 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 fitted 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. 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 gas. 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 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 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. 98

99 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) (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. Clamp the other end of the new tube into the right clamp (5). 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) 99

100 (6) 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. 4.2 Unscheduled Maintenance 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 2.3.7). 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. 100

101 Refill the reservoir with salt water and run for approximately five minutes to flush any remaining sterilising agent 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 Clean or Unblock Salt Spray Atomiser Atomiser salt in Luer fitting assembly Atomiser Body & filter spacer Compressed Air Inlet Hose & Atomiser air in Luer fitting assembly Atomiser Cap Salt Solution Inlet Hose Salt solution Filter Housing (filter fitted) Plastic spacer Atomiser Nozzle 101

102 Open the chamber canopy (1) 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. (2) Unscrew the atomiser body, nozzle and cap from the salt solution filter housing. Wash the atomiser body and nozzle in warm running water. (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). (4) 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). (5) 102

103 4.3 Sample Daily Check Sheet Daily Checks for Month: Day Chamber Temp ( C) Air Saturator Temp ( C) Air Pressure (Bar) Fallout (ml/80cm² /hour) ph of Fallout Water Conductivity (µs) % Concentration of Salt Solution /Specific 103

104 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: or Fax

105 4.5 Cyclic Corrosion Chamber Exploded View CC450IP Control Compartment (Base Plate) No41) If the chamber has ACC29, ACC34 or ACC112 it has PNEA

106 4.5.1 CC450IP Control Compartment No44) If 480V chamber it has ELEC012 and ELEC014 not ELEC

107 4.5.1 CC450IP Service Panels (Rear External) 107

108 4.5.1 CC450IP Service Panel (Rear Internal) 108

109 4.5.1 CC450IP Rear Ascott Chamber 109

110 4.5.1 CC1000IP Control Compartment (Base Plate) No16) If the chamber has ACC29, ACC34 or ACC112 it has PNEA

111 4.5.2 CC1000IP Control Compartment No44) If 200V or 480V chamber it has ELEC012 and ELEC014 not ELEC

112 4.5.2 CC1000IP Services Panels (Rear External) 112

113 4.5.2 CC1000IP Services Panel (Rear Internal) 113

114 4.5.2 CC1000IP Rear Ascott Chamber 114

115 4.5.3 CC1300IP Control Compartment (Base Plate) No16) If chamber has ACC29, ACC34 or ACC112 it has PNEA

116 4.5.3 CC1300IP Control compartment No39) If 200v or 480v chamber use ELEC012 and ELEC014 not ELEC

117 4.5.3 CC1300IP Service Panels (Rear External) 117

118 4.5.3 CC1300IP Service Panels (Rear Internal) 118

119 4.5.3 CC1300IP Rear Ascott Chamber 119

120 4.5.4 CC2000IP Control Compartment (Base Plate) No63) If chamber has ACC29, ACC34 or ACC112 it has PNEA

121 4.5.4 CC2000IP Control Compartment No39) If 200v or 480v chamber use ELEC012 and ELEC014 not ELEC

122 4.5.4 CC2000IP Service Panels (Rear External) 122

123 4.5.4 CC2000IP Services Panels (Rear Internal) 123

124 4.5.4 CC2000IP Rear Ascott Chamber 124

125 4.5.5 CC2600IP Control Compartment No16) If chamber has ACC29, ACC29 OR ACC112 it has PNEA

126 4.5.5 CC2600IP Front Ascott Chamber No44) If it is a 200v or 480v chamber is has ELEC012 and ELEC014 not ELEC

127 4.5.5 CC2600IP Services Panels (Rear External) 127

128 4.5.5 CC2600IP Service Panels (Rear Internal) 128

129 4.5.5 CC2600IP Rear Ascott Chamber 129

130 4.6 Air Saturators (Welded fabrication) CC450ip, CC1000ip and CC1300ip 130

131 131

132 132

133 4.6.2 CC2000ip and CC2600ip 133

134 134

135 135

136 4.7 Air Saturators (Glass fabrication) CC450ip, CC1000ip and CC1300ip 136

137 137

138 138

139 4.7.2 CC2000ip and CC2600ip 139

140 140