Salt Spray manual

Salt Spray Test
Chamber Models:
S120/450/1000/2000iS
Ascott Analytical Equipment Limited,
Unit 6 Gerard, Lichfield Road Industrial Estate,
Tamworth, Staffs. B79 7UW Great Britain
Telephone: +44 (0) 1827 318040 Fax: +44 (0) 1827 318049
E-Mail: info@ascott-analytical.com Website: www.ascott-analytical.com
1
FILE NOTE
A COPY OF THIS INSTRUCTION MANUAL HAS
BEEN SENT WITH THE CHAMBER
Instruction Manual iS Issue - L
Issue
Date First
Issued
- March 2015
Description Of Amendments
A
Nov 2009
Original Issue ( Draft)
B
Aug 2010
Change to H&S Statement
C
June 2011
Multiple updates to specification
D
June 2011
Test mode reference added
F
June 2012
CE updates
G
October 2013
General Updates
H
February 2014
Updated contents page, layout.
I
March 2014
Updated Layout, pictures and Headers
J
March 2014
Updated Layout, Pictures and tables.
K
June 2014
Updated Atomiser Pictures, tables and Air saturator drain.
L
March 2015
Updated Layout & services quality warning added
2
Contents
Contents ......................................................................................................................................... 3
Introduction - General Description of machine operation..................................................... 7
Part 1 -
Health & Safety ........................................................................................................... 8
1.1
Health and Safety Policy ................................................................................................8
1.2
Transport and Lifting ......................................................................................................13
Part 2 -
Installation .................................................................................................................. 14
2.1
Operating Environment ................................................................................................14
2.2
Positioning .......................................................................................................................15
2.3
External Services ............................................................................................................16
2.4
Part 3 -
2.3.1
Electrical Supply............................................................................................. 17
2.3.2
Compressed Air Supply ................................................................................. 18
2.3.3
De-ionised Water Supply .............................................................................. 18
2.3.4
Salt Solution Reservoir .................................................................................... 19
2.3.5
Condensate Drain ......................................................................................... 20
2.3.6
Exhaust Vent to Atmosphere ....................................................................... 22
2.3.7
Air Saturator Drain.......................................................................................... 23
Atomiser Set up ..............................................................................................................24
Operation .................................................................................................................. 26
3.1
Human Machine Interface (HMI) Screen ...................................................................26
3.2
Initial Power Up...............................................................................................................27
3.3
3.2.1
Contact Details .............................................................................................. 27
3.2.2
Chamber Information ................................................................................... 28
3.2.3
Run Screen...................................................................................................... 28
Run Screen......................................................................................................................29
3
3.4
3.5
3.3.1
Stopped / Running ........................................................................................ 29
3.3.2
Starting/Stopping a test ................................................................................ 30
3.3.3
Test Mode ....................................................................................................... 30
3.3.4
Canopy ........................................................................................................... 31
Run Mode .......................................................................................................................34
3.4.1
Chamber Temperature Display ................................................................... 34
3.4.2
Air Saturator Temperature Display .............................................................. 35
3.4.3
Hours Run Display........................................................................................... 35
Setup Mode ....................................................................................................................36
3.5.1
Time to stop .................................................................................................... 36
3.5.2
Hours Run – Reset ........................................................................................... 38
3.5.3
Air Saturator (Moist air / Dry Air) ................................................................... 38
3.5.4
Pump Speed(s) .............................................................................................. 39
3.5.5
Chamber Temperature Set point ................................................................ 42
3.5.6
Air Saturator Temperature Setpoint ............................................................ 43
3.6
Alarm Status....................................................................................................................44
3.7
Control ............................................................................................................................45
3.8
3.9
3.7.1
Emergency Stop ............................................................................................ 45
3.7.2
Mains Isolator .................................................................................................. 45
3.7.3
Air Pressure Gauge & Regulator .................................................................. 46
3.7.4
Flow Meter(s) & Peristaltic Pump(s) ............................................................. 47
Setting Up Procedure ....................................................................................................48
3.8.1
Determine the test parameters ................................................................... 48
3.8.2
Set up chamber ............................................................................................. 49
3.8.3
Set the Salt Fog Fallout Rate ........................................................................ 51
Shut down procedure: ..................................................................................................52
4
Part 4 4.1
4.2
Care & Maintenance............................................................................................... 53
Routine Maintenance ...................................................................................................53
4.1.1
Daily Checks................................................................................................... 53
4.1.2
Weekly Maintenance.................................................................................... 54
4.1.3
Three–Monthly Maintenance ....................................................................... 57
4.1.4
After Use .......................................................................................................... 58
Unscheduled Maintenance .........................................................................................59
4.2.1
Storage & Contamination ............................................................................ 59
4.2.2
Deionised Water Inlet Filter ........................................................................... 59
4.2.3
Clean or Unblock Salt Spray Atomiser ........................................................ 60
4.3
Sample Daily Check Sheet...........................................................................................62
4.4
Fault Finding ...................................................................................................................63
Part 5 -
Optional Accessories Manual (If Ordered) ........................................................... 64
5
Attention!
Please read the enclosed instruction manual before
connecting this chamber to its external service utilities and
attempting to use it.
This chamber has been despatched with its air saturator emptied of water in order
to reduce weight. As a consequence, when power is first applied, the HMI display
will default to an alarm condition, with an audible alarm sounding:
Whilst the HMI is displaying the above, pressing;
MUTE - mutes the audible alarm.
RESET - resets the alarm*
* Note: The alarm can be silenced, but it will not be possible to reset the alarm
until the actual alarm condition has been cleared. This will require the air
saturator to be filled with water; this will happen automatically if the chamber is
connected to a de-ionised water supply.
6
Introduction - General Description of
machine operation
The Salt Spray test (also known as a salt fog or salt mist) has been the benchmark
corrosion test in many industries for decades
The Ascott Salt Spray chambers (iS) meet the requirements of basic, continuous salt
spray tests conducted at a single temperature only, such as ASTM B117 and similar
international test standards, and may be used with pH neutral salt solutions (NSS) or
those acidified by the addition of Acetic Acid (ASS) or Cupric Acid (CASS).
7
Part 1 - Health & Safety
1.1 Health and Safety Policy
The manufacturer is required to ensure, for reasons of Health and Safety at Work that, as
far as is reasonably practicable, the articles which we design, produce and supply are
as safe as possible and of minimal risk to health.
We are required to provide information on the safety and handling precautions to be
observed when installing, operating and maintaining our product. Such advice is
contained in this manual.
We should also like to point out, however that you as users have an important responsibility
in the provision and maintenance of safe working practices and conditions.
Accordingly we draw to your attention the following matters:
i. This apparatus should only be used as intended and within its design parameters by
suitably qualified and trained personnel who have read and understood the relevant
sections of this manual.
ii This manual should be readily available to such personnel at all times.
iii In addition to that which is written in the manual, normal common-sense safety
precautions must be taken at all times to avoid the possibility of accidents.
ivInstallation, maintenance and connection to electrical supplies should only be carried
out by suitably trained personnel.
We would recommend that users produce their own risk assessment for the entire
testing process for which this apparatus will be used.
The normal operation noise levels for the chamber are shown below and if they exceed
these parameters then there is a problem with the chamber. Please obtain advise from
your local agent / distributor or Ascott themselves to ascertain problem. Some
accessories may deviate from these levels.
Warning! - connecting an Ascott chamber to poor quality external service utilities (ie;
water and compressed air) and/or a failure to maintain Ascott products regularly in
accordance with Ascott recommended maintenance procedures, could lead to a
catastrophic and potentially dangerous failure of the product safety systems.
8
Declared Dual-Number Noise Declaration
Manufacturer
Ascott Analytical Equipment Ltd
Type
Cyclic Corrosion Test Chambers (CC1000iP)
Declared Dual Number Noise Emission Values according to EN ISO
4871
A-Weighted Emission Sound Pressure Level at the Work Station
Measured value Lpa in decibels
51.59
Uncertainty Kpa in decibels
1.50
A-Weighted Emission Sound Power Level
Measured Value Lwa in
Decibels
69.02
Uncertainty Kwa in decibels
1.50
The determination, declaration and verification of airborne noise emission
have been carried out in accordance with EN 14462 as required within
clause 5.5.2 (Noise reduction at source at the design stage) of EN129211:2005+A1:2010
Values determined according to the noise test code EN 14462 using the basic
standards EN ISO 11201 (Grade 2) and EN ISO 3744.
9
Training is available if required. Please contact Ascott or your Agent / Distributor for
more details.
No specific PPE is required during standard operation of the chamber as the chamber is
designed to purge the atmosphere before opening the canopy to the chamber
working area. Some accessories may require PPE to be worn. All accessories that utilise
sub-zero temperatures will require gloves to be worn when handling anything inside the
chamber. Accessory ACC46 – SO2 testing facility must follow the instructions for the
accessory as the atmosphere and bi products can be extremely hazardous.
Under no circumstances should anyone be inside the chamber during operation or
exposed to the corrosive atmosphere of the chamber. All leaks must be reported and
repaired. Chamber must be isolated immediately if any atmosphere or water leaks are
detected.
No structural changes or fitting of customers own tools / accessories without first
contacting Ascott or its associates.
In the event of a breakdown consult Ascott or its associates immediately as further
damage to the chamber and / or personnel may occur.
Ascott chambers will have the following
safety labels attached to the side panel
work.
Warning people of potential
Electric shock.
Warning people of hot water, confined space and sharp edges.
10
The control panel also has two labels to identify the Air Pressure Gauge for the chamber
and the regulator for the air Supply.
Denotes Pressure Gauge
Denotes Pressure Regulator
11
Inside the control compartment the earthing point of the chamber is clearly identified
with the following symbol
12
1.2 Transport and Lifting
Lifting of the chamber should only be done with a fork truck and lifted using the
designated lifting points at the rear of the chamber. The lifting points are identified with
the following logos.
When transporting the chamber ensure it is locked and strapped into position preferably
chocked up off the castors using the chassis frame. No loads are to be put on the top.
Drains must be emptied before loading.
13
Part 2 - Installation
CAUTION
THE EQUIPMENT SHOULD ONLY BE INSTALLED BY SUITABLY QUALIFIED
PERSONNEL. DAMAGE CAUSED DUE TO INCORRECT INSTALLATION WILL
NOT BE COVERED BY THE WARRANTY.
2.1 Operating Environment
This equipment is designed for internal use only, in an environment controlled to within
the following limits:-
Ambient Temperature:+18 to +23°C (no icing)
Note: The minimum operating temperature of the chamber will depend directly upon the
actual ambient temperature of the environment in which it is located .
Ambient Humidity:45 to 85% RH (no condensation)
14
2.2 Positioning
Move the Salt Spray Test Chamber into position as shown:
Chamber
The rear castors can be locked when the chamber has been
positioned.
15
2.3 External Services
Note:All hoses and pipes up to 3 metres (10ft) in length, and the power cable are supplied
with the chamber.
Electricity – single phase with neutral
& earth.
Compressed air – 12.5 mm (½”) bore
hose
Salt Water – 3 mm (1/8”) bore hose
(to separate salt solution reservoir)
Water – 12.5 mm (½”) bore hose
16
2.3.1
Electrical Supply
We recommend this equipment is connected to an electrical supply protected
by a residual current device (earth leakage circuit breaker). Before connecting
this equipment to an electrical supply, check the information given on the
equipment rating plate and ensure that:

Your supply voltage is of the correct frequency.

Your supply voltage is the correct type (three phase or Single phase
depending on model)

Your supply voltage is within the stated range.

The current rating is within the capacity of your supply outlet.

Your plug or outlet circuit is suitably fused.
WARNING: THIS APPARATUS MUST BE EARTHED
17
A rotary electrical isolator switch is
mounted in a prominent position on the
chamber. This isolates the chamber
from the incoming electrical supply (live
and neutral) when the switch is rotated
to the '0' position, and can be
padlocked in this position if required.
The electrical supply is connected when
this switch is rotated to the '1' position.
2.3.2
Compressed Air Supply
Note:The compressed air supply must be clean, dry (a cohesive dryer of grade 2
which will give 3 microns cleanliness) and oil free. It must have a minimum pressure of
4.0 bar (57 psi) and a maximum pressure of 6.0 bar (87 psi). Between these pressures,
the flow rate should be at least 75 litres per minute (2.6 cubic feet per minute)
equating to a free flow at atmospheric pressure of approximately 102 standard litres
per minute (3.6 standard cubic feet per minute).
Connect the 12.5 mm bore air hose supplied, between the air inlet at the rear of the
chamber and the compressed air supply. (See above).
2.3.3
De-ionised Water Supply
Note: The de-ionised water supply must have a minimum pressure of 0.5 bar (7PSI) and
a maximum of 5 bar (72PSI).
Connect the 12.5 mm bore water hose supplied, between the two water inlet hose
connections at the rear of the chamber and the de-ionised water supply. (See above).
18
2.3.4
Salt Solution Reservoir
Position the Salt Solution Reservoir to the left of the chamber.
Salt Solution Reservoir – The side wall
has a hole to allow the salt solution
hose to pass through.
Salt solution inlet hose
120L
Only
Feed the end of the 6 mm salt solution hose that is fitted with a filter, into the Salt
Solution Reservoir ensuring that the filter unit lies at the bottom of the reservoir.
19
2.3.5
Condensate Drain
Drain – 22 mm (7/8”) diameter pipe
Connect the 22 mm diameter push-fit pipe to the rear of the chamber
Connect the other end to the service drain.
20
2.3.5.1
Manual Base Drain
Drains the chamber completely.
With the tap handle in the vertical
(closed) position, salt fog
condensate will accumulate in the
chamber base to a predetermined
level, before draining to waste. This
assists in maintaining a high humidity
during testing, and is the correct
position for most continuous salt
spray tests.
With the tap handle in the horizontal
(open) position, salt fog condensate
will drain away. This drains the
chamber interior for cleaning.
21
2.3.6
Exhaust Vent to Atmosphere
Exhaust –50mm (2”) diameter pipe
for all iS chambers.
Connect the exhaust pipe provided to the exhaust outlet to the rear of the chamber.
If the length of the vent pipe route is greater than 5 metres, a larger diameter pipe may
be required.
Route the other end to outside atmosphere, maintaining a straight run-up or run-down
to avoid sags where condensate may collect and cause backpressure.
22
2.3.7
Air Saturator Drain
Air Saturator Drain
Do not connect anything to the Air
Saturator Drain; it is provided for
maintenance purposes only.
To drain when required:
Set the chamber to salt spray mode with
the air saturator ‘switched off’. Then use a
flat bladed screwdriver to open the drain
tap.
(See section- Running a program / Air saturator mode)
Note: If chambers are left unused for any length of time it is recommended that the air saturator
is drained to prevent the build up of algae which could cause system blockages or of bacteria
which might present a potential health risk.
To drain when required:
Reduce the air pressure on the
control panel to zero. Then use a flat
blade screwdriver to open the drain
tap.
23
2.4 Atomiser Set up
On 450L/1000L & 2000L chambers, the atomiser is mounted in a PVC holder located on
the rear wall of the chamber. It is locked into position using plastic thumbscrews.
Position and lock the atomiser so that when atomising, the spray impacts in the centre
of the inside of the canopy viewing window when the canopy is closed. This position
can be adjusted to achieve even fallout results during salt spray testing.
24
On 120L chambers, the atomiser is mounted in a PVC holder located on a sideways
moveable mount. Position the atomiser so that when atomising, the spray impacts in
the sealing gasket between the canopy and the GRP chamber, when the canopy is
closed. This position can be adjusted left to right to achieve even fallout results during
salt spray testing.
Note: Please see the care and maintenance section for details of how to remove and maintain
the atomiser.
25
Part 3 - Operation
3.1 Human Machine Interface (HMI) Screen
The chamber control system utilises a Human Machine Interface (HMI) screen mounted
in the chamber control panel. This operates in conjunction with a Programmable Logic
Controller (PLC) mounted within the chamber. The HMI screen is touch sensitive and
uses ‘virtual’ push buttons for the selection of various functions.
Display
LCD screen with backlight.
The HMI screen uses a menu driven format, where functions are selected from a
variety of ‘pop-up’ screens. The
through the screens.
buttons are used to navigate
26
3.2 Initial Power Up
When the chamber is first switched on; after a few moments, the following
screens will be displayed in sequence.
3.2.1
Contact Details
Ascott Main Menu Page:
Press the
buttons to scroll between screens.
After a few moments the screen will display the chamber information screen.
27
3.2.2
Chamber Information
This screen displays three
pieces of information required
by an Ascott engineer if
contact with Ascott is to be
made. They are:
Chamber serial number, PLC
software revision number and
HMI software revision number.
Press the
buttons to scroll between
screens.
After a few moments the screen will display the Run screen.
3.2.3
Run Screen
After a few moments the
screen will move on to display
the Run Screen.
Press the
buttons to scroll between
screens.
28
3.3 Run Screen
Once the start sequence has completed the screen will display the Run
Screen.
The Run Screen displays the
current status of the chamber.
The canopy can also be
opened from this page.
3.3.1
Stopped / Running
The Run Screen displays the
current status of the chamber.
The chamber will be either
STOPPED or RUNNING.
The canopy can also be
opened from this page.
29
3.3.2
Starting/Stopping a test
Press
to start a test.
(Hours run counter starts)
Press
to stop a test.
(Hours run counter pauses)
3.3.3
Test Mode
If you start a test with the canopy open, the chamber will enter ‘test
mode’. It will start spraying but will not apply any heat to the chamber. It
will stop automatically after 5 minutes.
The screen will revert to the
normal run screen after a short
time.
30
3.3.4
Canopy
Chambers are fitted with a pneumatically operated canopy that opens and closes at
the press of a button on the HMI.
The chamber must be connected to a suitable compressed air supply before the
canopy will open/close.
To open the Canopy:
From the Run Screen press
If no test has been started the
canopy can be opened
immediately by pressing
An alarm will sound for a few
seconds and the canopy will
open automatically.
31
If a test has been started the
chamber will need to go through
a purge cycle to remove salt fog.
An alarm will sound for a few
seconds and the canopy will
open.
Once the purge has completed
the canopy can be opened by
pressing
An alarm will sound for a few
seconds and the canopy will
open automatically.
Once the canopy is open, the chamber can be operated in ‘test mode’ for
five minutes. No heat is applied.
32
If the chamber is RUNNING a test
and you press
, the
screen will display this message
and will continue testing. The
screen will revert to the run
screen after a few seconds.
To close the Canopy:
From the Run Screen, press
Note: If you run a test with the
canopy open, no heat is applied
but the spray atomiser
To close the canopy press and
hold
Keep pressing until the alarm
stops.
33
3.4 Run Mode
The chamber has two operating modes; Setup and Run:
Run mode allows the user to view the current status of the chamber.
When in Setup mode, the
change to Run mode.
button is displayed to allow you to
When in Run mode, the
button is displayed in many of the menu
screens to allow you to change to Setup mode.
When in Setup mode, press
Press the
to change to Run mode.
buttons to scroll through the various Run screens.
Note: Values cannot be adjusted when the chamber is in Run Mode
3.4.1
Chamber Temperature Display
When in Run Mode the
setpoint and actual values for
chamber temperature are
displayed.
34
No adjustment can be made
3.4.2
Air Saturator Temperature Display
When in Run Mode the set
point and actual values for air
saturator temperature are
displayed.
No adjustment can be made
3.4.3
Hours Run Display
When in Run Mode the hours
set, run and remaining are
35
displayed.
No adjustment can be made
3.5 Setup Mode
Setup mode allows the user to change the chamber parameters.
To enter the Setup mode press
Press the
screens.
3.5.1
buttons to scroll through the various settings
Time to stop
The chamber can be set to run a test for a predetermined length of time
using the Time to Stop facility. The maximum value for this is 999.9 hrs.
36
If the value 999.9 hrs is selected, the chamber will continue to run without
stopping and the hours run counter will rise accordingly.
To adjust the value press
A key pad will appear.
Type in the number required.
Press
to confirm
Press
to escape without
making changes.
Once the test is started, the hours run timer will increase. Once the timer
reaches the Time to Stop value the test will stop automatically.
If you wish to start a new test
you must reset the hours run
counter.
Press
37
to exit to the
run screen immediately.
After a short period the screen
will revert to the run screen
automatically.
3.5.2
Hours Run – Reset
To reset the counter to 0000.0,
press
3.5.3
Air Saturator (Moist air / Dry Air)
In the ‘Moist air’ mode of operation, compressed air for the salt spray
atomiser is bubbled through the chamber air saturator to apply heat and
38
moisture. This is the factory set condition, since this is a requirement of
most salt spray test standards.
Note: The chamber will automatically revert to this mode whenever the chamber power
is switched off and back on again.
The current selection is shown
in the centre of the display.
To change press
3.5.4
or
Pump Speed(s)
The peristaltic pump is used to control the flow of salt solution to the
atomiser.
39
To adjust the value press
A key pad will appear.
Type in the number required.
Press
to confirm
Press
to escape without
making changes.
2000L chambers have two peristaltic pump motors. Pump 1 on the left,
pump 2 on the right.
Press the
button to scroll to the second pump setting.
40
To adjust the value press
A key pad will appear.
Type in the number required.
Press
to confirm
Press
to escape without
making changes.
41
3.5.5
Chamber Temperature Set point
To adjust the value press
(Maximum 50C)
A key pad will appear.
Type in the number required.
Press
to confirm
Press
to escape without
making changes.
42
3.5.6
Air Saturator Temperature Setpoint
To adjust the value press
(Maximum 63C)
A key pad will appear.
Type in the number required.
Press
to confirm
Press
to escape without
making changes.
43
3.6 Alarm Status
The chamber has a number of inbuilt alarms that will indicate the nature of a potential
problem. An alarm buzzer will sound and the screen will be backlit with a red lamp. The
nature of the alarm will be displayed.
Press
to silence the
alarm. The screen will return to
the run page. If the ‘fault’ is still
present the alarm will re-occur
after a few seconds.
Press
to reset the alarm
condition once the cause of the
alarm has been investigated and
cleared.
See section 5 regarding care and maintenance
44
3.7 Control
3.7.1
Emergency Stop
Pressing the chamber emergency
stop button during canopy opening
or closing will ‘freeze’ the canopy in
its current position.
An audible alarm sounds. When the emergency stop button is returned to its normal
position, the HMI screen will return to the canopy Open/Close screen.
3.7.2
Mains Isolator
Isolates the chamber from the
electricity supply.
45
3.7.3
Air Pressure Gauge & Regulator
Air Pressure Gauge and Regulator
These indicate and control the pressure of the compressed air supply to
the atomiser(s).
They will only operate when air is supplied to the atomisers.
To adjust the air pressure:
(i).
Pull out the regulator knob to unlock.
(ii).
Rotate anticlockwise to decrease the pressure and clockwise to
increase it.
(iii).
Push in the regulator knob to lock.
46
3.7.4
Flow Meter(s) & Peristaltic Pump(s)
Flow meters and Peristaltic
pumps
(2000L- pictured)
450L and 1000L chambers are fitted with one flow meter and one peristaltic
pump. 2000L chambers are fitted with two flow meters, and two peristaltic
pumps, one of each for each atomiser. The flow meter(s) monitor the flow rate
of salt solution from the reservoir to the atomiser(s). The peristaltic pump(s) draw
salt solution from the reservoir and pass it to the atomiser(s).
47
3.8 Setting Up Procedure
3.8.1
Determine the test parameters
(i).
Salt Spray Test to be performed.
(ii).
Composition of the salt solution.
(iii).
Atomiser air, dry/moist, heated/unheated.
(iv).
Salt fog fall out rate.
(v).
Test duration.
48
3.8.2
Set up chamber
(i).
Ensure mains isolator is ON.
(ii).
Load the test samples into the chamber.
(iii).
Prepare the salt solution and transfer it to the salt solution reservoir.
(iv).
Ensure that the salt solution reservoir is connected to the chamber.
(v).
For 120L chambers, fill the integral salt solution reservoir:
(vi).
Ensure that the drain and exhaust are connected and not blocked.
(vii).
Load required test program.
(viii). If pre-humidification of the atomiser air is required and the chamber
is not connected to a pressurised supply of deionised water for
automatic filling of the Air Saturator, and a manual fill facility has
been provided instead (optional accessory), then fill the Air
Saturator manually as follows:
49
(xi)
Depressurise the air saturator by selecting dry air within the global
settings page.
(xii)
Open the hand operated ball valve at the manual filler port by
rotating it fully anti-clockwise.
(xiii)
Insert a funnel into the open orifice of the manual filler port and
slowly fill with deionised or distilled water.
(xiv)
Stop filling when high water lamp on the side of the chamber
illuminates.
(xv)Remove the funnel and close the ball valve
(xvi)Reselect moist air within the global settings page.
(i).
Run the loaded test program.
(ii).
Adjust the pressure regulator and/or the salt solution flow rate to
give the required salt fog fall-out rate.
50
3.8.3
Set the Salt Fog Fallout Rate
(Usually carried out in advance of testing of components)
The method for measuring the Salt Fog Fallout Rate is specified as being a
100 mm-diameter funnel in conjunction with a measuring cylinder
graduated in millilitres. This procedure is used to collect salt fog fallout at
various points across the chamber workspace (no closer than 100 mm
from the chamber walls or atomiser) for set periods of time.
From these measurements the average fog fallout rate and the spread of
the fog throughout the chamber can be determined.
Generally, the spread of the fog within the chamber is controlled by the
air pressure, and the density of the fog is controlled by the salt solution
flow rate.
With the atomiser positioned centrally in the chamber, increasing the air
pressure will tend to increase the salt fog fallout at the extremes of the
chamber, whilst decreasing the air pressure will tend to increase the
fallout in the centre of the chamber.
Increasing the salt solution flow rate will increase the salt fog fallout at any
point in the chamber, whilst decreasing the flow rate will reduce the
fallout at any point.
51
Only very small adjustments to the air pressure and flow rate should be
made at any one time, before rechecking the results.
(i).
Set the air pressure to 1.4 bar (20 psi).
(ii).
Set the initial flow rate so that the peak flow is approximately 10 to
15 ml/min. The ball in the flow meter will fluctuate up and down with
every half revolution of the peristaltic pump.
(iii).
Adjust the air pressure to obtain an even spread of fog within the
chamber, regardless of the actual amount of fallout collected.
(iv).
Adjust the flow rate to bring the fallout within the limits specified in
the test standard.
(v).
Recheck the spread of the fog and repeat operations iii and iv
above until satisfactory.
3.9 Shut down procedure:
(i).
Stop any running programs.
(ii).
Switch electrical isolator to OFF.
52
Part 4 - Care & Maintenance
4.1 Routine Maintenance
Routine maintenance is essential to keep the chamber in good working order.
The following maintenance is recommended for a chamber that is in regular use.
4.1.1
Daily Checks
Record chamber variable parameters on the Daily Check Sheet. A sample Daily Check
Sheet is provided at the end of this manual.
Ensure that corrosion waste or small samples are not gathering in the base of the
chamber. This can lead to blockages within the drain system and will affect chamber
performance.
Contamination may also lead to changes in corrosivity within the chamber that could
affect test results!
Ensure that the drain is clear.
Ensure that the chamber exhaust is clear and is not restricted.
Check that deionised water supply is within specification.
53
4.1.2
4.1.2.1
Weekly Maintenance
Consumables kit
Ascott Ref. No.: ACC12/1
A kit of consumables parts is available for Ascott salt spray and cyclic corrosion
test chambers. These contain user replaceable items sufficient for up to 1 year.
1m x PERC012 – Silicone Tube
2pk x SALC010 - Salt Filter Wadding
1pk x ELEC690 - Cable Ties
ATOA110 - Atomiser air in luer fitting
assembly
ATOA120 - Atomiser salt in luer fitting
assembly
SALC012 - Salt Filter Housing Tube
54
4.1.2.2
Maintenance of Atomiser
Atomiser ‘salt in’
Luer fitting
assembly
Atomiser Body & filter
spacer
Salt Solution Inlet
Hose
Salt solution Filter
Housing (filter fitted)
Compressed Air Inlet
Hose & Atomiser ‘air in’
Luer fitting assembly
Atomiser Cap
Plastic spacer
Atomiser Nozzle
1) Check that the chamber service connections are secure and are not leaking.
2) Switch off the power supply to the chamber.
3) Withdraw the atomiser and filter assembly from its support, taking care not to
damage the two hose connections.
4) Check the salt solution filter material for discoloration.
5) Disconnect the compressed air inlet hose (BLACK) by rotating the collar of the ‘air in’
fitting assembly anti clockwise.
6) Unscrew the atomiser body and cap as a complete assembly, from the salt solution
filter housing. If the atomiser and cap are dirty or have been giving poor fallout
7) Withdraw the salt solution filter material from the salt solution filter housing using
tweezers.
8) Wash the filter material in warm water and mild detergent.
9) If the filter material is badly contaminated or damaged, discard it and replace it with
new filter material.
55
10) Reassemble the salt solution filter.
Roll the filter material into a cylindrical shape
and insert into the filter housing (1&2).
(1)
(2)
Screw the atomiser body, nozzle and cap
onto the filter housing ensuring Re-attach the
compressed air inlet hose (3).
Refit the atomiser and filter assembly onto its
mount.
Switch on the power supply to the chamber.
3)
56
4.1.3
Three–Monthly Maintenance
Change the silicone rubber tube of the peristaltic pump every three months or earlier if
it splits or becomes deformed with usage.
Replace the tube as follows:
Switch off the chamber.
Release the two clamps that hold the silicone rubber
tube in the pump body (1).
(1)
Pull gently on end of silicone rubber tube, whilst
turning the pump roller clockwise by hand, to
withdraw the tube from the pump (2).
Unscrew the cap of the plastic compression fitting
on both ends of the silicone tube (3).
Pull the two silicone tube ends out of the
compression fittings and retain the olive and cap for
re-use.
(2)
Cut a length of new silicone rubber tubing to exactly
the same length as the original tubing and fit the
compression fitting cap and olive to each end.
Reconnect one end of the new tube to the left
compression fitting.
(3)
Place the tube into the left clamp (4)
Whilst turning the pump roller clockwise by hand,
feed the pipe under the pump roller mechanism
until the whole length has been drawn correctly into
the pump. Ensure that the tube is not twisted or
stretched, and lies naturally in the pump.
(4)
Clamp the other end of the new tube into the right
57
clamp (5).
Reconnect the remaining end of the new tube to
the right compression fitting (6).
(5)
Restart pump, and release right clamp for a few
minutes to allow the silicone rubber tubing to find its
natural position.
(6)
4.1.4
After Use
Remove corrosion waste and any dropped components by scooping out. Do not flush
down the drain as this will lead to blockages.
Clean the chamber interior and canopy by washing with warm water and mild
detergent.
If the chamber is not going to be used for a period of one week or longer, refer to
‘unscheduled maintenance’ section of this manual.
58
4.2 Unscheduled Maintenance
4.2.1
Storage & Contamination
If the chamber is to stand unused for a period of more than one week, or if
contamination by algae growth is detected in the salt solution reservoir, the following
procedure is recommended:

Switch off the chamber.

Drain the air saturator (refer to section 3.7).

Discard any salt solution remaining in the reservoir.

Clean the reservoir thoroughly.

Partly fill the reservoir with a biocidal sterilising agent solution and replace the salt
filter housing in the reservoir.

Switch on the chamber and run it in the Salt Spray mode of operation for
approximately five minutes, with the canopy closed. This will flush all the salt
solution hoses and fittings with the sterilising agent.

Switch off the chamber and leave to stand until required for use.

Discard the sterilising agent and clean the tank thoroughly.

Refill the reservoir with salt water and run for approximately five minutes to flush
any remaining sterilising agent.
4.2.2
Deionised Water Inlet Filter
Detach deionised water supply hose from the bulkhead fitting at the rear of the
chamber.
Withdraw the wire mesh filter from inside the bulkhead fitting.
Scrub the filter clean with a brush under running water, or replace the filter.
Re-insert the filter into the bulkhead fitting.
Reconnect the deionised water supply.
59
4.2.3
Clean or Unblock Salt Spray Atomiser
Atomiser ‘salt in’
Luer fitting assembly
Atomiser Body & filter
spacer
Salt Solution Inlet
Hose
Salt solution Filter
Housing (filter fitted)
Compressed Air Inlet Hose
& Atomiser ‘air in’ Luer
fitting assembly
Atomiser Cap
Plastic spacer
Atomiser Nozzle
Open the chamber canopy
Switch off the power supply to the chamber.
Withdraw the atomiser and filter assembly
from its support, taking care not to damage
the two hoses.
Detach the compressed air inlet Hose (1).
(1)
Unscrew the atomiser cap (2).
Wash the atomiser cap in warm running
water.
60
Unscrew the atomiser body, nozzle and cap
from the salt solution filter housing.
Wash the atomiser body and nozzle in warm
running water.
(2)
(3)
If the nozzle is blocked, clear the obstruction
by operating the chamber (canopy open)
and place atomiser assembly, without the
filter attached, into a cup of clean water (3).
Water should be drawn through the atomiser
to create a spray.
Place finger over atomiser outlet to blow
air/water back through the atomiser,
clearing any obstruction (4).
Only if this does not work should the atomiser
cone be cleaned with a fine wire.
(4)
Take care not to damage the cone!
Reassemble the Salt Spray Atomiser and test
once again (5).
(5)
61
Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
62
Gravity
/Specific
of Salt Solution
Concentration
%
(µs)
Conductivity
Water
of Fallout
/hour)
pH
(ml/80cm²
(Bar)
Fallout
Pressure
Air
Temp (C)
Air Saturator
Temp (C)
Chamber
4.3 Sample Daily Check Sheet
Daily Checks for Month:……………………………
4.4 Fault Finding
We hope that the ownership of your Ascott corrosion chamber is problem free. But it
should be noted that corrosion chambers do benefit form routine servicing and
maintenance. Please contact your distributor for details.
Additional Technical Support can be found by logging on line to Ascott’s Chamber
Doctor Application. Access is free during the warranty period of the chamber. Further
access can be obtained by contacting Ascott Technical Support.
Access to Chamber Doctor is
gained by entering the password
& login details given on the
technical support card, provided.
http://www.ascottanalytical.com/support_card.htm
Silver and Gold Technical support packages, can also be purchased for remote
technical support, providing direct access to an Ascott engineer after the warranty
period has expired. Please contact Ascott Technical Support for assistance on Tel: +44
1827 318040 or Fax +44 1827 318049
63
Part 5 - Optional Accessories Manual
(If Ordered)
64