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Chamber Models:
S120/450/1000/1300/2000/2600IS
Instruction Manual IS Issue - P
Telephone: +44 (0) 1827 318040 Fax: +44 (0) 1827 318049
1
Contents
Contents ____________________________________________________________________ 2
Introduction - General Description of machine operation _____________________________ 5
Part 1 - Health & Safety _____________________________________________________ 6
1.1 Health and Safety Policy _______________________________________________________ 6
1.2 Transport and Lifting ________________________________________________________ 11
2
3.5.1 Time to stop_______________________________________________________________________ 35
3.5.2 Hours Run – Reset __________________________________________________________________ 37
3.5.3 Air Saturator (Moist air / Dry Air) ______________________________________________________ 37
3.5.4 Pump Speed(s)_____________________________________________________________________ 38
3.5.5 Chamber Temperature Set point ______________________________________________________ 39
3.5.6 Air Saturator Temperature Setpoint____________________________________________________ 40
3.7 Control____________________________________________________________________ 42
3.7.1 Emergency Stop____________________________________________________________________ 42
3.7.2 Mains Isolator _____________________________________________________________________ 42
3.7.3 Air Pressure Gauge & Regulator _______________________________________________________ 43
3.7.4 Flow Meter(s) & Peristaltic Pump(s) ____________________________________________________ 44
3
4.5.3 S1000is Rear Ascott Chamber ___________________________________________________________ 72
4.5.3 S2000is Control Compartment (Base Plate) ________________________________________________ 73
4.5.3 S2000is Front Ascott Chamber __________________________________________________________ 74
4.5.3 S2000is Services Panel (Rear External) ____________________________________________________ 75
4.5.3 S2000is Services Panels (Rear Internal) ___________________________________________________ 76
4.5.3 S2000is Rear Ascott Chamber ___________________________________________________________ 77
4
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).
5
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 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.
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.
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.
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.
6
Declared Dual-Number Noise Declaration
Values determined according to the noise test code EN 14462 using the basic
standards EN ISO 11201 (Grade 2) and EN ISO 3744.
7
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.
8
The control panel also has two labels to identify the Air Pressure Gauge for the chamber
and the regulator for the air Supply.
9
Inside the control compartment the earthing point of the chamber is clearly identified
with the following symbol
10
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.
11
Part 2 - Installation
CAUTION
This equipment is designed for internal use only, in an environment controlled to within
the following limits:-
Note: The minimum operating temperature of the chamber will depend directly upon the
actual ambient temperature of the environment in which it is located.
12
2.2 Positioning
Chamber
The rear castors can be locked when the chamber has been
positioned.
13
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.
14
2.3.1 Electrical Supply
• Your supply voltage is the correct type (three phase or Single phase
depending on model)
15
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.
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).
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).
16
2.3.4 Salt Solution Reservoir
120L
17
For 120 Litre chambers, an external
reservoir can be used in place of the
internal reservoir
18
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
2.3.5.1 Manual Base Drain
20
2.3.6 Exhaust Vent to Atmosphere
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.
21
2.3.7 Air Saturator Drain
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.
22
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.
23
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.
24
Part 3 - Operation
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
The HMI screen uses a menu driven format, where functions are selected from a
25
3.2 Initial Power Up
When the chamber is first switched on; after a few moments, the following
screens will be displayed in sequence.
Press the
buttons to scroll between screens.
After a few moments the screen will display the chamber information screen.
26
3.2.2 Chamber Information
Press the
buttons to scroll between
screens.
After a few moments the screen will display the Run screen.
Press the
buttons to scroll between
screens.
27
3.3 Run Screen
Once the start sequence has completed the screen will display the Run
Screen.
28
3.3.2 Starting/Stopping a test
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.
29
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.
30
If a test has been started the
chamber will need to go through
a purge cycle to remove salt fog.
Once the canopy is open, the chamber can be operated in ‘test mode’ for
five minutes. No heat is applied.
31
If the chamber is RUNNING a test
hold
32
3.4 Run Mode
Run mode allows the user to view the current status of the chamber.
33
3.4.2 Air Saturator Temperature Display
34
3.5 Setup Mode
Setup mode allows the user to change the chamber parameters.
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.
If the value 999.9 hrs is selected, the chamber will continue to run without
stopping and the hours run counter will rise accordingly.
35
To adjust the value press
Press to confirm
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.
36
3.5.2 Hours Run – Reset
press
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
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.
To change press or
37
3.5.4 Pump Speed(s)
The peristaltic pump is used to control the flow of salt solution to the
atomiser.
Press to confirm
2000L chambers have two peristaltic pump motors. Pump 1 on the left,
pump 2 on the right.
38
To adjust the value press
Press to confirm
(Maximum 50C)
39
Type in the number required.
Press to confirm
(Maximum 63C)
Press to confirm
40
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.
41
3.7 Control
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.
42
3.7.3 Air Pressure Gauge & Regulator
These indicate and control the pressure of the compressed air supply to
the atomiser(s).
43
3.7.4 Flow Meter(s) & Peristaltic Pump(s)
(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).
44
3.8 Setting Up Procedure
45
3.8.2 Set up 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.
46
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.
(ix). Adjust the pressure regulator and/or the salt solution flow rate to give
the required salt fog fall-out rate.
47
3.8.3 Set the Salt Fog Fallout Rate
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.
Only very small adjustments to the air pressure and flow rate should be
made at any one time, before rechecking the results.
48
(i). Set the air pressure to between 12 and 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.
(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.
49
Part 4 - Care & Maintenance
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!
50
4.1.2.1 Consumables kit
1m x PERC012 – Silicone Tube 2pk x SALC010 - Salt Filter Wadding 1pk x ELEC690 - Cable Ties
ATOA110 - Atomiser air in luer fitting ATOA120 - Atomiser salt in luer fitting SALC012 - Salt Filter Housing Tube
assembly assembly
51
4.1.2.2 Maintenance of Atomiser
Atomiser ‘salt in’ Atomiser Body & filter Compressed Air Inlet
Luer fitting spacer Hose & Atomiser ‘air in’
assembly Luer fitting assembly Atomiser Cap
1) Check that the chamber service connections are secure and are not leaking.
3) Withdraw the atomiser and filter assembly from its support, taking care not to
damage the two hose connections.
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.
9) If the filter material is badly contaminated or damaged, discard it and replace it with
new filter material.
52
Roll the filter material into a cylindrical shape
and insert into the filter housing (1&2).
(1)
Screw the atomiser body, nozzle and cap
onto the filter housing ensuring Re-attach the
compressed air inlet hose (3).
3)
53
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.
(4) Clamp the other end of the new tube into the right
54
clamp (5).
(6)
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.
55
4.2 Unscheduled Maintenance
(v). Partly fill the reservoir with a biocidal sterilising agent solution and replace the salt
filter housing in the reservoir.
(vi).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.
(vii).Switch off the chamber and leave to stand until required for use.
(ix).Refill the reservoir with salt water and run for approximately five minutes to flush
any remaining sterilising agent.
(i). Detach deionised water supply hose from the bulkhead fitting at the rear of the
chamber.
(ii). Withdraw the wire mesh filter from inside the bulkhead fitting.
(iii).Scrub the filter clean with a brush under running water, or replace the filter.
(iv).Re-insert the filter into the bulkhead fitting.
(v). Reconnect the deionised water supply.
56
4.2.3 Clean or Unblock Salt Spray Atomiser
Atomiser ‘salt in’ Atomiser Body & filter Compressed Air Inlet Hose Atomiser Cap
Luer fitting assembly spacer & Atomiser ‘air in’ Luer
fitting assembly
57
from the salt solution filter housing.
(4)
(5)
58
9
8
7
6
5
4
3
2
1
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
Day
Chamber
Temp (°C)
Air Saturator
Temp (°C)
Air
Pressure
(Bar)
59
Daily Checks for Month:……………………………
Fallout
(ml/80cm²
/hour)
4.3 Sample Daily Check Sheet
pH
of Fallout
Water
Conductivity
(µs)
%
Concentration
of Salt Solution
/Specific
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.
http://www.ascott-
analytical.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
60
4.5 Salt Spray Chamber Exploded Views
4.5.1 S120is Control Compartment (Base Plate)
61
4.5.1 S120is Front Ascott Chamber
62
4.5.1 S120is Rear Ascott Chamber
63
4.5.2 S450is Control Compartment (Base Plate)
64
4.5.2 S450is Front Ascott Chamber
65
4.5.2 S450is Services Panels (Rear External)
66
4.5.2 S450is Service Panels (Rear Internal)
67
4.5.3 S1000is Control Compartment (Base Plate)
68
4.5.3 S1000is Front Ascott Chamber
69
4.5.3 S1000is Services Panels (Rear External)
70
4.5.3 S1000is Services Panels (Rear Internal)
71
4.5.3 S1000is Rear Ascott Chamber
72
4.5.3 S2000is Control Compartment (Base Plate)
73
4.5.3 S2000is Front Ascott Chamber
74
4.5.3 S2000is Services Panel (Rear External)
75
4.5.3 S2000is Services Panels (Rear Internal)
76
4.5.3 S2000is Rear Ascott Chamber
77
4.6 Salt Spray Chamber Exploded Views
4.6.1 S120is Air Saturator
78
79
80
4.6.2 S450is, S1000is and S1300is
81
82
83
4.6.3 S2000is and S2600is
84
85
86
4.7 Air Saturators (Glass fabrication)
87
88
89
4.7.2 SS200is and SS2600is
90
91
92
5 Optional Accessories Manual (If
Ordered)
93
Issue Date First Description Of Amendments
Issued
A Nov 2009 Original Issue ( Draft)
K June 2014 Updated Atomiser Pictures, tables and Air saturator drain.
94