CORROSIONBOX 1000 litres salt spray chamber enhanced model

Document code: 06520109E-1/2013

CORROSIONBOX 1000 litres

salt spray chamber enhanced model

Instruction Manual

Machine serial number: 474

Year of manufacture: 2014

Country of origin: Italy

IMPORTANT! READ THIS MANUAL CAREFULLY BEFORE TO OPERATE CORROSIONBOX

Srl – Via Zuccoli 18, 20125 MILANO – Tel. +39–02-67072112 Fax +39-02-6691270 e-mail: [email protected] - web: www.cofomegra.it

mailto:[email protected]

http://www.cofomegra.it/

Document code: 06520109E-1/2013.

INDEX

0 PRELIMINARY STATEMENTS page 4

0.1 Document Identification page 4

0.2 Purpose of the document page 4

0.3 Standards references page 4

0.4 Persons concerned with this manual page 4

1 GENERAL INFORMATION page 5

1.1 Manufacturer identification page 5

1.2 Guarantee and liability page 5

1.3 Hazards relating to the use of the instrument page 5

1.4 Proper use page 6

2 SAFETY INSTRUCTIONS page 6

2.1 Meaning of symbols page 6

2.2 Training of operator page 7

2.3 Installation page 7

2.4 Maintenance page 7

3 TRANSPORT AND STORAGE page 8

3.1 Sizes and weight page 8

3.2 Packing page 8

3.3 Unpacking page 8

3.4 Storage page 8

3.5 Instrument inactivity page 8

3.6 Demolition and Disposal of the chamber page 9

4 Corrosionbox 1000e DATA page 9

4.1 Accessories for installation included page 9

4.2 Accessories to hold specimens page 9

4.3 Accessories for Prohesion cyclic test page 9

4.4 Technical data page 9

4.5 Noise level page 10

4.6 Copy of CE mark page 10

5 INSTALLATION page 11

5.1 Place of installation page 11

5.2 Levelling page 11

5.3 Electrical connection page 11

5.4 Connection to air supply page 11

5.5 Connection to deionised water supply page 12


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5.6 Connection of fog outlet page 12

5.7 Connections of chamber and solution tank drains page 12

5.8 Inlets and outlets arrangement page 13

5.9 Set up of supplies page 14

5.10 Set up of drains page 14

6 CORROSIONBOX DESCRIPTION page 16

6.1 Chamber front view page 16

6.2 Chamber right side view page 18

6.3 Principle of functioning page 20

7 CONTROL PANEL page 21

7.1 General description page 21

7.2 Function of the software buttons page 23

7.3 Menu of choice page 23

7.4 Choice of a program (Select Program) page 25

7.4.1 Execution of a program (test) page 26

7.4.2 Summarising table of test parameters page 29

7.4.3 Summarising table of stored programs page 30

7.4.4 Test report page 31

7.5 Program editing or erasing (Edit program) page 32

7.5.1 Program editing page 32

7.5.2 Program erasing page 35

7.6 Print option page 36

7.7 Calendar set page 37

7.8 Alarm messages page 38

8 STARTING A TEST page 41

8.1 Salt spray test page 41

8.2 Condensation test page 41

8.3 Prohesion cyclic test page 42

8.3.1 Introduction page 42

8.3.2 How fog period is performed page 42

8.3.3 How dry-off period is performed page 42

8.3.4 How to set air heater temperature page 43

8.3.5 Test execution: alarm and warning messages page 43

9 SAFETY ADVICES page 44


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10 CORROSIONBOX PROTECTIONS page 44

10.1 Heater protection page 44

10.2 Humidifier protection page 44

10.4 Air heater protection page 44

11 MAINTENANCE page 45

11.1 Chamber stop for some weeks page 45

11.2 Chamber cleaning page 45

11.3 Metering pump page 45

11.4 Spray nozzle page 47

11.4.1 Spray nozzle setting page 48

11.5 Humidifier page 49

11.6 Air heater page 50

12 PROBLEMS AND SOLUTIONS page 51

12.1 No fog page 51

12.2 Chamber temp. do not get the requested value page 51

12.3 Humidifier temp. do not get the requested value page 51

12.4 Air heater temp. do not get the requested value page 51

12.5 Nozzle pressure falls page 51

ENCLOSED

Electric and pneumatic drawings

Air heater instruction manual

Gas Injector (only with Option C203)


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0 PRELIMINARY STATEMENTS

0.1 Document Identification This operating manual is drafted by CO.FO.ME.GRA. Srl and is an integral part of the instrument. This instruction manual is identified by document code on the cover to allow traceability. The copyright of this instruction manual belongs to CO.FO.ME.GRA. Srl via Luciano Zuccoli 18, 20125 Milan, Italy.

0.2 Purpose of the document The purpose of this document is to put the customer and his operators in a position to operate this instrument in safety.

0.3 Standards references This instruction manual has been drafted taking account of the suggestions of the following standards:

2006/42 CE and following modifications.

ISO 12100-2

0.4 Persons concerned with this manual All the persons concerned with the use of the instrument should know the safety guidelines advised in this manual. Primarily the user management is liable for:

Operator general knowledge of the regulations for accident prevention and safe work.

Operator training to operate the instrument. The Operator “musts” are:

Follow the general instruction for accident prevention and safe work.

Know and comply with the safety instructions of this instructions manual.


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1 GENERAL INFORMATION

1.1 Manufacturer identification The identification of CO.FO.ME.GRA. Srl as manufacturer is performed according to European standards in force by means of the following deeds:

Declaration of compliance.

CE mark.

Instruction manual. The manufacturer’s address is: CO. FO.ME.GRA. Srl via Luciano Zuccoli 18, 20125 Milan, Italy. Phone (0039) 2-67072112 fax (0039) 2-6691270. A metallic plate with CE mark and all the required information is applied to the machine on the right side.

1.2 Guarantee and liability The instrument is guaranteed to be free from workmanship defects and defects of components for a period of one year from delivery to customer. The guarantee obligation is limited to repair the instrument returned to the factory. For repair, the instrument shall be returned well packed with transportation charge prepaid. For guarantee service performed by the distributor, manufacturer obligation is limited to supply the replacement part free of charge. Guarantee and liability in case of injury to persons cannot be claimed if related to the following causes:

Incorrect installation and supply connections of the machine .

Improper use of the instrument.

Modifications to the instrument.

Tampering with the safety components. .

1.3 Hazards relating to the use of the instrument The machine has been manufactured in accordance with directive 2006/42/CEE and subsequent amendments. All the European standards concerning this instrument have been applied taking account of the actual state of technology; nevertheless hazardous situations may occur if:

Instrument is used improperly.

Instrument is operated by inexperienced operators.

Safety instructions of this manual are ignored.


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1.4 Proper use The CORROSIONBOX is intended exclusively for salt corrosion and humidity tests, every other use is improper use and CO.FO.ME.GRA. Srl is not liable for any damage to the instrument or injury to operator related to improper use. The CORROSIONBOX must not be used for testing specimens of materials for which temperature or corrosive solution can cause fire, explosion or hazard.

2 SAFETY INSTRUCTIONS

2.1 Meaning of symbols The following symbols are used in this instruction manual to give evidence of hazards.

DANGER

Possible danger to the life or health of persons.

WARNING

A situation that can create danger to the life or health of persons.

WARNING

Danger of electrical shock.

WARNING

Danger of hot surfaces.


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2.2 Training of operator The instrument may be operated only by operators who are properly trained; the operator must know:

The risk connected with corrosion tests.

This instruction manual prescription for safe work.

Local prescriptions for safe work. A copy of this instruction manual should be consigned to the operator and signed by him as knowledge of it.

2.3 Installation Connection of the energy must be performed by a qualified electrician and technical personnel following the guidelines furnished in this manual.

2.4 Maintenance Inspection of the instrument and instrument cleaning have to be performed at regular intervals following the guidelines of maintenance § 11.

DO NOT operate the machine if, during inspection, some defects involving safety are found. Service must be performed only by specialised technicians; if some parts have to be replaced, use only original spare parts to restore original performance and safety conditions.


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3 TRANSPORT AND STORAGE

3.1 Sizes and weight See the installation § 5.1 for complete evaluation of machine appearance, sizes and weight are:

CORROSIONBOX 1000e Physical external dimensions and weight

Width: 1.640 mm. Depth: 820 mm. Height: 1.750 mm. Net weight: 300 kg. approx.

CORROSIONBOX 1000e Chamber internal dimensions

(dome not included) and capacity

Width: 1.100 mm. Depth: 800 mm. Height: 1.100 mm. Capacity: 968 litres

3.2 Packing Packing may change in accordance with type of transport and destination. Packed machine sizes and gross weight are:

CORROSIONBOX 1000e Shipping dimensions and weight

Width: 1.950 mm. Depth: 1.180 mm. Height: 2.010 mm. Gross weight: 465 kg. approx.

> Pictorial symbols on packing must be observed for transport and movements. <

3.3 Unpacking Check packing before unpacking for possible transport related damage, remove packing and check the instrument and all the parts.

3.4 Storage If it is necessary to store the instrument:

Store instrument in its original packing.

Store in a dry room with temperature between 10-40 °C.

3.5 Instrument inactivity If the chamber is not to be used for several weeks:

Disconnect main plug.

Clean the chamber and the spray nozzle following the instructions of § 11.

3.6 Demolition and Disposal of the chamber

The room is completely made of PP (or PPS, on demand for flameproof), remove the cabinets and dispose of the various parties according to law.


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4 CORROSIONBOX 1000e DATA

4.1 Accessories for installation included

Water filter to be place outside of the CORROSIONBOX, before the connection point between the water pipeline and the chamber inlet.

4 meters of green tube 6/4 for water connection.

Air filter to be placed outside of the CORROSIONBOX, before the connection point between your compressed air network and the inlet on the chamber.

4 meters of white tube 6/4 mm for compressed air connection.

Replacement parts for metering pump, placed near the pump site.

Fog outlet fitting.

4.2 Accessories to hold specimens

6 bars specimen holders.

4 racks panel holders.

4.3 Accessories for Prohesion cyclic test

1 titanium panel to be putted on the chamber floor. Panels will transform the “wet bottom chamber” normally used for salt spray (fog) test., in a “dry bottom chamber” as required for cyclic fog dry test.

4.4 Technical data

Test chamber dimensions, dome not included: W. 1100 X D. 800 X H. 1120 mm.

Capacity: 6 racks, up to 150 test panels size 150 X 60 mm.

Test temperature range: ambient up to 55 °C.

Electrical data: 230 Vac 50/60 Hz, 13 A max (16 A max, with Prohesion option).

Fuses: 230 Vac, 2 x 20 Amp.; 24 Vac, 1 x 6 A.

Compressed air supply: 3 – 6 bar.

Compressed air consumption (Salt spray): approx. 4 Nm3/h.

Demineralised water consumption: approx. 0.3 l/h.


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4.5 Noise level The continuous noise level emitted from the instrument does not exceed 70 dB(A).

4.6 Copy of CE mark

A label with technical data and CE mark is fixed on the right side of the instrument.


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5 INSTALLATION

5.1 Place of installation The CORROSIONBOX 1000e must be set up in a suitable location in a room with a temperature range 20-30 °C. A distance of 500 mm between the chamber and the walls is needed for the periodical inspections.

5.2 Levelling Fill the bottom of chamber with demineralised water and level the CORROSIONBOX using the adjustable feet.

5.3 Electrical connection The CORROSIONBOX is equipped with a line cord in conformity to the standards. The plug with earth is 230 Vac, 16 A, UE standard.

CAUTION: the local line voltage, frequency and current must be in agreement with following CORROSIONBOX requirements.

WARNING

Voltage: 230 Vac, +10%, single phase. Frequency: 50 Hz. Current consumption: 13 Amp. max. (16 A DRY option)

5.4 Connection to air supply

The air supply pipe must feed compressed air to the chamber only. The pipe must have a cock and the air filter, supplied with the chamber, has to be placed conveniently. Using the white tube 6/4 connect the air filter to the air inlet on the chamber. The air pressure should be between 3 and 6 bar.


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5.5 Connection to de-ionised water supply

The water supply pipe must feed water to the CORROSIONBOX only. The pipe must have a cock and the water filter, supplied with the chamber, has to be placed conveniently. Using the green tube supplied, connect the water filter to the water inlet on the chamber. The water pressure must be between 2 and 4 bar.

Caution - the use of non de-ionised or distilled water can rapidly damage the

humidifier due to the scaling.

5.6 Connection of fog outlet It is very important that fog leaves the chamber freely without obstacles. Connect a tube to the fog outlet, this tube must go directly without curves to a natural extraction flue.

5.7 Connection of chamber and solution tank drains The chamber drain and the salt solution tank drain are situated on the back side of chamber. During the test time the exhausted salt solution from the chamber runs down to the chamber bottom. The quantity is about 1–2 litres/hour and must flow freely to a reservoir or to a sewerage. It is very important that the drain is completely free, without obstacles, so as not to compromise the smooth operating of the chamber.


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5.8 Inlets and outlets arrangement The picture shows the arrangement of the inlets and outlets on the back side of the test chamber.

1. Electrical power cable. 2. Air inlet , connect the white pipe 6/4. mm. 3. Water inlet, connect the green pipe 6/4 mm. 4. Test chamber drain, connect a 25 mm pipe. 5. Salt solution tank drain connect a 25 mm pipe.


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5.9 Set up of supplies

5.10 Set up of drains


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6 CORROSIONBOX DESCRIPTION

6.1 Chamber - front view


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A. Adjustable foots to level the chamber. B. Salt solution level sensor. When in the tank the salt solution is near to end, a

message on the display will inform the operator. C. Connection between solution tank and metering pump, inside of the salt solution

tank there is a filter. D. Front door, access to the test chamber. E. Salt solution tank, capacity 260 litres. F. Level meter of salt solution. G. Spray nozzle. H. Panels holder rack. I. Shield to avoid samples direct spraying. L Fog drain to be connected to a chimney (see § 5.6). M Air inlet. Press Purge push button to introduce fresh air for fast fog evacuation

before door opening. Heated air is introduced during dry phase of Prohesion cyclic test.

N Spray nozzle pressure regulator, the correct value is about 1 bar. O Control panel. P Printer (option) or serial interface RS232 connector. Q Main switch. R Water level sensor inside of the test chamber, if the water level is below the

minimum the test is interrupted and a message ask to feel manually the water in the chamber (see § 7.8).

T Chamber drain tap (the picture shows it in opened position) in order to blow off the liquid inside the test chamber.

U Chamber heaters, a red pilot shows when the heating elements are on. V Salt solution tank tap (the picture shows it in opened position) in order to blow off

the salt solution. Z Chamber temperature sensor.


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6.2 Chamber - right side view


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A. Dosing pump. Its function is to proportion the salt solution to the spray nozzle. The pump must be inspected frequently (see § 11.3). The dosing pump speed can to be adjusted using a screw driver.

B. Humidifier. The compressed air, when the solenoid valve Y1 is open, crosses the pressure regulator and enters into the bottom of the humidifier across a scrubber. The compressed air from the upper side of the humidifier goes to the spray nozzle. There is a pressure gauge to monitor the actual pressure on the control panel.

C. Air heater. Its function is to heat the air during dry phase of Prohesion cyclic test. The air temperature depends from the air supply pressure and the position of the regulating potentiometer positioned on the air heater.

D. Protection thermostat. If air temperature rise up to 80 °C the thermostat trip out disabling the heater.

E. Humidifier by pass. When lever is in the vertical position (Salt) air will pass through the humidifier before reach nozzle; this is required by Standards for salt spray. When lever is in the horizontal position (Prohesion) air reach directly the nozzle, air without humidity is required by Standard describing Prohesion test conditions.

F. One way valve. Positioned at the end of air heating circuit, its function is to avoid that corrosive fog reaches the heating component. Valve can easy inspected unscrewing the cap with red ring.

G. Solenoid valves. Y1 is the air compressed inlet valve, it is always opened during salt tests. Y2 is the water inlet valve, it is opened only during the automatic filling of the humidifier. During this operation the test is suspended. Y3 is the air compressed inlet valve to the chamber to remove the fog from the chamber. Only when the test is interrupted pressing Purge is it possible to open this Y3 valve.

H. Electrical circuits board. I. Fuses holder (see electrical diagram). L. Test chamber water level sensor. It will open electro valve M to refill the bottom of

the test chamber when water level is too low. M. Solenoid valve. Water level sensor N will open this valve to refill the test chamber

bottom when water level is too low.


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6.3 Principle of functioning

Salt spray test. Atomising the salt solution with compressed air the spray-nozzle produces a corrosive fog. The air pressure in the spray nozzle is adjusted via the pressure regulator. The humidifier supplies the spray nozzle with warm saturated compressed air. The humidifier is supplied with air and de-ionised water, whereby the air is filtered through an air/oil scrubber beforehand. The salt solution is proportioned via the dosing pump into the spray nozzle and the quantity is adjusted via the pump speed. The chamber temperature is controlled via the PTC temperature sensor in the corrosion chamber.

Condensation test. To perform the condensation test the humidifier and the spray nozzle are not in operation. The bottom of the chamber must be filled with water up to the water outlet. The water on the bottom is heated creating a damp heat atmosphere in the test chamber.

Prohesion test. It is a cyclic test explained in Annex 5 of ASTM G 85-98 Standard. The test consists of cycles of 1 hour fog and 1 hour dry off. During fog period no heating is applied to the test chamber and air haven’t to be humidified. During dry-off period the chamber is purged with heated air. Within ¾ h from the fog period all visible moisture is dried off the specimens and the test chamber temperature shall reach 35 °C.


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7 CONTROL PANEL

7.1 General description

1) Liquid crystal display 4 lines of 20 characters. 2-5) Buttons the function of which is defined by software messages.

6) Start button, to start the test execution.

7) Stop button, to stop the test execution.

8) Purge button: it switches on the test chamber ventilation for rapid demisting.

9) Joker push button, no function for Corrosionbox chamber. 10-13) LED on means that the respective button is operating. LED off, the respective

button is not operating.


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7.2 Functions of the software buttons

01 DIN 50021 salt TIME Chamb-T Bar 45:12 35.0° 1.12

MENU

The 4 lines display of 20 characters simplifies the understanding and the use of the considerable resources that the machine offers. A heavy contribution to the understanding is due to the fact that the function of the 4 buttons is defined by the software and clearly indicated on the 4° line of the display on each button. The buttons without a function description in the display cannot operate.

MENU

The MENU button allows the user to enter in the choice menu. The menu function can be used only if no test is working or if no procedure is open.

ESC

The button ESC can be used when a procedure is open. The

button ESC can also be used to go back to the previous display page.

The button allows the user to enter a procedure, to confirm choices or to input parameters.

PRN

The button PRN allows to start the transmission of the data concerning the test in execution to the serial interface RS232.

>

The button > allows the user to see on the display the pages following the actual one, or to select the desired position during the introduction of numerical values or alphanumerical labels.

The button allows the user to make a choice that have to

be confirmed with or to introduce numerical values or alpha numerical labels.


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SET

During the test execution the button SET allows the user to visualize for few seconds the set parameters concerning the running test.

RESET

The button RESET allows the user to cancel the test in execution, making reset all the stored data are cancelled.

7.3 MENU of choice

CO.FO.ME.GRA.

CNS serie 600e

At power on this message appears on the display for few seconds. Then appears the next message.

01 DIN 50021 salt TIME Chamb-T Hum-T 96 35.0° 50.0°

MENU

The display shows the first page of the selected program; the

button MENU allows the user to enter in the menu of choice,

the button allows the user to enter in the selected program.

SP Select Program EP Edit Program PO Print Option

ESC

Push MENU. The display shows the first page of the menu

choice. The button allows the choice of one of three

options, the button allows the user to enter the choice

made; the button > allows the user to go to the next page; the

button ESC allows the user to return to the previous page.

Push > to go to the second page of menu.

CS Calendar Set

ESC

The display shows the second page of the menu choice.


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SP Select Program This procedure allows the user to recall one of the memorized programs. All the parameters concerning the recalled test are stored but some of them can be modified by the operator before the test execution. The memory contains up to 15 programs; some programs amongst the most frequently used (standard) are loaded in the factory. The operator can input other programs in the memory freely establishing their characteristics.

EP Edit Program This procedure allows the user to edit a new program or to cancel an existing one. The edition of a new program is considerably facilitated choosing before, (with Select Program) a program with characteristics similar to the one you want to edit. In fact this program is proposed as an outline to introduce functioning parameters and options of the new one. The new program, to which it is possible to attribute an identification name, is loaded in a free position of Select Program.

PO Print Option This program allows the user to enter the communication modality to a printer or to a external pc (optional). The data concerning to the test running are stored and than transmitted to the external device.

CS Calendar Set This programs allows the update of the internal clock and the measure of the age in hours of some components of the equipment.


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7.4 Choice of a program (Select Program) SP 1


ESC

Press menu, than with , select SP Select Program and

push to enter.

SP2 Choice of the test to be executed

SP 01 DIN50021

02 Test B 03 Test C

ESC

The display shows three of the stored tests, the memory can contain up to 15 tests.

With > call on display the next pages until the one containing

the required test is displayed; with move the arrow to

select your test and with the button enter the selected test.

ESC allows the user to return to the main menu. SP3 first page of the selected test

01 DIN 50021 salt TIME Chamb-T Hum-T 96 35.0° 50.0°

MENU

When a test has been selected, the display shows the first page with the most important set values concerning the test.

Push START to start the test execution to modify the test time.

SP4 how to modify the test time

01 DIN 50021 TIME Chamb-T Hum-T 96

ESC

This page allows the user to modify the test time. The most significant figure will blink and it is possible to modify it with

the button .The button > moves to the next figure. When

the time value required has been introduced press , now it is

possible to go to the next page SP5 or with ESC to go back to page SP3 and start the test.

SP5 how to modify the number of cycles

01 DIN 50021 N° of cycles 0001

ESC

This page allows the user to modify the number of cycles to be executed, when the test to be performed is at constant climatic conditions load 0001. The most significant figure will

blink and it is possible to modify it with the button .The button > moves to the next figure. When the cycles number

value required has been introduced with , it is possible to go

to the next page SP6 or with ESC to go back to SP3 and start the test.

SP6 label attribution for the identification of the test

01 DIN50021 Label B2

ESC

This page allows the user to assign an identification label to the test to be executed, the mark can be alpha numerical up to 7 characters and will be visualized on the first line of the

display and printed in the test reports. The button allows

the user to select the required character, the button > moves

to the next character, press ESC to go back to SP3 and start the test.


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SP3 test starting

01 DIN 50021 B2 TIME Chamb-T Hum-T 96 35.0° 50.0°

MENU

After test selection of the test to be executed, the test can be

started by pushing the button START; a bright LED on the button confirms that the button is operating.

7.4.1 Execution of a program (test)

RP1 test starting


MENU

Before starting the test, the display shows the first page with

the set parameters. Push START to start the test.

RP2 test in execution: actual data page 1

01 DIN 50021 B2 TIME Chamb-T Bar 95:58 19.5° 1.12°

SET PRN

The display shows the elapsed time expressed in hours (i.e.: 499) or, in hours and minutes (i.e.: 45:27), the chamber

temperature value and the nozzle pressure value. Push > to

go to the next page RP3; push SET to visualize temporarily the set parameters values RP7.

RP3 test in course: actual data page 2

01 DIN 50021 B2 TIME Hum-T Pump 95:58 46,5° 313

SET PRN

The second page shows the actual value of the humidifier temperature, the speed of the metering pump in rph, the message N/A is displayed if the pump is not monitored (other chamber models).


01 DIN 50021 B2 N° of cycles 0

SET PRN

The third page shows the cycles to be performed to the end.


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RP5 test in course: pause

01 DIN 50021 B2 P A U S E D

RESET SET

The program can be stopped at every time by pushing the

button STOP, push START to resume the program execution,

push RESET to reset the initial conditions. BE CAREFUL the

button RESET cancels all the information concerning the test

in course, push to have information on the pause.

RP6 test in course: pause information

01 DIN 50021 B2 Suspended test

10:24 11/14/00

SET

The page shows the time and the date (mm,dd,yy) of the

stop, push START to resume the test execution.



SET PRN

During a program it is possible, pushing the button SET, to visualize for a short time the set parameters.

RP7 test in course: set data page 1


Pushing the button SET the display shows the first page of the set parameters of the phase under execution, push the

button > to access to the second page.

RP8 test in course: set data page 2

01 DIN 50021 B2 N° of cycles 1

The second page shows the number of cycles.



SET PRN

During the execution of a program is possible, pushing the

PRN button, to go to the page for the printing out of the data relived and stored during the test execution.


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RP9 test in course: print of data

01 DIN 50021 B2

Current Print out History Print out

PRN

With select Current Print out if you want to print only the last set of the relived values, select History Print out to print all the stored values.

RP10 test in course: print of data

01 DIN 50021 Printing TIME Chamb-T Bar 95:58 19.5° 1.12°

Push PRN to start the print out of the values, the message Printing appears for the time needed for the data transmission.

RP11 test in course: conclusion of the test

01 DIN 50021 B2

Test done! RESET PRN

At the end of the test, push PRN to print the complete test

report and then push RESET to clear the memory completely.


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7.4.2 Summarizing table of the test parameters The software can control cycling test combining the following phases:

Salt spray phase.

Condensation phase.

Dry phase.

Ambient phase.

To perform cycling test the chamber must be equipped with optional parts, the tablet report, for each phase, the limit values.

Table 1

Parameter Value range

minimum maximum

Salt phase

1 Phase time 1 min 9999 hours

2 Chamber temperature 20 °C 50 °C

3 Humidifier temperature. 20 °C 80 °C

4 Nozzle air pressure. monitored

5 Dosing pump speed. monitored

Condensation phase



Dry phase



3 Humidifier temperature. 20 °C 80 °C

Ambient phase


2 Chamber temperature monitored


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7.4.3 Summarizing table of the stored programs The table 2 summarize the programs stored in the memory, these programs meets the most important test conditions of the most applied Standards.

Table 2

Test type Salt spray tests

Test number 01 02 03 04

Program name ISO NSS 9227

ASTM B117

ASTM B117

ASTM B117

Salt phase

Phase duration 1000 h 2 h 24 h 96 h

Chamber temperature 35 °C 35 °C 35 °C 35 °C

Humidifier temperature 50 °C 50 °C 50 °C 50 °C

Nozzle pressure ** 1 bar 1 bar 1 bar 1 bar

Dosing pump speed ** 300 t/h. 300 t/h. 300 t/h. 300 t/h.

Condensation

phase

Phase duration 0 0 0 0

Chamber temperature X X X X

Dry

phase

Phase duration 0

0

0

0

Ambient

phase

Phase duration 0 0 0 0

Cycles number 1 1 1 1

Test type Condensation test/Prohesion test

Test number 05 06 07 08

Program name DIN SK 50017

UNI 9590

Prohesion

Salt phase

Phase duration 0 1 h 1 h

Chamber temperature X 55 °C 0 °C

Humidifier temperature X 60 °C 0 °C

Nozzle pressure ** X 1 bar 1 bar

Dosing pump speed ** X. 300 t/h 300 t/h

Condensation

phase

Phase duration 1000 h 0 0

Chamber temperature 40 °C X X

Dry

Phase

Phase duration 0 1 h 1 h

Chamber temperature X 55 °C 0 °C

Humidifier temperature X 0 °C 0 °C

Air temperature ***

Ambient

Phase

Phase duration 0 0 0

Cycles number 1 1000 100 ** Nozzle pressure and dosing pump speed are adjusted manually, the table report the recommended pressure value and an indicative value for the pump speed. *** Drying air temperature is setted on air heater.


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7.4.4 Test report It is possible to print a complete test report connecting a printer to the serial interface connector. During the test execution 100 measures are sampled at regular intervals (not less then 10 minutes) the measured values together with other information are stored and printed by the user during the test or at its end. Follows an example of test report:

01 ASTM B117 B2 ----------- Set Values-----------salt----

-----

Time T-Ch. T-Hum. hh:mm °C °C 02:00 35.0 50.0

----------Current Values-----------

Time T-Ch T-Hum Air-P

Pump

hh:mm °C °C Bar rph - Started on: 11/12/00 13:43

02:00 19.6 21.4 0.0 00 01:50 23.4 35.8 1.23 360 01:40 29.0 52.0 1.23 363 01:30 33.7 49.3 1.24 359

Paused on: 11/12/00 14:18 Resumed on: 11/12/00 15:45

01:20 31,0 50.7 1.21 360 01:10 35.2 51.3 1.22 358

Pw Fail on: 11/12/00 16:02 Restored on: 11/12/00 16:03

01:00 34.8 50.14 1.21 360 The report shows the name (ASTM B117) and the label (B2) attributed to the program in execution, and then it indicate all the set values. Follow the list of the current values with data and time of the test beginning. The first measurement is made just at the start of the test, others follow at regular intervals and this interval is calculated in minutes dividing the total test time by 100 (with a minimum of 10 minutes). If the test is stopped, time and data of stop and restart of the test are registered. In case of line voltage fail the machine switches off, but it restarts automatically when line voltage comes back. This event, too, is registered on the test report. All the stored values are cancelled by RESET.


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7.5 Program editing or erasing (Edit Program)


ESC

After having re-called the choice menu with select EP Edit

Program and push to enter the test program.

EP1

EP

Edit Program Delete Program

ESC

Use the button to select Edit Program for a new program edition or Delete Program for erasing an existing program.

7.5.1 Program editing

EP2 Program editing page 1

EP Program number 05

Name: Test E

ESC

After having chosen Edit Program, the display shows the number and the name of the program previously selected.

With the button it is possible to scan all the stored programs and to choose the most similar to the one to be

edited. Push .

EP3 Program editing page 2 salt phase

EP – Insert salt Time 0100

ESC

The program in development may be at constant climatic conditions or a cycling test. If a salt phase must be performed load the phase time, if the salt phase must be left out load 0000. Load the time in hours up to 9999, if the time to be

loaded is lower than 1 hour load 0000 and press .


EP – Insert salt Time 00 minutes

ESC

Load the time in minutes up to 59, if the salt phase must be left out load 00.


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EP – Insert salt Chamber temp. (°C) 35.0

ESC

Load the chamber temperature value for salt phase.


EP – Insert salt Humidif. Temp . (°C) 50.0

ESC

Load the humidifier temperature value for salt phase.

EP7 Program editing page 6 condensation phase

EP – Insert cond Time 0100

ESC

The program in development may be at constant climatic conditions or a cycling test. If a condensation phase must be performed load the phase time, if the condensation phase must be left out load 0000. Load the time in hours up to 9999, if the time to be loaded is lower than 1 hour load 0000 and

press .


EP – Insert cond Time 00 minutes

ESC

Load the time in minutes up to 59, if the condensation phase must be left out load 00.


EP – Insert cond Chamber temp. (°C) 35.0

ESC

Load the Chamber temperature value for condensation phase.

EP10 Program editing page 9 dry phase

EP – Insert dry Time 0100

ESC

The program in development may be at constant climatic conditions or a cycling test. If a dry phase must be performed load the phase time, if the dry phase must be left out load 0000. Load the time in hours up to 9999, if the time to be

loaded is lower than 1 hour load 0000 and press .


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EP11 Program editing page 10 dry phase

EP – Insert dry Time 00 minutes

ESC

Load the time in minutes up to 59, if the dry phase must be left out load 00.

EP12 Program editing page 11 ambient phase

EP – Insert ambient Time 0100

ESC

The program in development may be at constant climatic conditions or a cycling test. If an ambient phase must be performed load the phase time, if the ambient phase must be left out load 0000. Load the time in hours up to 9999, if the

time to be loaded is lower than 1 hour load 0000 and press .

EP13 Program editing page 12 ambient phase

EP – Insert ambient Time 00 minutes

ESC

Load the time in minutes up to 59, if the ambient phase must be left out load 00.


EP – Insert N° of cycles 0001

ESC

If the test is of cycling type load the number of cycles to be executed. For test at constant climatic condition (salt spray or

condensation) load 0001and press .


EP – Insert Program name Test H

ESC

The name of the reference program is suggested; with the

button > and with the button a new name can be edited. The introduction of the parameters concerning the new

program is finished. Push to save the new program.


EP – Insert Saving Test H

ESC

The new program is saved, it will be selected and executed with Select Program.


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7.5.2 Program erasing

EP1

EP Edit Program

Delete Program

ESC

Choose with the button Delete Program if it is necessary

to cancel an existent program. Push .

EP17 Program erasing page 1

EP Program N° 5

Test E

ESC

Choose with the button the program to be cancelled. Push

.

EP18 Program erasing page 2

EP.- D E L E T E Name Test E Are you sure?

ESC

Confirm with to cancel the program indicated or go back

with ESC.


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7.6 Print option

SP Select Program EP Edit Program

PO Print Option

ESC

After having re-called the menu, with , select PO Print

Option and push to enter in print option program.

PO1 set of the print options page1

PO – Insert Baud Rate 9600

1 Start, 8 bit, 1 stop, NP

ESC

With set the baud rate of the printer and confirm it; with check if the other parameters of printer interface are

compatible with the parameters on the display. Push .


PO – Insert Output default to

Printer

ESC

With. select the interface record needed for a printer or a PC (for PC it is necessary to install on the own PC the

optional dedicated software) make the choice and push .


PO – Insert Print out MODE Stacked

ESC

With. choice Stacked if you prefer to store in the processor memory the measured values, at any moment the report will be printed on request of the operator. select Automatic if you prefer that the values are printed just when

measured, push .


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7.7 Calendar set

CS Calendar Set

ESC

After having re-called the second page of the choice menù,

with select CS Calendar Set and push to enter CS Calendar Set program.

CS1 Calendar set page 1

CS – Equipment life Working Hours 3964 ESC

The page shows the total working hours of the machine.

Push .


CS – Equipment life Pump Hours 654

ESC CLEAR

The page shows the working hours of the dosing pump. At the installation of a new dosing pump the time-meter can be

zeroed with CLEAR, push .


CS – Equipment life Pump tube Hours 654

ESC CLEAR

The page shows the working hours of the tube installed on the dosing pump. At the installation of a new tube the time-

meter can be zeroed with CLEAR, push .


CS – Equipment life Humidifier Hours 1328

ESC CLEAR

The page shows the working hours of the humidifier. At the moment of maintenance the time-meter can be cleared with

CLEAR, push .


CS – Insert Current time & Date 10:43 01/12/1

ESC CLEAR

The page shows the current hour and the date expressed in:

month/day/year. With and > up-date the hours and then

push , to up-date the minutes push . In the same way up-

date the date and push .


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CS – Activate Current time & Date 10:46 01/12/1

The page shows the message for the necessary time to activate the clock and then goes back to the selected program.

7.8 Alarm messages

AM1 Alarm message

05 Test E Alarm ! ! Cover is open

RESET

Pressing start button when the dome is open the test do not start and this message appear on the display. This message appears only in the chambers equipped with pneumatic driven dome.

AM2 Alarm message

Alarm ! ! Chamber out of water

The water level in the test chamber is lower than minimum

value. The chamber can’t run until water is added, press to enter in pause and than to re-start or reset the test.

AM3 Alarm message

Alarm ! ! Fault humidifier

During salt phase a failure is found in the humidifier functioning. The chamber can’t run until the failure condition is not solved.

AM4 Alarm message

Alarm ! ! Chamber Overtemp

During the test, the chamber temperature has reached 65°C, the test is suspended. The chamber can’t run until the failure condition is not solved.


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AM5 Alarm message

Alarm ! ! Humidif Overtemp.

During a salt spray test, the humidifier temperature has reached 80°C, the test is suspended. The chamber can’t run until the failure condition is not solved.

AM6 Alarm message

Alarm ! ! Missing air pressure ! !

During salt phase the air pressure at the nozzle is fault. The chamber can’t run until the air pressure is restored.

AM7 Alarm message

Alarm ! ! ADC Noise Detected

An internal problem is causing a software corruption, the processor is recovering the normal functioning, during this short time the test is suspended.

AM8 Alarm message

02 ASTM 117 Unrecoverable ADC Failure

The processor was not able to recovery the normal functioning, the test is suspended. Switch the main switch off, wait some minutes and switch on, if the test is not resumed a failure is interesting the control panel.

AM9 Informative messages

Wait Loading Hum Water

During salt phase the water level in the humidifier is gone down to the minimum level, the humidifier is loaded of water. During this automatic operation the test is suspended.


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WARNING ! ! Out of salt solution

During salt phase the salt solution level in the tank is gone down the minimum level, the test run normally but the message is displayed periodically until the tank is filled up of salt solution.


WARNING ! ! Low Air pressure

During salt phase the pressure is gone down 0.7 bar., the test run normally but the message is displayed periodically until the pressure is resumed to the correct value (1 bar).


WARNING ! ! High Air pressure

During salt phase the pressure is gone up 1.7 bar, the test run normally but the message is displayed periodically until the pressure is resumed to the correct value (1 bar).


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8 STARTING A TEST

8.1 Salt spray test

Check that the drain tap of the chamber and the drain tap of solution tank are closed.

Make the salt solution in a separate tank following the requirements of the Standard. Verify that the salt is completely dissolved and that there are not solid residua before pour out of tank into the CORROSIONBOX solution tank.

Fill the bottom of the chamber with distilled or demineralized water up to the water drain level.

Put the humidifier bypass lever in vertical position (Salt)

Check that the external taps of inlet water and inlet of compressed air are opened.

Select on the control panel the program (test) to be performed and input the test time.

Place accurately your samples on the chamber, you have to avoid that samples are interested from dripping coming from samples on upper level.

Start the test, the best pressure value in the spray nozzle is 1 bar, check the display value of the pressure and adjust it at the correct value.

Check that the metering pump speed is correct. The Standards ask for a collection of about 1–2 ml/h of salt solution measured using a rain gauge of diameter 80 mm. placed in the test chamber. The quantity of the collected salt solution depend from: spray nozzle adjustment, pressure level and metering pump speed. The spray nozzle is adjusted in the factory, the best pressure level is 1 bar so you should adjust the metering pump speed to get the correct collected quantity.

8.2 Condensation test

Rinse with a water jet the inside of the chamber if you have made salt spray tests.

Check that the water outlet of the chamber is closed.

Fill the bottom of the chamber of distilled or deionised water up to the drain level.

Select on the control panel the program (test) for the Standard to be performed and input the test time.

Place accurately your samples on the chamber, you have to avoid that samples are interested from dripping coming from samples on upper level.

Start the test.


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8.3 Prohesion cyclic test (only Prohesion option)

8.3.1 Introduction Prohesion test conditions are described in Annex 5 of ASTM G 85 Standard. § A5,1 of the standard says “This test consist of cycles of 1 h dry-off and 1 h fog. The electrolyte is a solution of sodium chloride and ammonium sulphate, and is much dilute than traditional salt fog. The fog is performed at room temperature, while the dry-off is at elevated temperature. In addition, the spray atomizing air is not saturated with water” To meet the test condition set the chamber as per salt spray corrosion test and:

Put the humidifier bypass lever in horizontal position (Prohesion). In this position spray atomizing air is not saturated in the humidifier.

Install on the bottom of the test chamber the titanium panel.

Select the program Prohesion on control panel and input the number of cycles to be executed.

8.3.2 How fog period is performed By pass lever in horizontal position avoid the humidifying of the air so to satisfy the Standard requirements, chamber heating is avoided simply with a programmed set value lower than ambient temperature (for example 0 °C). After lever positioning pressure regulator must be adjusted for correct nozzle pressure value.

8.3.3 How dry-off period is performed The chamber is purged with heated air. The Standard requirements are “within ¾ h all visible moisture is dried off of the specimens” and “the temperature throughout the exposure zone shall reach and remain at 35 °C within ¾ h” Titanium panels have to be installed on the bottom of the chamber. Titanium panel will transform the flooded bottom chamber used for salt spray test in a dry bottom chamber used for Prohesion test and will facilitate the dry-off. Air is heated with an air heater and introduced in the chamber via a pipe near the top of the dome.


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8.3.4 How to set air heater temperature Start the test and after some cycles check the chamber temperature value on display at the end of dry-off period. Adjust heater temperature red potentiometer to meet the standard requirement. Pay attention, if air temperature has to be increased, rotate slowly the red potentiometer clockwise of a very little step and make a test. A little moving of red wheel makes a big variation of temperature.

CAUTION: when you adjust air heater temperature check

out temperature.

How to measure out temperature of the air heater: remove the screw above the one way valve (point G, paragraph 6.2), place a thermometer in that hole where was the screw, turn a few red wheel and after 1 minutes check out temperature

It must be below 90 °C

WARNING

If it is installed air heater (only Prohesion Option) ,

DON’T TOUCH THE BLUE WHEEL

DON’T TURN RED WHEEL ABOVE LEVEL 1 (100°C). If red wheel is upper than level 1 the out temperature of air heater can be over 100°C and damage the whole DRY system

Don’t remove screws on the red and blue wheel

8.3.5 Test execution: alarms and warning messages During Prohesion test execution chamber is not heated, humidifier is not heated and air do not pass through it. But controller will check chamber water level and humidifier water level, this means that chamber bottom must be flooded under titanium panel to avoid test stop depending from alarm condition “missing water” and the humidifier water supplying cock must be opened.


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9 SAFETY ADVICE

WARNING

Risk of contact with high temperatures. The heaters on the bottom of the test chamber are safeguarded by a grate, but this heating elements heats the water in the bottom of the chamber up to 100 °C.

WARNING

Before opening the chamber to remove or check the samples, stop the test, press Purge to eliminate the fog and wait, at least, 10 minutes before opening the door.

Before washing the chamber switch off the main

switch.

10 CORROSIONBOX PROTECTION

10.1 Heater protection The heating elements are protected by a thermostat that opens the electrical feeding circuit of the heater when the temperature exceeds 120 °C. If the thermostat opens the heater circuit, you must find out the reason of the over- temperature and eliminate the problem before pressing the red over-heating protection switch on the heater box.

10.2 Humidifier protection On the pirex wall of the humidifier there is a thermostat that opens the electrical feeding circuit of the humidifier heater if the temperature is over 85° C. If the thermostat opens the heater circuit, you must find the reason of the over-temperature and eliminate the problem before resetting the thermostat by pressing the push button which can be found in the centre of the thermostat. The thermostat is protected by a silicon cap.

10.3 Air heater protection To avoid over temperature of the air heater there is a thermostat that opens the electrical feeding circuit of the air heater if the temperature, of the heater body, is over 80° C. If the thermostat opens the heater circuit, you must find the reason of the over-temperature and eliminate the problem before resetting the thermostat by pressing the push button which can be found in the centre of the thermostat. The thermostat is protected by a silicon cap.


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11 MAINTENANCE

11.1 Chamber stop for some weeks If the CORROSIONBOX is not in use for several weeks the spray nozzle should be rinsed out as follows:

Disconnect the transparent tube from the dosing pump.

Immerse the tube in a container with about 1 litre. of warm distilled water and allow the apparatus to run until the tank is empty.

Re-connect the transparent tube to the dosing pump.

11.2 Chamber cleaning Do not use detergents which have a scouring effect or plastic solvents for cleaning any part of the chamber.

11.3 Dosing pump

The metering pump must be checked at regular

intervals of time (suggested 500 hours), it contains

a tube which must be replaced from time to time. On the metering pump there is a speed sensor (1). This sensor can work only if the pump cover is completely closed. On the left side of the sensor an hole (2) in the cover of the metering pump cover allows to adjust the pump speed using a screwdriver.


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In order to check the tube and the rollers.

Remove the black screw (3) from the cover.

Take away the cover (4).

Pull up the solution inlet (5), left side.

Turn the rollers (6) so clockwise until you can

free the tube (7), then pull up the pump outlet. (8)

Check the tube surface that don’t have to show mechanical wear or scratches whereas it is normal a not perfect round section of the tube after some hundred of working hours. If it is necessary to replace the tube change the complete tube system (include the support). When you have to reassemble the tube you proceed in this way: Insert a terminal tube in the pump outlet place (8-right side) Slide the tube (7) between the roll (6) and the wall while turn the rollers in anticlockwise direction. Put the other terminal tube in the pump inlet place (5-left side) After close completely the transparent cover, secure the cover is well insert in the pump. For closing the cover insert well the reference on the cover into notch on the pump (4a).


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11.4 Spray nozzle The spray nozzle 7 is fixed with the nut 4 to the support placed on the back wall of the test chamber. The tube coming from the metering pump is fixed on the pipe connection 5, the air compressed tube coming from the humidifier is fixed on the pipe connection 6. The collar 1 is screwed on the nozzle body 7, the fog quality depend from the clearance between the needle 3 and the collar 1, the counter-nut 2 stop the collar 1 when the adjustment of the nozzle is made. If the fog is not produced the reason may be the blocking of the salt solution needle (diameter 0.6 mm). The obstruction may arise with unfiltered solid parts coming from the salt solution or from crystallised salt due to chamber stop. You must disassemble the nozzle, free the salt solution needle possibly using compressed air or using a wire but paying great attention not to damage the PVC parts of the nozzle.


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11.4.1 Spray nozzle setting Extend the tubes in order to handle comfortably the nozzle.

Switch on the chamber.

Screw down completely the counter-nut 2 on the collar 1.

Screw down completely the collar 1 on the nozzle body 7. So the clearance is completely closed and the air cannot come out from the nozzle.

Wait for the jet of the salt solution.

Unscrew the collar 1 about ½ turn, look at the spray beam, unscrew ¼ turn and look at the spry beam. The correct adjustment is when the beam is large , normally between 1,5 and 2,5 turns. Now adjust the pressure to 1 bar using the pressure regulator. When the spray is the best possible, fix the counter-nut 2 on the body 7. Place the nozzle on its small square and fix it with the nut 4.

Reassemble the nozzle protection.


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11.5 Humidifier The humidifier has to humidify and to clean for possible oil contamination the compressed air. The transparent construction in Pirex allow to control the correct working of the humidifier. You must use distilled or demineralised water only, in fact the use of normal water produces the obstruction of the scrubber holes. The parts of the humidifier are:

1. Air inlets: two scrubbers made of Teflon produces air bubbles in the water column.

2. Humidifier drain tap (not visible in the picture, under the bottom).

3. Humidifier heater. 4. Double level float, when the water

level is under the lower sensor the test is suspended, the water enters into the humidifier until the water get the upper level sensor.

5. Water temperature sensor. 6. Humidified air outlet. 7. On the Pyrex tube is fixed a safety

thermostat. Thermostat switches off the humidifier heater when the temperature get 85°C.

Caution the thermostat works at 230 Volt. Switch off the main switch and find the reason of the over temperature and solve the problem before resetting the thermostat pushing the push button on it without removing the protective cap.


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11.6 Air heater

1. Air heater. It is an industrial air heater with built in temperature regulating circuit and safety circuit. See instruction manual for more information.

2. In this position, on the heater body, is the temperature adjusting red potentiometer, pay attention, if air temperature have to be increased, rotate the potentiometer clockwise of a small step and make a test.

CAUTION: DON’T TURN RED WHEEL

ABOVE LEVEL 1 (100°c) 3. Thermostat, it switches off the air heater

when the temperature in this point get

85°C. Caution the thermostat works at 230 Volt. Switch off the main switch and find the reason of the over temperature and solve the problem before resetting the thermostat pushing the push button on it without removing the protective cap..

4. One way valve. It will avoid to the corrosive fog to reach the air heater and corrode it.

5. One way valve access. Remove the cap to reach the floating stopper, it can be removed for cleaning.

6. Humidifier bypass lever (option). Vertical position for humidifier exclusion, horizontal position for humidifier active.

7. You can measure out temperature of the air heater in this point. Remove the screw and insert a thermometer. Start a DRY/Prohesion test and when you turn the red wheel, you are sure that air heater out temperature must be below 90°C.


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12 PROBLEMS AND SOLUTIONS

12.1 No Fog

Checks:

Is there sufficient salt solution in the tank?.

Is the dosing pump running?.

Is compressed air available?.

Is the scrubber obstructed?.

Is the nozzle obstructed?.

12.2 Chamber temperature do not get the requested value

Check if the chamber bottom is completely flooded of water.

Check if the water on the chamber bottom is hot.

If the water is hot add water to increase evaporation surface, if the water is cold check the heating element and if the red pilot light is on, if the light is off check the heater thermostat.

12.3 Humidifier temperature does not get the requested value

Check that there is water and bubbles due to compressed air in the humidifier.

Check the humidifier thermostat.

12.4 Air heater temperature does not get the requested value

Check the air heater thermostat.

Check the supply air pressure it should be higher than 2 bar.

Check the air pressure switch.

12.5 Nozzle pressure falls .

Check the supply line

Check the presence of air after Y1 electronic-valve.

Remove the inlet pipe 1 of the humidifier, check the small holes for air diffusion in the water and clean them.

CORROSIONBOX 1000 litres salt spray chamber enhanced model

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Transcript of CORROSIONBOX 1000 litres salt spray chamber enhanced model