Table of Contents Rev. 4.70 AMTT Oct04

BCX Series Operating Manual Page 1

Table of Contents Rev. 4.70 AMTT Oct04

I. INTRODUCTORY NOTES.............................................................................................................. 5 A. Preface_________________________________________________________________________________ 5 B. Manual Conventions, Notes________________________________________________________________ 5

II. BCX SERIES OVERVIEW ............................................................................................................. 6 A. BCX Characteristics ______________________________________________________________________ 6 B. BCX Construction & Specifications _________________________________________________________ 6

III. SAFETY INSTRUCTIONS ............................................................................................................ 7 A. Please follow safety instructions and precautions_____________________________________________ 7

IV. GENERAL CABINET & CYCLING OVERVIEW .......................................................................... 8 A. Salt Fog Step____________________________________________________________________________ 8 B. Dwell Step ______________________________________________________________________________ 8

V. LOCATION & SITE PREPARATION ............................................................................................ 9 A. Unloading the BCX: Material handling Caution________________________________________________ 9 B. Site selection & Preparation _______________________________________________________________ 9

VI. INSTALLATION & REQUIREMENTS ........................................................................................ 10 A. Drain Connection (Customer supplied & installed) ___________________________________________ 10 B. Vent Connection ________________________________________________________________________ 11 C. Compressed Air Connection ______________________________________________________________ 11 D. Water Supply Requirements and Connection ________________________________________________ 12 E. Solution Reservoir overflow ______________________________________________________________ 12 F. Electrical Connection ____________________________________________________________________ 12 G. Level Floor ____________________________________________________________________________ 13 H. Location_______________________________________________________________________________ 13 I. Utility Services Testing___________________________________________________________________ 13 J. Lab Temperature and Humidity ____________________________________________________________ 13 K. Component Valves ______________________________________________________________________ 14 L. Solenoid Valve Assignments ______________________________________________________________ 15

VII. BCX SERIES COMPONENTS .................................................................................................. 16 A. Controller: OMRON _____________________________________________________________________ 16 B. Purge _________________________________________________________________________________ 16 C. cabinet Heater/s ________________________________________________________________________ 16 D. Bubble Tower __________________________________________________________________________ 16 E. Internal Salt Solution Reservoir ___________________________________________________________ 17 F. Fog Nozzle _____________________________________________________________________________ 17 G. Dispersion Tower/s _____________________________________________________________________ 17 H. Diffuser _______________________________________________________________________________ 18 I. Solution Transfer Pump __________________________________________________________________ 18

VIII. RUNNING THE CABINET ........................................................................................................ 19 Bubble Tower _____________________________________________________________________________ 20 Air Relief Valve (on the Bubble Tower) ________________________________________________________ 20 Standard Omron Controls - Temperature Setting________________________________________________ 21 Cycling Control Package____________________________________________________________________ 22 A. Introduction to Operating the PLC through the VCU __________________________________________ 23 B. Controller Overview _____________________________________________________________________ 25 C. Auto __________________________________________________________________________________ 27 D. Display Cycle Status ____________________________________________________________________ 28

Page 2 BCX Series Operating Manual

E. Profile Set-Up __________________________________________________________________________ 35 F. Manual ________________________________________________________________________________ 42 F. Machine Set-Up _________________________________________________________________________ 44 G. Password______________________________________________________________________________ 48 H. Display Setup __________________________________________________________________________ 52 I. Calibration _____________________________________________________________________________ 54 J. Control Buttons_________________________________________________________________________ 56

IX. ADVANCED OPERATION – COMPUTER CONTROLS.......................................................... 59 Introduction to operating the computer________________________________________________________ 59 Main Menu________________________________________________________________________________ 62 F1: select a test to run _____________________________________________________________________ 63 F2: status of current test ___________________________________________________________________ 65 F3: current test data _______________________________________________________________________ 73 F4: current I/O status ______________________________________________________________________ 77 F5: historical test data _____________________________________________________________________ 78 F6: calibration of cabinet ___________________________________________________________________ 79 F7: manual control ________________________________________________________________________ 81 F9: adjust machine parameters ______________________________________________________________ 83 F10: Program Test Specifications ____________________________________________________________ 89

X. OPERATING INSTRUCTIONS.................................................................................................. 101 A Salt Spray _____________________________________________________________________________ 101 B End-Of-Test Procedure __________________________________________________________________ 102

XI. SAMPLE RECOMMENDATIONS, USE OF RACKS, MOUNTS.............................................. 103 XII. FOG COLLECTION PROCESS & PROCEDURES ................................................................ 104

A. Fog Dispersion Control and Controls _____________________________________________________ 104 B. Determining & Measuring Collection Rates_________________________________________________ 105

XIII. TEST METHODOLOGY & SPECIFICATIONS....................................................................... 105 XIV. MAINTENANCE..................................................................................................................... 106

A. Check Before Each and Every Test: The Rule of Three_______________________________________ 106 B. Routine mounthly Maintenance __________________________________________________________ 106 C. Annual Service ________________________________________________________________________ 108 D. Calibration ____________________________________________________________________________ 109

XV. TROUBLESHOOTING, NOTES.............................................................................................. 110 A. General_______________________________________________________________________________ 110 B. Special Note on Solution Purity: filter, fog nozzle ___________________________________________ 110 C. Troubleshooting Contents_______________________________________________________________ 110 D. No Fog _______________________________________________________________________________ 111 E. Low Collection Rates ___________________________________________________________________ 111 F. High Collection Rates___________________________________________________________________ 111 G. Uneven Collection Rates ________________________________________________________________ 112 H. Low Relative Humidity __________________________________________________________________ 112 I. No Heat in Bubble Tower ________________________________________________________________ 112 J. Cover Bounces ________________________________________________________________________ 113 K. Cloudy Bubble Tower___________________________________________________________________ 113 L. Incorrect pH level ______________________________________________________________________ 113 M. Inconsistent Air Pressure in Bubble Tower_________________________________________________ 113 N. Bubble Tower Fills with Water over the Float Switch_________________________________________ 114 O. Salt Settles in Bottom of Salt Solution Reservoir ____________________________________________ 114

XVI. WARRANTY INFORMATION & SERVICE ............................................................................ 115


XVII. REPLACEMENT PARTS...................................................................................................... 116 XVIII. GLOSSARY ................................................................................................................................... 117 INDEX ....................................................................................................................................................... 123


Other Lab Testing Cabinets available from Atlas Material Testing Technology LLC and its authorized global representatives:

SF – Traditional Salt Fog (Spray) Cabinets SF-Walk-in/Drive-in – for oversized samples

CCX - Advanced Cyclic Cabinet Modified CCX – with pass-through

mechanical/electrical ports

SRC100 – variable pressure Spray/Rain Chamber


I. INTRODUCTORY NOTES A. PREFACE

Thank you for selecting an ATLAS lab corrosion test cabinet. Our success is measured, first, by your selection of a cabinet that is manufactured to our Total Quality standards and, second, by your continued satisfaction. Our commitment to total quality extends beyond manufacturing, and continues well into your future. If you have comments or suggestions regarding any aspect of the design, operation, or maintenance of our equipment, or this operation manual, please contact Atlas Material Testing Technology [ [email protected] ] or your authorized Atlas representative. Please mention the Revision #, found at the upper right of Page 1. Please read the following installation and operating instructions in their entirety before beginning. This manual covers installation, operation, maintenance, calibration and trouble-shooting of the BCX cabinet. When questions arise that are not answered by the manual, please contact Atlas or your authorized Atlas representative. Electrical, plumbing and layout drawings are shipped with each cabinet. During shipping, storage, and installation the BCX may collect dust, dirt, or other debris. If this occurs, clean the inside of the BCX thoroughly with a mild, non-abrasive cleanser and thoroughly rinse with distilled or deionized water prior to use. Since this unit can be used to perform many different tests, always refer to the particular test specification for temperature settings and other guidelines. Familiarity with the test specification(s), as well as cabinet operation, will make installation and operation of the unit easier. In the event of conflict, the test specification supersedes this manual. Also, we recommend operating the cabinet for 24 hours to adjust and monitor collection rates before running an actual test. If the BCX has not yet been delivered, please note the material handling caution noted in Section V, which also applies at any time the cabinet is moved. Please keep in touch with ATLAS regarding upgrades, desired options, or other testing needs. We will also maintain regular contact, and we wish many years of accurate, dependable testing.

B. MANUAL CONVENTIONS, NOTES

The end of a section is noted by this symbol: [ ] This manual is written and published by Atlas Material Testing Technology LLC under license. All rights reserved by the copyright owner. Nothing herein can be reproduced in any form by anyone other than direct ATLAS customers for internal use in operating or maintaining this equipment. Trademarks or trade names used in the manual remain the property of their respective owners.


II. BCX SERIES OVERVIEW

A. BCX CABINET CHARACTERISTICS • Durable, all plastic construction • Automated fill on Bubble Tower • Built-in Solution Reservoir • Front access to all cabinet components • Temperature with Wet Bulb & Dry

Bulb display • Translucent cover (excluding BCX9000

and BCX11000

B. BCX CABINET CONSTRUCTION & SPECIFICATIONS ATLAS manufactures the BCX cabinet using advanced fiberglass, providing high corro-sion resistance. State of the art techniques ensure longevity and strength. This cabinet will not rust from corrosive solutions that are used in many testing processes. ATLAS’ all plastic design provides a “natural” insulation that helps make testing conditions consistent, repeatable, and controlled. The dual magnetic cover seal (BCX9000 has a water seal) and proper ventilation keeps fog inside the cabinet.

BCX2000 BCX3000 BCX4000 BCX9000 BCX11000

Internal * Capacity

565 litres 20 ft3

850 litres 30 ft3

1130 litres 40 ft3

2548 litres 90 ft3

3115 litres 110 ft3

Test Space * Testing Plane

0.91 m2 9.81 ft2

1.37 m2 14.71 ft2

1.77 m2 19.01 ft2

2.21 m2 22.06 ft2

4.21 m2 45.4 ft2

Internal * Dimension

1270 mm L (50”) 717 mm W (28.25”) 641 mm H (25.25”)

1905 mm L (75”) 717 mm W (28.25”) 641 mm H (25.25”)

1905 mm L (75”) 927 mm W (36.5”)

641 mm H (25.25”)

1930 mm L (76”) 1143 mm W (45”) 1155 mm H (45.5”)

2267 mm L (89.25”)1860 mm W 73.25”)

762 mm H (30”) Total cabinet

Volume** 982.5 litres

34.7 ft3 1,472.5 litres

52.0 ft3 1,925.5 litres

68.1 ft3 3,822 litres

135 ft3 4870 litres

172 ft3

External Dimensions.

1930 mm L (76”) 889 mm W (35”) 1422 mm H (56”)

2565 mm L (101”) 889 mm W (35”) 1422 mm H (56”)

2565 mm L (101”) 1118 mm W (44”) 1422 mm H (56”)

2692 mm L (106”) 1321 mm W (52”) 2159 mm H (85”)

2820 mm L (111”) 2286 mm W (90”) 1829 mm H (72”)

Floor Space, incl. Operator

Access

2032 mm L (80”) 2057 mm W (81”)

2667 mm L (105”) 2057 mm W (81”)

2667 mm L (105”) 2286 mm W (90”)

2794 mm L (110”) 2540 mm W (100”)

3099 mm L (122”)3912 mm W (154”)

Solution Reservoir 132 litres / 35 gallons 132 litres / 35 gallons 132 litres / 35 gallons 132 litres / 35 gallons 132 litres / 35 gallons

* The inside dimensions given are “usable testing space.” They do not include unusable testing space: below the Air Diffuser where heaters are located, or space within the cover where fog moves laterally. ** Total Cabinet Volume provide as a means to compare against cabinets from other manufacturers that report volume within the cover.


III. SAFETY INSTRUCTIONS

A. PLEASE FOLLOW SAFETY INSTRUCTIONS AND PRECAUTIONS

1. Read this Manual in its entirety before operating the equipment. 2. Never install any device for the purpose of overriding any safety interlock. 3. Never alter the electrical wiring for the purpose of overriding any safety interlock. 4. All solutions and chemicals that may be used in the equipment must be handled and

disposed of in accordance with established safety procedures. 5. Never operate the equipment with any solutions or concentrations of solutions that are

not compatible with the materials of construction. 6. Never operate the equipment at temperatures that are not compatible with the

materials of construction. 7. Never operate the equipment when under the influence of drugs or alcohol. 8. Consult your own policies, procedures, or manuals that govern equipment installation,

utilities, safety, and regulatory compliance.


IV. GENERAL CABINET & CYCLING OVERVIEW

The ATLAS BCX is a lab corrosion test cabinet. Its purpose is to create a corrosive salt fog or high humidity environment within its exposure zone.

A. SALT FOG STEP

During the Salt Fog Step, salt solution is atomized into a fog. This is the same setup that normally would be used when operating according to ASTM B117. Hot, humid air is created by bubbling compressed air (usually at 1.03bar / 15 psi) through a vertical tube (Saturation Tower, Bubble Tower) that is about 3/4 full of heated 48°C (118°F) deionized water. Salt Solution is fed into the internal reservoir by a float switch and solenoid. When the pressurized air is routed to the Atomizer Nozzle, Salt Solution is drawn upward and atomized into a corrosive fog. The BCX is usually heated during this cycle at 35°C (95°F) by the cabinet heater/s. The temperature can be varied; the temperature is set at the controller.

The Salt Solution can be replaced with other electrolytes to create a corrosive fog with different properties.

B. DWELL STEP During the Dwell Step, no action is taken by any of the BCX components. If desired, the cabinet can be heated by the cabinet heaters.


V. CABINET LOCATION & SITE PREPARATION

A. UNLOADING THE BCX: MATERIAL HANDLING CAUTION

Be very careful when unloading or moving the ATLAS BCX . It is made of Fiberglas™ and can be damaged by forklifts. It is recommended that the BCX only be lifted from under the steel frame with a forklift, and with great care. After the BCX is unloaded, it can be rolled to the installation site.

B. CABINET SITE SELECTION & PREPARATION

It is very important to select an appropriate location for the ATLAS BCX unit. A poor or improper location may cause inaccurate results. Below is a list of considerations: • A climate controlled room with a clean, level floor (see NOTE 2). • Access to a floor drain. • Access to a roof vent or outside wall. • Near the proper electrical service. • Near a compressed air line. • Near a supply of pressurized DI (deionized) or distilled water (meeting ASTM D1193

Grade IV, ISO 3696, or JIS K8150). • Choose a location that will allow proper entry to the cabinet access panels for

maintaining and servicing. • Plan for access for 360° viewing of test items through the cabinet cover as desired.

NOTE 1: If any of these utility requirements are not available, they need to be brought to the location. See the drawing for locations of connections to the cabinet. NOTE 2: The cabinet location needs to be maintained at a consistent temperature and humidity range. The recommended temperature range is 20-25°C (68-77°F). As indicated above, warmer temperatures may cause the cabinet to operate out of specification for certain test cycles. Never allow the temperature around the cabinet to approach O°C (32°F).


VI. CABINET INSTALLATION & REQUIREMENTS

All connections and tests of service should be made prior to applying electrical power to the cabinet. There are several valves that must be in the proper positions before the BCX is started and used for testing. Failure to set these valves properly can result in flooded tanks, and/or empty Solution Reservoirs. Below is a listing of the proper valve setup procedures. A. DRAIN CONNECTION (CUSTOMER SUPPLIED & INSTALLED)

There are two different drain connections to be made. 1. cabinet Exposure Zone (main cabinet), 1.9 cm (3/4”), drain line 2. Solution Reservoir, 9.525 cm (3/8”) OD tube, drain line. 3. Bubble Tower Drain.

The BCX utilizes a dual vent/drain port on the back side of the cabinet. This port is 10.2 cm (4”) in diameter. A “T” (customer supplied) should be placed on this port and on one side of the “T” the size should be reduced to 1.9 cm (3/4”) drain line. This drain line MUST gravity feed to the supplied Wet Bottom Drain Assembly, and then to the customer’s floor drain. This cabinet is not designed to drain to a location above floor level. Do not directly connect into the floor drain. Allow the cabinet drain line to "lay" over the floor drain. Connected to this drain is a “Wet Bottom Drain” assembly.

This assembly is designed to keep the heater in the BCX’ exposure zone covered with water. This creates a more even heat as well as raises the humidity in the Exposure Zone. This assembly must be installed on the BCX in order for it to run correctly. If this device was not purchase from ATLAS, then it will have to be created during the installation process. The height of this device is critical. In addition, this assembly must be secured (usually to the floor) by the customer to

take the stress of the weight of the drain/vent system off of the cabinet’s drain/vent nipple.

Notice also that, during operation, the ball valve on this Wet Bottom Assembly must be CLOSED to make the wet bottom work. From the back side of the Wet Bottom Drain assembly, connect a drain line to the customer’s floor drain.


When the valves are installed into these drains, set them as follows;

cabinet Drain - CLOSED Solution Tank Drain - CLOSED - Ball valve #3 Bubble Tower Drain - CLOSED – Ball valve # 2

The above Drain valves that are normally closed can be opened for draining and cleaning.

B. VENT CONNECTION The cabinet utilizes a dual vent/drain port on the back side of the cabinet centered along the cabinet length and about 17.8 cm (7 inches) above the lab floor. This port is 10.2 cm (4”) in diameter. A “T” should be placed on this port and on one side of the “T” a vent should be run outside of the laboratory and building. If this vent length exceeds 4.5 meters, (15’) then the customer should consult an expert concerning proper “power” venting methods to ensure against any possible back pressure into the cabinet. In addition, there is a 2” vent port located on the center back part of the cabinet just above the 4” vent/drain connection. The customer must connect a 2” vent line to the same vent pipe leaving the laboratory.

See the drawing in that accompany the BCX to see how to configure the vent and drain. In addition, it may be required to connect a customer-supplied 47 lps (100 cfm) exhaust fan to this vent tube to draw the air out of the cabinet. Contact a building engineer or other ventilation expert for possible sizing.

C. COMPRESSED AIR CONNECTION Compressed air must be free of oil, water and other contaminants. If the compressed air is not clean, the customer must install an oil/water extractor in the air line prior to connection to the cabinet. In addition, this air must be regulated to 2.8 bar (40 psi). The BCX uses about 1.8 lps (3.5 cfm) during operation of the fogging cycles. The BCX cabinet has a “Quick-connect” fitting for the incoming air supply that will accept a 9.525 mm (3/8”) OD polyurethane tubing. If the cabinet is equipped with Air cover lifters, there will be a second air connection to the combination air regulator / filter which will be located about here.


D. WATER SUPPLY REQUIREMENTS AND CONNECTION

DI/Distilled water is used in the Bubble Tower and for mixing of the particular electrolyte (example 5% salt solution, CASS solution etc.) for the fogging system. The type of water used is usually described by the test specification as found in ASTM D1193 Grade IV, ISO 3696, and JIK K8150. Pay close attention to the type of water used. The only type of water to be used in this instrument is deionized or distilled water in compliance with the above specifications. The use of other water can damage the pH meter as well as certain components of the cyclic test cabinet. It is suggested that the user of a BCX cabinet get a copy of the above specifications and read the description for the different types of water. The BCX cabinet has a “quick-connect” fitting for the incoming water supply that will accept a 9.525 mm (3/8”) OD poly-urethane tube. This water supply pressure must be regulated to between 1-2 bar (15-30 psi).

E. SOLUTION TANK OVERFLOW

The cabinets 35 gallon solution tank has an overflow port. During installation, the customer should install a ¾” line to this port and run it to an open facility drain.

F. ELECTRICAL CONNECTION

This cabinet is wired for use with the electrical supply stated on the confirmed Purchase Order. The amperage draw for this set-up is listed on the electrical drawings. It is required that only a qualified electrician connect power wires the cabinet. The electrician will need to drill a hole into the fiberglass electrical enclosure, and bring the wires into the cabinet from a customer-supplied, lockable, fused disconnect. This connection is to be made to the electrical panel and attached to the proper terminal strip.


G. LEVEL FLOOR

The BCX must be installed on a level floor. If the floor is slightly uneven, the adjustable feet can be used to level the cabinet. Improper leveling of the cabinet can result in poor testing results.

H. LOCATION When the BCX is installed, the only access required for loading and maintenance is in the front of the cabinet. Choose a location that will allow proper entry to this area with at least 0.9 meters ( 3 feet) of open area in front.

I. UTILITY SERVICES TESTING After all utility services have been connected, they should be tested. All connections and lines should be inspected, as applicable:

1. Leaks at connections or on lines.

Inspect connections, and test all air, water, and drain lines for leaks. Refer to the relevant drawings that accompanied the BCX to locate the correct illustration.

2. Voltage

Inspect connection, and check the electrical service for proper voltage. Refer to the relevant drawings that accompanied the BCX to locate the correct illustration.

J. LAB TEMPERATURE AND HUMIDITY For the BCX to function properly it needs to be installed into a climate-controlled room at a consistent temperature and humidity range. The recommended temperature range is 20-25 °C (68-77° F). Never allow the temperature around the cabinet to approach O°C (32°F). The recommended humidity is not to exceed 60%. If the temperature or humidity is out of these ranges it may cause the cabinet to operate out of specification for certain test cycles.


K. COMPONENT VALVES

The cabinet is equipped with several “Ball Valves” for ease of operation and maintenance. They are listed as follows.....

Ball Valve # Description Valve Position

1 Salt Solution Filter Valve - OPEN Used to change the Salt Solution Filter

2 Bubble Tower Water Drain - CLOSED Used to drain the Bubble Tower for cleaning

3 Salt Solution from Solution Reservoir - OPEN Used to allow Salt Solution to leave the Solution Reservoir

4 Air to the Solution Transfer Pump - CLOSED Used to turn the transfer pump on and off. Normally this is in a closed position and will be opened as needed to turn the pump on

5 Air to Diaphragm Pump - OPEN Used to “throttle” the air into the Dispersion Tower Fill Pump.

9 External. Condensate Valve #1 - CLOSED Used to allow condensation to collect in the black tubing. Open when taking collection rates, then close.

10 External. Condensate Valve #2 - CLOSED 11 External. Condensate Valve #3 - CLOSED 12 External. Condensate Valve #4 - CLOSED 13 Air to the Electronics Enclosure (BV #9) - ADJUST

Used to “meter” air into the electronics enclosure; pressurizes area to keep salt out and cool electronics

27 Salt Solution Tank Drain (customer supplied) - CLOSED Used to drain the salt solution tank for cleaning & solution changeover

The OPEN and CLOSED status listed above are preset at the factory (with the exception of #27), and this one should remain in CLOSED position during testing. These valve positions can be altered for cabinet cleaning and maintenance.

The illustration in the back of this manual will show the approximate location of these valves.

NOTE: The numbering of these ball valves are not in sequence for a reason. This cabinet can be updated at a later date to a full cyclic corrosion (CCX) test cabinet. If that update occurs, then the numbers will stay consistent and remain the same for the CCC cabinet.


L. SOLENOID VALVE ASSIGNMENTS

The cabinet is equipped with three “Solenoid Valves” for automatic operation and delivery of air, DI water, and salt solution to cabinet components. They are listed as follows:

Solenoid # Description 1 DI Water to Bubble Tower When opened, it will allow DI water into the Bubble Tower. This solenoid is controlled by the Bubble Tower Level Switch. 2 Air to Bubble Tower (Moist Air ) When opened, it will allow compressed air into the Bubble Tower. This solenoid is controlled by the items selected by the operator for a specific test interval. 3 Salt Solution to Fog Nozzle Feed Reservoir When opened, it will allow Salt Solution to fill the fog nozzle feed reservoir. This solenoid is controlled by the Fog Nozzle feed reservoir float switch.

Note: On a BCX 3000 or 4000, Solenoid #3 is located under the second solution transfer pump. This solenoid will be located here.


VII. BCX SERIES COMPONENTS

The following sections provide brief notes on major components of the BCX Series.

A. CONTROLLER: OMRON The controller for all standard BCX Series cabinets is the OMRON controller. It is set to function in degrees Celsius. See the enclosed literature for specifics on this controller. Option cycling controller available.

B. PURGE The purge Toggle valve is located on the front of the control panel and allows the user to PURGE the fog out of the cabinet prior to opening the cover. This will prevent corrosive fog from entering the lab. Simply toggle the valve when you desire to purge the cabinet, and close when done. In a vertical position the air is directed to the bubble tower. In an offset position (in any direction) the air is directed to the inside of the cabinet for purging.

C. CABINET HEATER(S)

cabinet Heater(s) maintain the cabinet temperature during testing. They are controlled by the OMRON controller. These heaters are located at the floor of the cabinet, beneath the Diffuser Plate. The size and wattage of heaters depends upon the size of the cabinet.

D. BUBBLE TOWER

1. The function of the Bubble Tower (also called Saturation Tower or Humidifier) is to saturate the air with moisture and heat the air before it reaches the atomizer nozzle, where it mixes with solution to produce fog. Air must be saturated at temperatures higher than temperatures within the Exposure Zone.

2. Tower refill operations require a pause in operation. The Bubble

Tower Water Float Sensor will detect “low water,” the Tower Heater will be turned off; and the fog solenoid valve will close. The Water Fill solenoid will open, filling the Bubble Tower until the Water Float Sensor detects “high water,” and shuts the Water Fill solenoid valve. The test resumes at the place where it paused, and the test continues.

3. The Tower has two over-temperature protections.

a) Setpoint at the Controller. b) Thermocouple with a reset built into the Heater(s).


E. INTERNAL SALT SOLUTION RESERVOIR

The BCX reservoir holds 132 liters/ 35 gallons of salt solution, sufficient to perform 3-5 days of continuous salt spray testing depending on the cabinet size and settings.

1. Water: Use Dl or distilled water to make solution (according to the test specification). 2. In-line Filter: Large particulates and contaminants are prevented from entering the

system by the in-line salt solution reservoir filter, which needs to be replaced periodically (see Maintenance for details).

F. FOG NOZZLE

The fog nozzle appears to be a simple plastic nozzle, but it is a critical part in the proper functioning of the cabinet, and in obtaining accurate test results. Constructed of a clear, non-corroding, acrylic resin, it is carefully crafted to specification. Hole diameter of the nozzle are very small and precision-fabricated, and it must be kept clear and free of salt, crystalline buildup or obstruction (do not scrape or use rough tools). To keep the nozzle free of blockage, the whole system should be flushed with warm, clean water for an hour at the end of each test period to remove all residual salt, preventing crystallization.

G. DISPERSION TOWER

The dispersion tower is where the salt solution and the humidified air meet at the atomizer nozzle to create the fog. It consists of: a. vertical or horizontal baffle system b. pickup tube/baffle c. atomizer nozzle d. internal feed reservoir


H. DIFFUSER

What seems to be a “false floor” of the cabinet is actually an Air Diffuser; its function being to distribute air flow within the Exposure Zone. Samples or undue weight shouldn’t be placed upon it.

I. SOLUTION TRANSFER PUMP

This cabinet is equipped with a 35-gallon Solution Reservoir. This is not a mixing tank. The salt solution should be mixed in another container and transferred into this reservoir. Due to the location, it is not practical to “pour” the mixed salt water into this reservoir. To get the pre-mixed salt solution into the reservoir, a couple of simple steps must be taken.

1. Mix the salt solution in a

separate container. 2. Get this pre-mixed solution

close 1-1.5 m / 3-5’ to the BCX’s 35-gallon reservoir.

3. Put the tubing from the transfer pump’s inlet into the container holding the pre-mixed solution.

4. Change ball valve #3 (Salt Solution from solution reservoir) from its normally OPEN position to a CLOSED position

5. Change ball valve #4 (air to the Solution transfer pump) from its normally CLOSED position to an OPEN or partially OPEN position. The more you OPEN it, the faster the pump will move solution into this 35-gallon reservoir.

6. When all of the solution is moved, put these two valves into their original positions, coil up the tubing and the transfer is complete.

TRANSFER PUMP


VIII. RUNNING THE CABINET

Refer to drawing number 850001 1. Ensure that the Omni-Fog™ Dispersion Tower(s) is

inside the cabinet and that tubing is connected as shown in the appropriate drawing. The red tubing (connection #4) is for air to the atomizer nozzle, and the yellow tubing (connection #5) is for salt solution to the internal reservoir.

2. Connect the customer-supplied pressurized DI (or distilled) water supply to the fitting marked #2 as shown on the drawing. Use 9.525mm / 3/8” OD poly tubing to make this connection, and make sure the tubing is completely inserted into the plastic fitting before tightening. The recommended water pressure for this line is between 1.03-1.72bar / 15-25psi.

3. Make certain that the… • Manual valve (ball valve # 2) for the Bubble Tower Drain is CLOSED. • Manual toggle valve (located on the control panel) for Air to Purge Line or Air to

Bubble Tower is in the Bubble Tower position (centered and upright).

4. Make certain the cabinet cover is closed.

5. Set cabinet temperature control to desired temperature. (The cabinet temperature is preset at 35ºC.) Refer to Section IX, TEMPERATURE SETTING for temperature setting instructions.

6. Press the ON button located on the control panel’s ON/OFF switch.

7. Turn the cabinet heater switch to the ON position and check the electrical circuit to be certain the cabinet heaters are operating. The pilot light marked "cabinet Heaters" should be lit.

NOTE: Allow 15-30 minutes (depending on cabinet size, heater voltage, and room temperature) for the cabinet to heat to setpoint temperature. When the cabinet has reached the desired setpoint, the cabinet heaters will turn off and the pilot light will go out. (The pilot light will go on and off with the heaters to indicate the heaters are maintaining the desired temperature.)


BUBBLE TOWER

1. Now that pressurized DI water ( use only ASTM D1193 type IV water) is connected

to the Bubble Tower the cabinet controls will keep it full of water.

• When the float switch inside the Tower detects a low water condition, the Air Solenoid (#5) closes to depressurize the Tower, and the DI Water Solenoid (#1) opens to allow the Tower to Fill. When the float switch detects a full water condition, these solenoids reverse and normal operation resumes.

2. Turn Bubble Tower heater switch to an ON position and check the electrical circuit to be certain that the heater is heating properly. The Bubble Tower temperature control is factory preset at 48ºC.

3. Turn on the customer-supplied compressed air

(connected to fitting # 1) to the Bubble Tower air, and adjust the pressure (using the pressure regulator located on the control panel) until 15 psi (1.03 bar) is indicated on the pressure gauge located on the control panel.

The Bubble Tower is now in operation and ready for use.

AIR RELIEF VALVE (ON THE BUBBLE TOWER) All valves are factory set at 1.4bar / 20 psi when supplied with the cabinet. To adjust the valve:

• Turn up the pressure on the Bubble Tower until it reaches 20 psi (1.4bar). This will cause the valve to release pressure when it reaches this point.

• Pull up on the top portion of the valve and turn the valve until the desired setpoint is reached.

• Reduce Bubble Tower pressure to previous setting. (20-23 psi / 1.4-1.6bar).


STANDARD OMRON CONTROLS - TEMPERATURE SETTING

Two digital temperature controllers are located in the control panel. The controller marked "cabinet Temperature" has been preset to 35ºC (95ºF). The controller marked "Bubble Tower Temperature" has been preset to 48ºC (118ºF). They have been configured to operate in the ON/OFF mode, in degrees C, with alarms. A protective cover keeps salt fog from damaging the controllers. To read the wet bulb temperature, be sure temperature display switch is on "cabinet" and hold the spring-loaded switch to "Wet Bulb". (Always return switch to "Dry Bulb".) To change the setpoint:

Press the key, the letters SP should appear in the display data identifier just above the key. The main display will register the current setpoint. Press the , keys to either scroll down, or up to the new setpoint.

Press the key twice and the new setpoint will take effect. (Note: after pressing the key once, an AL will appear in the display window. This is the alarm setpoint, which is the temperature at which the controller will shut off the cabinet heaters and sound an alarm. An alarm will not clear until the condition that caused it is corrected. ) For further information, reference the Omron Temperature Controller section of the manual.


CYCLING CONTROL PACKAGE

There are two different controller options on the BCX cabinet, the STANDARD and cyclic control package.

The cyclic controller for the BCX Series cabinets is fully programmable, with an easy-to-use PLC operation (Programmable Logic Controller) accessed from a VCU (Video Control Unit). Standard industry test specifications are built in, pre-programmed, so the user can begin testing immediately after both installation and setup procedures are followed. Standard tests can be modified, and custom tests and procedures across multiple parameters can easily be programmed into the controller, providing flexibility, meeting multiple needs, and placing real control into the hands of the user. The VCU appears throughout this section for reference. The VCU allows input to the PLC and displays outputs.

The actual cabinet control is performed by the PLC, however, the VCU operator interface allows the user to communicate to the PLC for selecting a program to run, changing a program and so on. All operations, cycles (some require optional installed equipment), temperatures, times, setpoints, dry times, etc., are available for the operator to control. • The purpose of the cabinet controller is to activate the BCX cabinet components such

as heaters, blowers, pumps, air solenoids, DI water solenoids, salt solution solenoids and so on at the desired times for the desired lengths of times to produce the environmental conditions such as Salt Fog, Humidity, Dry off, and Solution Spray.

• The controller also stores the test profiles ready to be run at the operator’s discretion. • The controller monitors temperatures, solution levels and other conditions to keep the

cabinet running in a safe and repeatable manner. • The standard control package consists of a rack style micro PLC with 8 inputs, and 16

outputs. This PLC has enough memory to allow for all cabinet function programming and to hold 15 programs, each 16 steps long. It is adequate to control the BCX in the basic modes with standard cycling and nested looping. The operator interface for this standard package is a 2 line 20 character text display.


A. INTRODUCTION TO OPERATING THE PLC THROUGH THE VCU

The PLC and VCU are easy to learn and use. The PLC offers complete flexibility to custom program tests and test cycles. None of the operations are difficult to learn, whether running standard tests that are pre-programmed into the unit, or setting up custom testing programs.

This section provides basic information about operating the BCX Series PLC and VCU. Experienced operators of other PLCs should experience no difficulties in learning the variations found in this unit. Someone who has never used a PLC also should find no real difficulty, while it may take a little more time to become acquainted and proficient in running tests. This material is designed to make it even easier for both.

Learning Tip: This text is designed only to complement active exploration of the controls. The first-time operator should be in front of the VCU panel with the unit turned on to go through the learning steps. While some may wish to read through this material first, real learning will take place not by reading, but by exploring. 1. Conventions used in this section:

“Page” and “Screen” mean the same thing in the material that follows, referring to the lighted display area that is providing information and choices. The 5 physical areas of the VCU are designated by starting with a capital letter and in italics, as follow: Display Area, Control Buttons, Touch Panel, Numeric Keypad, and Position Keys. Identifying parts of the page Display Area that are selection areas or provide information to the operator are in quotation marks. Most Display Area items are in BOLD CAPITALS. Terms specific to actions, such as “Press,” “Push,” “Enter,” “Choose,” or “Select” are synonymous, and signify actions the operator must take in operating the VCU. These actions, and others, may appear in bold.

2. Basic VCU Features and Functions

a) Display Area - Shows information and status of operations, depending upon what screen is shown.


b) Control Buttons - Push these to control or select certain functions. c) Numeric Keypad - use these to enter numerical functions; it is the same as a

telephone keypad. d) Touch Panel - Use these to make choices and enter selections within areas shown

on the screen in the Display Area. e) Position Keys - Use these to move around the display area to change a number,

make a choice or move from one Display Area to another.

NOTE: When viewing the VCP please note that the display area for this standard controller is limited to 20 characters including spaces. Therefore, many words are abbreviated.


B. CONTROLLER OVERVIEW

SELECT OPERATING MODE

1. Auto 2. Profile Set-Up 3. Manual 4. Machine Set-Up 5. Password 6. Display Set-up 7. Calibration 8. O.E.M. Set-up

1. Select Test to Run 2. Profile Set-Up 3. Manual 4. Machine Set-Up

1. ASTM B117 2. CCT-1 3. CCT-IV 4. ASTM G85 A5 5. 9540P/B 6. Test 6 …….. 15. Test 15

1. ASTM B117 2. CCT-1 3. CCT-IV 4. ASTM G85 A5 5. 9540P/B 6. Test 6 …….. 15. Test 15

cabinet Heater Bubble Tower Heater Air Blower Spray Pump Moist Air Mix Air DI Fog Salt Fog Fill Trap Trap Drain Nozzle Drain User Output 1

Purge ON Time Mixer ON Time Bubble Tower Temp. SP #1 Bubble Tower Temp. SP #2 Bubble Tower Temp. SP #3 Enable Manual Step Power Loss Code Mixer On Time


Controller Overview – Continued

NOTE: When viewing the VCP please note that the display area for this standard controller is limited to 20 characters including spaces. Therefore, many words are abbreviated.

SELECT OPERATING MODE

1. Auto 2. Profile Set-Up 3. Manual 4. Machine Set-Up 5. Password 6. Display Set-up 7. Calibration 8. O.E.M. Set-up

5. Password 6. Display Set-up 7. Calibration 8. O.E.M. Set-up

Enter Password – Change level

Enter Current Password

Enter New Password

Setup - Contrast Adjust Dark, Light

Dry Bulb, Read – Display Bub Twr, Read – Display Wet Bulb, Read – Display

Bub Twr Over-Fill – 5 Manul Cntrol Time – 10 cabinet Over Temp – 75 Bub Twr Over Temp – 70 Chmbr Ht Ovr Time – 30 B. T. Ht Ovr Time – 27 DI to Trap Time – 25 Drain Trap Time – 90 Ovr Fill Fog Time – 25 Drain Fog Time – 90 % Htr on >20 <30 – 6 % Htr On >30 <40 – 7 % Htr on >40 <50 – 8 % Htr On >50 <60 – 10 % Htr On >60 <70 – 19 Rate – 45 Offset – 2.5 Fine Band Offset – 0.5 Blower Offset – 2.0 Blower On Time – 30


C. AUTO

This section will instruct the user on how to start a test in the automatic mode. Start from the very first page of the operator interface. If not already there, PUSH the

HOME Key one time. When at the first page, the DISPLAY should show:

Now simply PUSH the ENTER Key once. The DISPLAY area, will show:

Use the left and right arrow keys to select the desired test profile. As these two keys are PUSHED, notice that the TEST names change from ASTM B117 to CCT-1 and so on until the end with TEST 15. When the test desired name/number is showing

on the DISPLAY area, PUSH the ENTER key once. The DISPLAY area will show: The test number selected will show up in the above box. If this is the test desired, to run

in the automatic mode, then start the test now by PUSHING the START key once. (This key is one of the Control Buttons located on the right side of the operator interface.) If there are no ALARM conditions the cabinet will start the selected test in the automatic mode. For example, if test ASTM B117 is selected, and everything was done properly during this start-up, then in the DISPLAY area will show:

Select Operting Mode 1>AUTO

Select Test to Run 01> ASTM B117

TEST # XX STEP XX Cycle Comp

ASTM B117 STEP 1 IN Cycle Salt Fog


D. DISPLAY CYCLE STATUS This section will instruct the user on how to display the cycle status of the cabinet. The process for viewing the cycle status is the different by one step depending on if a test is running (in cycle) or not (out of cycle).

IF THE CABINET IS IN CYCLE the following will apply

Start from the very first page of the operator interface. If not already there, PUSH the

HOME Key one time. When at the first page, the DISPLAY area should show:

Now PUSH the ENTER Key once. The DISPLAY area will show:

This screen will show the operator; • what test was selected in this example TEST XXX • what step the cabinet is in in this example STEP X • the condition of the test in this example IN CYCLE • the name of the step running in this example Salt Fog Of course the words shown in this DISPLAY area will change depending on the test name/number running, the step the cycle is in, and the status (In Cycle, Stopped Cycle, Alarm condition) that the cabinet is in.

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows the amount of Time that was programmed for this step in the cycle, and the amount of time remaining in this step.


Time of Step XX Time Remaining XX

TEST XXX STEP X IN CYCLE Salt Fog


PUSH the NEXT Key once. The DISPLAY area will show: This screen shows what the cabinet Temperature Setpoint is for this step in the cycle. Below that, both the Dry Bulb (cabinet) and Wet Bulb actual temperatures is shown.

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows what the Bubble Tower Temperature Setpoint is. This setpoint has 3 different possible setpoints that change depending on the test condition being run. These setpoints are pre-programmed at the factory and are changeable by the user.

• Bubble Tower Temp. SP #1 is activated during a Salt Fog test • Bubble Tower Temp. SP #2 is activated during a Humidity test • Bubble Tower Temp. SP #2 is activated during all other test conditions

Below that is displayed the actual Bubble Tower temperature.

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows the Event Code assigned for this step in the cycle. The number shown corresponds to a particular condition in the cabinet. For example if this number is 1 then the cabinet will run a Salt Fog Cycle.

cabinet Tmp Set Pt XX Dry XX Wet XX

Bub TwrTemp Set Pt XX Bub Twr Cur. Temp XX

Event Code XX


Below is a list of all the Event Codes for this cabinet.

Description Event Code Salt Fog Cycle 1 High Humidity Cycle (100%) 2 Dry Cycle (low RH) or Purge 4 Solution Spray 8 Set current Step to Seconds (not minutes) 16 Guaranteed Soak ON 32 Cover Open / Close 64 User Output 1 128

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows what the looping parameters are for LOOP #1 of this test cycle. From - is the step the cycle will start the looping To - is the step the cycle will go to after completing the “FROM” step Set - is the number of times the controller will repeat this loop Togo - is the number of times the controller still has to repeat this loop

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows what the looping parameters are for LOOP #2 of this test cycle. From - is the step the cycle will start the looping To - is the step the cycle will go to after completing the “FROM” step Set - is the number of times the controller will repeat this loop Togo - is the number of times the controller still has to repeat this loop

LOOP1 - From: XX To: XX Set XX Togo XX



PUSH the NEXT Key once. The DISPLAY area will show: This screen shows the looping parameters set for LOOP #3 of this test cycle. From - is the step the cycle will start the looping To - is the step the cycle will go to after completing the “FROM” step Set - is the number of times the controller will repeat this loop Togo - is the number of times the controller still has to repeat this loop

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows that the operator has returned back to the beginning of this section. If

the NEXT Key is PUSHED, it will keep “scrolling” through the information shown in this section.


TEST XXX STEP X IN CYCLE Salt Fog


IF THE CABINET IS NOT IN CYCLE the following will apply





This screen will show the operator; • what test was selected in this example TEST XXX • what step the cabinet is in in this example STEP 00 • the condition of the test in this example IN CYCLE Of course the words shown in this DISPLAY area will change depending on the test name/number running, the step the cycle is in, and the status (In Cycle, Stopped Cycle, Alarm condition) that the cabinet is in.

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows a 0 (zero) for the amount of Time since the controller is not in cycle.


Time of Step 0 Time Remaining 0

ASTM B117 STEP 00 CYC CANCEL

Select Test to Run 1>ASTM B117


PUSH the NEXT Key once. The DISPLAY area will show: Note that the cabinet Temperature Setpoint is 0 (zero) since the controller is not in cycle. Below are both the Dry Bulb (cabinet) and Wet Bulb actual temperatures.

PUSH the NEXT Key once. The DISPLAY area will show: This screen shows that the Bubble Tower Temperature Setpoint is 41oC since the controller is not in cycle. Below that is the actual Bubble Tower temperature.

PUSH the NEXT Key once. The DISPLAY area will show: The screen shows that the Event Code is 0 (zero) since the controller is not in cycle.

PUSH the NEXT Key once. The DISPLAY area will show: The screen shows that all looping information is 0 (zero) since the controller is not in cycle.

cabinet Tmp Set Pt 0 Dry XX Wet XX

Bub TwrTemp Set Pt 41 Bub Twr Cur. Temp XX

Event Code 0

LOOP1 - From: 0 To: 0 Set 0 Togo 0




PUSH the NEXT Key once. The DISPLAY area will show: The screen shows that the operator has returned to the beginning of this section. If the

NEXT Key is PUSHED, it will keep “scrolling” through the information shown in this section.



ASTM B117 STEP 00 CYC CANCEL


E. PROFILE SET-UP

This section will instruct the user on how to set-up a new test profile, or edit an existing one. Start from the very first page of the operator interface. If not already there, PUSH the


Now PUSH the right arrow key once. The DISPLAY area will show:

PUSH the ENTER Key once. The DISPLAY area will show: The controller is waiting for the appropriate password for this screen. Using the numeric

keypad, PUSH the 2 key and then the ENTER Key once. If the password was entered correctly, the DISPLAY area will show:

Use the left and right arrow keys to select the desired test profile. As these two keys are PUSHED, the TEST name/numbers change from ASTM B117 to Test 15.


Select Operting Mode 2>Profile Set-up

Protected Lvl: 2 Password: __

Select Test to Pgm. 01> ASTM B117


When the desired test number is showing on the DISPLAY area, PUSH the ENTER key once. The DISPLAY area will show:

There are four TOUCH PANEL keys under the DISPLAY area (as shown above). Pressing either of the left two keys will Edit the Step DATA for the chosen test. Pressing either of the right two keys will edit the LOOP data for the chosen test.

To edit the Step DATA, PUSH one of the left two TOUCH PANEL keys once. The DISPLAY area will show:

PRESS the left arrow key once to change the Time for this Step. Using the numeric keypad enter the number(s) (in minutes) for how long like this step should run.

After PUSHING the numbers, PUSH the enter key once to save the selection.

Now it is time to set the Temperature that this step will run at. PRESS the NEXT

key once, and the DISPLAY area will show:

Editing TEST XX(name of test) Step 1 TEMP XX

Edit Step Edit Loop Data Data

Editing TEST XX(name of test) Step 1 TIME XX


PRESS the left arrow key once to change the temperature setpoint of this Step. Using the numeric keypad enter the number for (from 1 to 71) the temperature of this Step. Remember that this cabinet has no cooling equipment; therefore, a number entered into this area that is lower than the actual temperature surrounding the equipment will not be achieved. This controller works in metric and uses the number input as degrees

Celsius. PUSH the enter key once to save the selection. Now that the Time and Temperature of this Step are set, the actual test condition must be set.

PUSH the NEXT Key once. The DISPLAY area will show:

PRESS the left or the right arrow key once to position the cursor to change the Event Code of this Step. Using the numeric keypad enter the number (1, 2, 4, 8,16, 32, 64 or 128) corresponding to the desired Event Code for this Step. As shown previously (and below), Event Code numbers correspond to actual test conditions.

Description Event Code

Salt Fog Cycle 1 Event not available on this model 2 Purge 4 Solution Spray (optional) 8 Set current Step to Seconds (not minutes) 16 Guaranteed Soak ON 32 Cover Open / Close (optional) 64 User Output 1 128

PUSH the enter key once to save the selection.

Editing TEST XX(name of test) Step 1 EVENT XX


For example if this number is 1 then the cabinet will run a Salt Fog cycle. These numbers can also be added to combine test conditions. For example, if a Dry/Purge cycle (Event Code number 4) with the Guaranteed Soak feature (Event Code number 32) enabled, add these two numbers (4 + 32 = 36) and enter this number as explained above. NOTE: Take care in adding numbers when combining events. If events are combined that conflict with one another (for example Salt Fog and Dry ) the cabinet will not give usable testing results.

PUSH the NEXT Key once. The DISPLAY area will show: As shown, the Display Area has now indexed from Step #1 to Step #2 in the test parameter set-up for this Test. To continue editing (or viewing) other Steps of this Test, simply repeat the instructions of this section. A total of 16 steps for each Test exists in this standard controller.

Editing TEST XX(name of test) Step 2 TIME XX


When all of the Steps of this Test are correct, the Looping can be set-up. To get to the Loop set-up, Start from the very first page of the operator interface. If not already there, PUSH the


Now PUSH the right arrow key once. The DISPLAY area will show:


keypad, PUSH the 2 key and then the ENTER Key once. If the password was entered correctly, the DISPLAY area will show:

Use the left and right arrow keys to select the desired test profile. As these two keys are PUSHED, the TEST name/numbers change from ASTM B117 to Test 15.


Select Operting Mode 2>Profile Set-up


Select Test to Pgm. 01> ASTM B117


When the desired test number is showing on the DISPLAY area, PUSH the ENTER key once. The DISPLAY area will show:

There are four TOUCH PANEL keys under the DISPLAY area (as shown above). Pressing either of the left two keys will Edit the Step DATA for the chosen test. Pressing either of the right two keys will edit the LOOP data for the chosen test.

To edit the LOOP DATA, PUSH one of the RIGHT two TOUCH PANEL keys once. The DISPLAY area will show: To program a sample LOOP, read the following. For example, if after running Step 3 of the test it is desired to run Step number 1 and repeat this LOOP 5 more times, then enter the following data.

Using the left and right arrow keys, position the cursor in the DISPLAY area to the right of the From section in the DISPLAY area. Using the numeric keypad,

PUSH the 3 key and then the ENTER Key once. Again, using the left and

right arrow keys, position the cursor in the DISPLAY area to the right of the To section in the DISPLAY area.

Loop # 1 From XX To: XX Repeat XX

Edit Step Edit Loop Data Data


Using the numeric keypad, PUSH the 1 key and then the ENTER Key once.

Using the left and right arrow keys, position the cursor in the DISPLAY area to the right of the Repeat section in the DISPLAY area. Using the numeric keypad,

PUSH the 5 key and then the ENTER Key once. Now the DISPLAY area of the operator interface will show; Now Loop number 1 is complete.

If a Loop number 2 or 3 is needed, PRESS the next key once or twice to

display loop number 2 or 3. Use of the home and next key will allow the user to move between these 3 different loop set-up screens. Follow the above listed instructions to set the Looping parameters for Loop 2 and/or 3.

Loop # 1 From 3 To: 1 Repeat 5


F. MANUAL

This section will instruct the user on how to use the manual pages of the controller. This section of the controller will allow the user to turn individual cabinet components on and off with the touch of a button. Start from the very first page of the operator interface. If not already there, PUSH the

HOME Key once. When at the first page, in the DISPLAY area should show:

Now PUSH the right arrow key twice The DISPLAY area will show:

PUSH the ENTER Key once. The DISPLAY area will show: The controller is waiting for you to enter the appropriate password for this screen. Using

the numeric keypad, PUSH the 3 key and the ENTER Key once. If the password was entered correctly, the DISPLAY area will show:


Select Operting Mode 3>Manual


cabinet Htr Bub Twr Htr On OFF On OFF


Using the TOUCH PANEL keys the user can turn these devices on and off individually. For example, to turn the cabinet heater on, press the TOUCH PANEL

key to the far left. To turn the cabinet heater off, press the TOUCH

PANEL key that is second from the left.

In the same way, to turn the bubble tower heater on, press the TOUCH PANEL key that is third from the left, (or second from the right). To turn the bubble tower heater

off, press the TOUCH PANEL key that is all the way to the right.

Use the NEXT and PREVIOUS keys to choose other items to control. Below is a complete list of all of these items.

1. Cabinet Heater 2. Bubble Tower Heater 3. Air Blower – (purge solenoid for BCX cabinet) 4. Spray Pump 5. Moist Air Solenoid 6. Mix Air Solenoid (not available on BCX) 7. DI Fog Solenoid (not available on BCX) 8. Salt Fog Solenoid 9. Fill Trap Solenoid (not available on BCX) 10. Trap Drain Solenoid (not available on BCX) 11. Nozzle Drain Solenoid (not available on BCX) 12. User Output 1

This entire section is only active for a preset amount of time. That is, when the user enters this section of the controller, an internal timer is activated. When the pre-set amount of time elapses, all components that were turned on in the MANUAL mode by the user are turned off, and the DISPLAY area is changed back to the first screen.


F. MACHINE SET-UP

This section will instruct the operator on how to use the cabinet set-up pages of the controller. This section of the controller will allow the operator to set certain functions of the controller to customize testing. Start from the very first page of the operator interface. If not already there, PUSH the


Now PUSH the right arrow key three times the DISPLAY area will show:


keypad, PUSH the 4 key and then the ENTER Key once. If the password was entered correctly, the DISPLAY area will show: Manual Purge Time is the amount of time (in minutes) that the purge blower will operate when it is activated on the front of the control panel. When the time has elapsed, the blower will turn off, and the cabinet is now safe to open for parts inspection or service.


Select Operting Mode 4>Machine Set-up


Purge ON Time XX Mixer ON Time XX


To set the Manual Purge time to 15 minutes, follow the steps listed below.

Using the left and right arrow keys, position the cursor in the DISPLAY area to the right of the Purge ON Time section in the DISPLAY area.

Using the numeric keypad, PUSH the 1 and 5 keys and then the ENTER Key once to save the time. The DISPLAY area will show:

The Mixer ON Time sets the time (in minutes) that the optional air sparger in the salt solution mixing tank will stay on.

Using the left and right arrow keys, position the cursor in the DISPLAY area to the right of the Mixer ON Time.

Using the numeric keypad, PUSH the 1 and 0 keys and then the ENTER Key once to save the time. The DISPLAY area will show: .

Purge ON Time 15 Mixer ON Time XX

Purge ON Time 15 Mixer ON Time 10


PUSH the NEXT key once. The DISPLAY area will show:

This shows 2 of the 3 possible Bubble Tower Temperature Setpoints that change depending on the test condition being run. These setpoints are pre-programmed at the factory and are changeable by the user.

• Bubble Tower Temp. SP #1 is activated during a Salt fog test = 48oC • Bubble Tower Temp. SP #2 is activated during a Humidity test = 62oC • Bubble Tower Temp. SP #3 is activated during all other test conditions = 41oC

The usual temperature setpoint for SP # 1, Bub Twr Temp is 48ºC (118ºF). Using the

left and right arrow keys, position the cursor in the DISPLAY area to the right of the 1- Bub Twr Temp SP text. Using the numeric keypad, PUSH the 4 and the 8

key and the ENTER Key once. The DISPLAY area will show: NOTE: This controller operates in degrees Celsius, the standard SI units in which most test specifications are written, or to which they are being converted. Follow the same procedure above to set SP# 2 Bub Twr Temp to equal 62.

Then PUSH the NEXT key once. The DISPLAY area will show: Follow the above procedures to set SP # 3 Bub Twr Temp SP to 41.

1- Bub Twr Temp SP 48 2- Bub Twr Temp SP XX

1- Bub Twr Temp SP XX 2- Bub Twr Temp SP XX

3- Bub Twr Temp SP XX


PUSH the NEXT key once. The DISPLAY area will show:

The Enable Manual Step function allows the operator to “step” from one step in a test to the next with the push of a button. If this function is enabled, then the operator can execute the manual step; if not, then the test cycle will only proceed automatically. To enable this feature a 1 must be entered in the controller; to disable this feature, the 0

(zero) is used. To enable Manual Step, use the left or right arrow keys to position the cursor in the DISPLAY area to the right of the Enable Manual Step text.

Using the numeric keypad, PUSH the 1 key and the ENTER Key once. The code is now set, and the DISPLAY area will show: .

Using the left and right arrow keys, position the cursor in the DISPLAY area to the right of the Power Loss Code text. The Power Loss Code sets the activity of the controller if the electrical power is lost to the cabinet and then returns. Below is a list of the codes, and their meaning.

Power Loss Fault Codes 0 = Stop Cycle 1 = Continue Cycle upon Power Return 2 = Enter "Pause" mode with outputs off

To set the Power Loss Code to ONE, position (as stated above) the cursor in the DISPLAY area to the right of the Power Loss Code text. Using the numeric keypad,

PUSH the 1key and the ENTER Key once. The code is now set, and the DISPLAY area will now show;

Enable Manual Step 1 Power Loss Code 1

Enable Manual Step XX Power Loss Code XX

Enable Manual Step 1 Power Loss Code XX


G. PASSWORD This section will instruct the operator on how to use the password page of the controller. There are 6 different passwords used in this controller as listed below:

Page name Password Level Password Profile Set-up 2 2 Manual 3 3 Machine Set-up 4 4 Password 5 5 Display Set-up 5 5 Calibration 6 Not published OEM Set-up 7 Not published

Each password level will activate its level as well as all levels below. For example, entering the password for level 2 will open up level 1 and 2. However, entering the password for level 5 will open all levels from 1 through 5. When a password is entered, an internal timer is activated in the controller that will allow the user to move in and out of that level as needed. When the timer has elapsed, the user must re-enter the password in order to gain access to the level again. NOTE: Certain passwords, such as for levels 6 & 7, are not published and can only be entered by qualified ATLAS service personnel.

To change a password:



Now PUSH the right arrow key four times . The DISPLAY area will show:


Select Operting Mode 5>Password



keypad, PUSH the 5 key and then the ENTER Key once. If the password was entered correctly, the DISPLAY area will show: The controller is now waiting for the user to enter the number of the level of password that the user wishes to change. For example this tutorial will change the password for level 1 since this password or level is not used for this controller.

Using the left and right arrow keys, position the cursor in the DISPLAY area to the right of the Change Level: section in the DISPLAY area.

Using the numeric keypad, PUSH the 1 key and then the ENTER Key once to save the number. The DISPLAY area will show:

The controller is now waiting for the user to input the current password for the level chosen. Without the current password, the controller will not allow the level’s password to be changed.


Enter Password Change Level: ___

Enter Current Password: ___


Using the numeric keypad, PUSH the 1 key The DISPLAY area will show:

PRESS the ENTER Key once to save the number. The DISPLAY area will show:

The controller is now waiting for the user to input the NEW password for the level chosen. To change the password to 2, PUSH the 2 key on the numeric key-pad. The DISPLAY area will show:

PRESS the ENTER Key once to save the number. The DISPLAY area will show:

The controller is now waiting for the user to re-input the NEW password for the level chosen. Using the numeric keypad, PUSH the 2 key. The DISPLAY area will show:

PRESS the ENTER Key once to save the number.

Enter Current Password: *_

Enter New Password: __

Enter New Password: *_

Re-enter New Password: *_

Re-enter New Password: *_


The DISPLAY area will show:

The password change is now complete. Although the screen indicates the user should restart the controller, this is not necessary. If at anytime the user inputs an incorrect password, the DISPLAY area will show:

The user must now go to the beginning of this section and start this entire process over.

When complete, PUSH the HOME Key one time to go back to the main menu page.

Password Changed Restart

Incorrect Password Restart


H. DISPLAY SET-UP

This section will instruct the operator on how to change the contrast on the controller. Start from the very first page of the operator interface. If not already there, PUSH the


Now PUSH the right arrow key five times. The DISPLAY area will show:


keypad, PUSH the 5 key and then the ENTER Key once. If the password was entered correctly, the screen will show:


Select Operting Mode 5>Display Set-up


Setup Contrast Adjust


There are four TOUCH PANEL keys under the DISPLAY area (as previously described).

Press any of the three left keys and the DISPLAY area will show:

Pressing the far left key will darken the display. Pressing the key second from the left will lighten the display. Pressing the key all the way to the right will return the controller to the previous screen.

Experiment with this section by using the various keys to adjust the contrast to a comfortable level.

When the display area is adjusted properly, press the extreme right key to save the change. The DISPLAY area will show:

Now PUSH the HOME Key one time. This will put the controller back to the main menu page.

Setup Contrast Adjust

Setup Dark Light Back


I. CALIBRATION

This section will instruct qualified Atlas Tech Service personnel on how to adjust the offsets for temperature calibration. Start from the very first page of the operator interface. If not already there, PUSH the


Now PUSH the right arrow key six times. The DISPLAY area will show:

PUSH the ENTER Key once. The DISPLAY area will show: The controller is waiting for the appropriate password for this screen. Using the numeric keypad, PUSH the proper numbers (representing the password) and then the ENTER

Key once.


Select Operting Mode 6>Calibration



If the password was entered correctly, the DISPLAY area will show:

The XX.X represents the current reading of the temperature. The YY.Y represents what the controller is reporting to the user on status screens. In this case, the temperatures shown are for the dry bulb temperature.

Use of the next and previous keys to change the DISPLAY area to show the bubble tower and wet bulb temperature offset pages.

To change the displayed reading, use the TOUCH PANEL keys under the DISPLAY area (as shown above) for the Add or Sub function. If you press the key under the Add area is pressed the displayed reading will increment one tenth of a degree in value for each press of the key. If the key under the Sub area is pressed, the displayed reading will increment one tenth of a degree in value for each press of the key.

Experiment with this section by using the two TOUCH PANEL keys to adjust these temperature displays. When finished with the temperature adjustments to equal the readings of the calibration

equipment PUSH the HOME Key one time. This will save the values and put the controller back to the main menu page.

Dry Bulb Read XX.X Add Sub Disp YY.Y


J. CONTROL BUTTONS

This section will instruct the operator on how to use the various CONTROL BUTTONS located on the outer left and right edges of the controller. There are a total of eight CONTROL BUTTONS.

When the light next to this key is green, all cabinet conditions are operating correctly. If the light turns red, then there is an abnormal condition. Touch the ALARM key and in the DISPLAY AREA of the screen the alarm message will be

displayed. If there are multiple alarms, using the left and/or right arrow will allow the operator to “scroll” from message to message. When the ALARM key is PUSHED the following is shown in the DISPLAY area;

PUSHING the left CONTROL BUTTON will acknowledge (‘ack’) the alarm in the DISPLAY area. To acknowledge (‘ack’) all alarms at once, PUSH

the CONTROL BUTTON that is second from the left, the ‘ALL’ button. When all the alarms are acknowledged, they can be reset by PUSHING the

RESET CONTROL BUTTON on the right section of the operator interface.

> “scrolling alarm messages” Ack All


The purpose of the PURGE CONTROL BUTTON is to evacuate the inside of the cabinet exposure zone of its current environment. When this button is pushed, the cabinet’s Air Blower will turn on and stay on for the amount of time specified in the MACHINE SET-UP section of the controller.

A common reason for using this button is turn on the PURGE blower and evacuate salt fog prior to opening the cabinet cover for parts examination. This can help prevent corrosive salt fog from damaging the surrounding areas.

The purpose of the STEP CYCLE CONTROL BUTTON is to manually advance an automatic cycle from one step to the next. Basically, this feature allows the operator to “override” the cycle timer and proceed to the next cycle step. This feature is particularly useful when trouble-shooting a newly written test cycle to ensure the intended next cycle is achieved.

The purpose of the CYCLE PAUSE CONTROL BUTTON is to put the cabinet into a pause mode during an automatic cycle. When this button is pushed, the automatic test that is currently running will be temporarily suspended. The light next to the START CONTROL BUTTON will flash, indicating a pause mode. To

restart the test, push the START CONTROL BUTTON.

If this option is purchased, this CONTROL BUTTON will be activated. As covered earlier in this manual, the time specified in the MACHINE SET-UP section of the controller for the MIX TANK feature can be pre-set and changed. If this timer was set for 30 minutes, for example, when the operator pushes this CONTROL BUTTON the air sparger in the solution tank will be activated and stay on until the time has elapsed, or the operator pushes this button again, whichever comes first.


This feature allows the operator to start mixing a salt solution at the touch of a button and walk away knowing that the controller will automatically turn off the mixer.

As covered earlier, this CONTROL BUTTON is used to “clear” any alarms. PUSH this button while in the ALARM feature, and the controller will reset all alarm messages.

When a test cycle has been chosen to run in the automatic mode, pressing this button will start that test. This button also re-starts a test in the automatic mode if the cabinet is placed in a pause condition.

This button will stop a test that is being run in the automatic mode.

NOTE: PRACTICE ONLY! MAKE SURE TO CHANGE THE SETTING BACK TO ITS

ORIGINAL VALUE.


IX. ADVANCED OPERATION – COMPUTER CONTROLS

The controller for all BCX Series cabinets with computer controls is fully programmable, with an easy-to-use microprocessor-based programmable controller. In the case of the Computer Controls Package, an IBM PC-compatible computer controls cabinet operation. This computer is connected to an I/O (input/output) module to actuate cabinet components. Several standard industry test specifications are built in and pre-programmed, so the user can begin testing immediately after both installation and setup procedures are followed. Standard tests can be modified, and custom tests and procedures with multiple parameters can be easily programmed into the controller, providing flexibility, meeting multiple needs and placing real control into the hands of the user. The computer is normally located on or above the control panel on the right side of the cabinet. Since some customers have specified a desktop model, the computer may be located in an area adjacent to the BCX cabinet rather than on the cabinet. ATLAS’ computer design includes a comprehensive datalogging feature. The position or status of every control function of the cabinet such as cycle time, cycle status, temperature, input status, output status etc., is output to a file for ultimate control, analysis, diagnostics and, most importantly, test documentation. Test reports can be programmed to be almost automatic, in graph and other formats, providing accuracy and documentation that make traditional chart recorders look primitive in comparison. Spreadsheet downloads and graphing provide capabilities that go far beyond the performance of a test, enabling testing and management personnel to integrate information, feedback, and performance into decision-making processes. I. INTRODUCTION TO OPERATING THE COMPUTER

The computer is very easy to learn and use. If not familiar with Windows, then it is suggested to take a basic Windows training class prior to the operation of this cabinet.

1. Operating System

The operating system used on PC-controlled cabinets is Windows NT by Microsoft. This provides for a more robust and secure control of the computer itself. The cabinet is set-up for a direct boot right into the BCX control program. The administrative rights are password protected to prevent unauthorized use of the computer such as installation and operation of non related programs that may interfere with the BCX control program. None of the computer’s set-up should be changed unless authorized in writing by ATLAS. Non-authorized changes to the computer’s operating system setup will void the warranty and subject the user to all consequences and costs arising from such a change.


2. Computer

In most cases, ATLAS installs an IBM PC-compatible notebook computer on the cabinet. Most of the cabinet functions can be actuated using the computer mouse. On notebook computers, the mouse is usually replaced by a “glide point” (Compaq Armada), “track ball” or “track point” (IBM Thinkpad). If the user is not accustomed to these devices, practice will be required. In this manual, all of these different pointing devices will be referred to as the “MOUSE.” The computer will include a color screen and keyboard. Some cabinet functions must be operated by use of the keyboard. Communication to the cabinet I/O block is accomplished by use of a standard serial cable attached to the computer’s 9-pin RS232 port. This cable must be attached at all times.

3. Computer Security and Protection

If the cabinet includes a notebook computer there is a locking mechanism to keep it secure. The sliding acrylic door on the control top panel has a push lock on the uppermost edge of the door. Turn the key 360 degrees and the lock pin will eject. Now the door can be pushed up. When the cabinet is in operation it is necessary to keep this door closed to protect the computer from possible contaminants in the lab air.

4. Computer Performance

Many factors affect the performance of the computer during the control of the BCX. It is important to avoid as many factors that will slow down the performance since the main function of the computer is to control the cabinet. Avoid loading other software on the computer as this will slow it down. Be careful of network traffic to the computer if it is connected to a LAN. It is very important to reboot the computer on a regular basis, but not less that every other week. Re booting the computer clears out the RAM memory and any other potential file problems that could cause the CPU to ‘lock-up” and stop controlling the cabinet. This is a part of regular maintenance. This is very important where the datalogging frequency of the control software is high, as it creates a very large data file.


5. Controller Overview

There are 13 basic pages built into this control platform. There are additional pages accessible from one of these main pages that will be explained later, The major areas are as follows: MAIN MENU – from this main menu, the following can be selected F1 = SELECT A TEST TO RUN F2 = STATUS OF CURRENT TEST F3 = CURRENT TEST DATE F4 = CURRENT I/O STATUS F5 = HISTORICAL TEST DATA F6 = CALIBRATION OF CABINET F7 = MANUAL CONTROL F8 = REVIEW MAINTENANCE – (NOT YET ACTIVE) F9 = ADJUST MACHINE PARAMETERS F10 = PROGRAM TEST SPECIFICATIONS F11 = PREVIEW ATLAS PRODUCTS – (NOT YET ACTIVE) F12 = ON LINE MANUAL – (NOT YET ACTIVE) Not all 12 sections are active at this time. Sections F8, F11 and F12 are scheduled to be activated during future revisions of the program. Since these sections in no way inhibit the use of the cabinet they will be covered after development. To move from page (section) to page Steps: 1. Using the mouse, left-click on the “tab” that is labeled with the name of the

section or page desired. If on the Main Menu page, use one of the twelve “function” keys to go to that section.

2. If already on one of the 12 pages, or in a section nested in one of the main 12 pages, use the mouse to left-click on the button labeled RETURN. This moves back one level or set of screens.

3. The selected page will appear.


MAIN MENU

After the boot up of the computer, the BCX control program loads. The control program will automatically index to the “MAIN MENU” page shown. Along with the ATLAS logo, the 12 main program pages are displayed along with the corresponding function key. Additionally, the version of this program is shown in the upper right section of the screen. For example, this screen shows Ver. 6.12 which is the version of operating software (OS) the BCX uses. This information should be available in the event ATLAS is called for technical support. Periodic updates may be offered to enhance cabinet control features.

From this screen, all other areas of the program are accessible. To review each page of the controller, review the following. Press F1 or using the mouse, click once using the left mouse key over the section of the screen labeled “Select a Test to Run.”


F1: SELECT A TEST TO RUN

This screen is used to start a test profile in the automatic mode. Prior to starting a test, one must be programmed. The programming of a test will be covered later in this manual. Notice the green section on the top right corner of this screen. It states, “All devices OK.” This must be the case, or a test cannot be started. If any device on this BCX is not in a “start-ready” mode, then this box will change color and an error message will be displayed in this status box. Until this condition is corrected, the cabinet will not go into an automatic run mode. Sometimes, due to a communication error with the I/O module, the controller will show a “phantom” fault when this page is selected. Prior to investigating a possible fault, use the mouse and left-click once on the “reset fault” button just beneath the fault message box. If it is a phantom fault, it will clear and put the status box back into a green color and “All Devices OK” condition. To start a test, use the mouse and select one of the twenty tests located in the slide window located in the middle of the screen. Using the mouse, left-click once on the desired test. This will highlight the test, as shown above with ASTM B117. There are additional tests not shown that can be seen by using the slide bar on the right edge of this center window. When the desired test is highlighted, use the mouse and left-click once on the green “START TEST” button on the right side of the screen. If all conditions are OK, the cabinet will start the desired test and proceed to the F2 STATUS OF CURRENT TEST page. If the datalogging feature is turned on, then one additional step is required before the test will start.


Datalogging can be activated or deactivated in the ADJUST MACHINE PARAMETERS (F9) page. This will be covered later in the manual. If Datalogging is enabled, then a file name must be specified prior to a test being started. When a test name has been selected, and the start test button pressed, a “Choose file to log temperature to” box will open in the center of the screen. In the “File name” box, a default file name will be inserted by the computer. This default name will be based on the date and time that is on the computer when this test is started. If this file name is satisfactory then use the mouse and left-click once (or press enter on the keyboard) on the “save” button of this box. If a custom file name is desired, type it in and then use the mouse and left-click once on the “save” button of this box. If the name chosen already exists, the computer will prompt the user to overwrite the file. Answer the question as desired and continue. When this step is completed, the computer will start the desired test and proceed to the F2 STATUS OF CURRENT TEST page.


F2: STATUS OF CURRENT TEST

This page can be activated from either the “MAIN MENU” page, or the “SELECT A TEST TO RUN” page as described above.

This is the main cabinet status page. This page gives a synopsis of what the cabinet is doing. Some of the information shown on this page will not be present on certain cabinets. For example, if the cabinet is not set up for immersion, then all of the items associated with immersion will not show up on this screen. Most of this screen is self-explanatory. For example, this screen shows that the test being run is “ASM B117.” It is in step number 1 and the next step is number 1 - it is looping to itself in this example. This screen shows that Step 1 is “Salt Fog.” On the left side of the screen many of the test parameters are shown with their ACTUAL, SETPOINT and REMAINING condition.


Each of these parameters are explained below. Step Time in Minutes – This is the amount of time this step in the cycle will run.

It can run in Minutes or Seconds, the units are user-settable.

Cabinet Temp. in deg. C - This is the temperature the cabinet exposure zone is

programmed to reach during this step of the program. Bubble Tower Temp. in …- This is the temperature the bubble tower is programmed

to reach during this step of the program. Cabinet % Relative Hum…- This is the percent RH the cabinet exposure zone is

programmed to reach during this step of the program. Immersion Tank Temp. - This is the temperature the immersion tank is

programmed to reach during this step of the program. Laboratory Temperature - This is a readout of the current laboratory temperature in

degrees Celsius. Current Loop - This is the number of loops this step has performed. Total number of loops- This is the number of loops this step is programmed to

perform.


There are several buttons (circled below) that actuate mixing and fill cycles if purchased. To activate one of these optional features, put the mouse pointer over the green/red button and left-click once. If the button is red, then the feature is OFF. If the button is depressed inward and green in color, then the feature is ON. From left to right, these features are described below (not all cabinets have all features). Mixing Tank Sparger – This activates an air agitation sparger in the solution tank. This sparger

stays on until it is manually turned off (the same way it was turned on) or until the user specified timer runs out.

Mixing Tank Fill - This activates a water fill in the 60-gallon solution tank on the left side of the cabinet. The water stays on until the top float switch signals a full condition to the computer. When a full condition is signaled, it turns the water off until it is manually activated again. This feature ensures that the tank will not over-fill.

Immersion Tank Sparger - This works in the same way as the Mixing Tank Sparger explained above. The difference is that the air sparger is located in the immersion tank.

Immersion Tank Fill - This works in the same way as the Mixing Tank Fill explained above. The difference is that it is the immersion tank that is automatically filled.

NOTE: These features are optional and not on each cabinet. They will only appear if the options were purchased with the cabinet.


Along the lower part of the preceding screen is a PAUSE button. Using the mouse to click on the PAUSE button will cause the cycle to “PAUSE” and the button will change to a green color and change its label to “CONTINUE.” This button does not show the condition of the test, but instead what it will do to the test if it is pressed. When test was paused, the condition of the test is shown next to the test that was selected. The screen shows the cabinet in a pause mode. In the pause mode, all cabinet functions that were turned on in the automatic mode are turned off. The pause button is commonly used to check the samples being tested. After the test is put into a PAUSE mode, it is recommended to purge the cabinet’s exposure zone prior to opening the cabinet cover. The example above shows the purge blower turned on. This is accomplished by using the mouse. Place the mouse over the ‘PURGE BLOWER” switch on the screen and left-click once. The switch on the screen will move into the up position and turn on the blower. The blower will remain on until the user-defined time elapses, or until the user manually turns off the blower. The blower is turned off the same way it was turned on.


When a test has been paused and the exposure zone purged of its environment, the cover can be opened for sample inspection. In the same way that the purge blower was turned on and off, the cover can be opened or closed. Use the mouse to point to the COVER switch and left-click on it once. It may take a several (or even up to 60) seconds for the cover to open. This is due to the time it takes for the air cover lifters to fill with the compressed air and overcome the weight of the cover and pull of the dual magnetic seal. If the cover will not open it is most likely do to low air pressure. Call the ATLAS factory for assistance in this condition. When the cover is open, a message is displayed in the “Fault” condition box located in the upper right corner of the screen. The test cannot be put back into a run mode until the cover is closed. To restart the test, use the mouse and close the cover. When the cover is closed and the “All Devices OK” message shows in the “Fault” condition box, the test can be restarted. To restart the test, use the mouse and left-click once on the green “CONTINUE” button. If done properly, the test will continue where it left off.


The looping schedule can be shown at a touch of a button. On the status page, find the looping button and left-click on it once. This will bring up the window shown below.

This window will show the programmed loop for each step of the program. With this information, the user can identify exactly where

in the nested loop the program currently resides. Without this schedule, the user will see only the looping status of the current step of the running program. To close this looping window, use the mouse and left-click once on the return button located inside of this looping window There are a number of green message boxes located close to the center of this status page. These are present only to tell the operator the position of the motorized valves. These motorized valves are parts of certain options, and therefore are not included on all cabinets.


These motorized valves are for the following purposes; RH Valve in Fresh Air Position - The valve position dictates the type of air put into the

exposure zone by the blower motor. In a “Fresh Air Position” the ambient lab air is sent in. In a “recirculation” position, the cabinet’s exposure zone air is sent back into the cabinet.

Cabinet Drain Open - The valve position directs the cabinet drain fluid. In an

“Open” position, the fluid in the exposure zone is sent to the facilities’ floor drain. In a “Closed” position, fluid is held into the exposure zone and prevented from going “down the drain.” The closed position is used during an immersion cycle or a wet bottom RH cycle.

Jet Exhaust Valve in Recirculation Position - This valve directs the flow of the environment being

vented out of the exposure zone. It is either sent to the facilities’ outside vent pipe, or the optional recirculation system.

NOTE: These features are optional and not on each cabinet. They will only appear if the options were purchased with the cabinet.


There could be many causes for “Faults” on the BCX. A fault is a condition that causes the cabinet controller to display a message and, in many cases, stop the test by putting the cabinet into a pause mode. There are two main types of fault conditions; latching and non-latching faults. A latching fault is one that causes the cabinet to stop its current testing and requires the condition to be corrected before any further testing can proceed. Above is an example of a latching fault. Latching faults are shown in a red colored box. When the condition that created the fault is corrected, the fault must be reset. This is accomplished by using the mouse and pointing to the “reset fault” box and left-clicking once on this box. If the condition is corrected, the status box above will return to a green color and display an “All Devices OK” message. Non-latching faults may also be described as a warning message. These conditions are also displayed in the status box. They do not stop the test, or prevent the user from starting a test. When a non-latching fault is displayed, the status box it is in will be yellow in color. If there is more than one fault condition at a time, they will cycle one after another in the status box displaying the message along with the appropriate color. As on all pages, to return to the prior page use the mouse and place the cursor over the return button and click once on the left mouse key. In this case, clicking on the return

button from this screen will return the user to the “MAIN MENU” screen.


F3: CURRENT TEST DATA

This page can be activated from either the “MAIN MENU” page, or the “STATUS OF CURRENT TEST” page as described above. To activate it from the “MAIN MENU” page, press the F3 key on the keyboard or, using the mouse, place the cursor over the “Current Test Data” box on the right side of the screen and left-click once. To activate it from the “STATUS OF CURRENT TEST” page, use the mouse, place the cursor over the graph box located at the bottom of the “STATUS OF CURRENT TEST” page and left-click once. The purpose of this screen is to show the user a graphical form of the analog input signals. An analog input signal is a signal that has a range of values. For example, temperature signals are analog values. They typically have a range on this piece of equipment from 20ºC to 55ºC. This change in value is plotted on the screen as shown above. Bubble tower pressure and lab temp are other examples of analog signals that are shown on this page. If the user of this cabinet has set the datalogging feature on, all of this information is saved in a ‘.txt file’ on the computer’s hard drive. The name and path of this file is shown at the top of this page. The list of items shown on this screen is dependent on the installed options and features. For example, if the user has not purchased the immersion option, then the immersion reservoir temperature setpoint and actual temperature will not be shown on this list of analog input signals. The list of available signals for the user’s BCX are shown on the right side of this page.


Shown below on the “CURRENT TEST DATA” page is a list of the inputs that can be plotted. Since space necessitated an abbreviation of the labels for these inputs, the list below defines the signal. Some future inputs planned are “Bubble Tower’s pressure – IN”, “Bubble Tower Air Flow,” and several spare temperature measurements. As described on the earlier page, next to the description of the analog input the actual value for this signal is shown. Any item listed as a SP (setpoint) is not actually an analog input. This is a value set by the user on the programming page. These values are listed here to allow the user the ability of comparing setpoint against actual values in a graphical form. NOTE: Some described features are optional and not on each cabinet. They will only appear if the options were purchased with the cabinet.

Abbreviation Definition Cabinet The exposure zone’s current actual

temperature in degrees Celsius. Cabinet SP The exposure zone’s setpoint in degrees

Celsius for the current step. Bub Twr The bubble tower’s current actual

temperature in degrees Celsius. Bub Twr SP The bubble tower’s setpoint in degrees

Celsius for the current step. Lab The laboratories current actual

temperature in degrees Celsius. RH The exposure zone’s current actual

percent relative humidity. RH SP The exposure zone’s setpoint for relative

humidity in percentage for the current step.

BT Pres The bubble tower’s current actual pressure in P.S.I. (pounds per square inch) as it exits the bubble tower (OUT).

Imm Temp The immersion tank’s current actual temperature in degrees Celsius.

Imm Temp SP The immersion tank’s setpoint in degrees Celsius for the current step.


Using the mouse, position the cursor over one of the available inputs being plotted. With the click of the left mouse key, a control window will open. In this window, the user can change all of the plot types and colors. The best way to get familiar with these features is to experiment with them. Changing these functions are not permanent. On the lower right section of this page there is a “Clear Graph” button. Pressing this button will clear all data from the graph. As new data is produced, it will be displayed in the graphing area. Clearing the graph only affects the display, not the physical data stored on the hard drive. Beneath the “Clear Graph” button is a “Print Window” button. If this feature is activated, and a properly configured printer is attached to the computer, pressing this button will send an image of what is displayed on the screen to the printer. The yellow “Set Data Logging Interval in Minutes” button allows the user to set the interval at which data is stored onto the hard drive. The number entered represents the number of minutes separating data points. Be careful with the frequency at which the data is logged. The more frequent the data is logged, the larger the data file will be. If the data file grows to over 1.4 megabytes, then the data file can no longer be extracted from the computer for evaluation via the 3.5” disk drive. If this occurs, the user will have to use the CD Write capability or install a LS 120 or ZIP disk type of media storage device to extract the file.


The screen below shows further examples of how to change what is displayed on the screen. Using the mouse, position the pointer over one of the black boxes next to the name of the items being graphed. With one click of the left mouse key, the graphing line can be turned on and off for display. This will not affect what is being logged, only what is being displayed. Using the mouse, experiment with the graph display keys to change the X and Y axes ranges. This will allow for close up examination of the data being displayed. The green recording shows the status of the datalogging feature. If it is green, and has the word “Recording” in it, then data is being saved to the hard drive. If it is red and has the word “Not Recording” in it, then data is not being saved to the hard drive. The status of recording feature can be changed in the “ADJUST MACHINE PARAMETERS” section of the controller. User notes can also be typed into the “note pad record” box. After a note is typed in, using the mouse press the button just to right of the box. Prior to pressing it, the button will be green and have the words “Press to log Note” in it. When it is pressed, it will be yellow and read “Note will be logged at next data log interval.” The box will remain yellow until the next data point is saved to the hard drive, as set by the user. When logged, the box will revert to its original green color. The best way to become familiar with all of the features of this page is to experiment. Nothing can be damaged with this experimentation. The user is encouraged to adjust all of the available features until comfortable with how to use them.


F4: CURRENT I/O STATUS

This page can be activated from either the “MAIN MENU” page, or the “STATUS OF CURRENT TEST” page. To activate it from the “MAIN MENU” page, press the F4 key on the key board, or using the mouse, place the cursor over the “Current I/O Status” box on the right side of the screen and left-click once. To activate it from the “STATUS OF CURRENT TEST” page, use the mouse, place the cursor over the “display I/O status” box located at the bottom of the “STATUS OF CURRENT TEST” page and left-click once. The purpose of this screen is to show the user a visual representation of all of the important inputs and outputs, both digital and analog. The top part of the screen with the red and green “switches” shows the status of the digital outputs. A red switch means that the output is OFF. A green means that the output is ON. This is useful information while the cabinet is running a test. During the test, the user can see what is ON and OFF. The lower section displays all of the inputs. The left lower section shows all analog inputs, such as temperatures and pressures. The right lower section shows all of the digital inputs, such as a float switches and proximity switches. A black box indicates that the switch is closed or “made,” a gray box indicates that the switch is open.


F5: HISTORICAL TEST DATA

This page is activated from the “MAIN MENU” page. To activate it go to the “MAIN MENU” page, press the F5 key on the key board, or using the mouse, place the cursor over the

“HISTORICAL TEST DATA” box on the right side of the screen and left-click once. The purpose of this screen is to allow the user to open an existing data file and display the graph on the computer screen. When the user activates this screen, a “Choose Data Logged file to display” box will appear. Use the mouse to select the data file to open, and click on the OPEN key on the lower right side of this box. When a data file is chosen, the computer will display the data in a graph form in the same format as explained in the F3 “Current Test Data” section of this manual. Refer back to that section for instruction on using this page.


F6: CALIBRATION OF CABINET

This page is activated from the “MAIN MENU” page. To activate it go to the “MAIN MENU” page, press the F6 key on the key board or, using the mouse, place the cursor over the “CALIBRATION OF CABINET” box on the right side of the screen and left-click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The passwords for each password-protected page are different. From the factory, the passwords are as follows; F6 CALIBRATION OF CABINET not published, call factory F7 MANUAL CONTROL 2 F9 ADJUST MACHINE PARAMETERS 3 F10 PROGRAM TEST SPECIFICATIONS 1 The password for the calibration page is not published since only trained calibration personnel should be making adjustments to these parameters. When a calibration is needed, contact Atlas Tech Service or your authorized represen-tative for instructions. A factory trained calibration technician can be scheduled to visit.


The purpose of this screen is to allow the trained calibration technician to calibrate the cabinet’s analog inputs. Using the mouse, position the pointer over the ‘Select Input’ box and left-click once. A window will open allowing the user the ability to choose which input to calibrate. After choosing, follow the instructions in the calibration instruction box. At the end of the calibration procedure, the computer will supply a set of offset numbers. The user must take the offsets supplied and enter them into the offset boxes. For further details, contact Atlas Tech Service or your authorized Atlas representative.


F7: MANUAL CONTROL

This page is activated from the “MAIN MENU” page. To activate it go to the “MAIN MENU” page, press the F7 key on the key board or, using the mouse, place the cursor over the “MANUAL CONTROL” box in the middle of the screen and left-click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The password for this page is 2. Enter a 2 in the password box and, using the mouse, click on the OK button. The purpose of this screen is to allow the user to manually turn ON and OFF the cabinet devices. This screen CANNOT be activated while a test is being conducted. If a test is running, the user will have to wait until the test is complete or stop the test to activate this page. This page is particularly useful when troubleshooting. The user can turn (activate) on a device and verify the output. For example, if the cabinet heaters are activated, the user can verify heat. If the DI to Trap is turned on, water will enter the air trap assembly, and the input representing the Trap level switch will light as the water level fills. If the Trap Drain Solenoid is activated the water will drain, and the Trap level switch input will turn gray showing an empty position.


This page is much like the “Current I/O Status page” discussed earlier. The main difference is that on the “Current I/O Status page” the user could not turn on devices, but only view the status of these devices. With this page, the user can actually turn the cabinet devices ON and OFF. This can be done by using the mouse, pointing it to one of the red switches and left-click once over the switch. When this is done, the switch will turn green, move to the right and turn on the device chosen. As explained earlier, the lower section of this page shows the status of all of the inputs on the cabinet. NOTE: Some displayed features are optional and not on each cabinet. They will only appear if the options were purchased with the cabinet.


F9: ADJUST MACHINE PARAMETERS

This page is activated from the “MAIN MENU” page. To activate it go to the “MAIN MENU” page, press the F9 key on the key board or, using the mouse, place the cursor over the “ADJUST MACHINE PARAMETERS” box in the middle of the screen and left-click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The password for this page is 3. Enter a 3 in the password box and, using the mouse, click on the OK button. The purpose of this screen is to allow the user to set certain parameters specific to the user’s needs. These parameters will be set globally for all areas of the controller. See the next page for an overview of this page


Below is a view of this entire page. There are four main sections, PID parameters, Edit Test Names, Timers & Passwords, and enable/disable datalogging & step mode. When anything is changed on this page, the user must use the mouse and click on the “save data to file” button. This will store all of the changed values to the controller’s memory. There are four different “Set XXXXXXX PID Parameters” buttons on the top left section of this page. There is one for each control loop that needs to be adjusted. Using the mouse, click on the Set cabinet PID Parameters button and the window at the right will open. This screen is used to adjust the temperature control for the cabinet’s exposure zone. Careful attention must be used when changing this page. Contact ATLAS prior to making any adjustments to this page. Any wrong parameter changes could prevent the cabinet from operating properly.


PID is a very complicated formula that controls the way a device reaches a setpoint condition. If the user is not familiar with PID and would like a further explanation, it is suggested that a PID controls manual be purchase and studied. All of the PID settings are set at the factory prior to shipping. If the cabinet is unable to reach or maintain temperature or humidity setpoints, these PID settings may have been changed. The next section of the “Adjust Machine Parameters” page to be discussed is the Edit Test Names section. Using the mouse, position the cursor over the purple “CLICK to Edit Test Names” button and left-click on it once. This will take the user to a page that will display all of the current names assigned to the test profiles. There are a total of 20 tests available for computer controls. At the factory, the first seven (7) tests are named and pre-programmed. Any of these names can be changed. As an example, to change the name of Fan Test, use the mouse and place the cursor in the box that has “Fan Test” in it. Use the backspace key to erase “Fan Test.” Using the keyboard, type in the new name desired. For example, type in “Your Test” in its place. When the new name is typed in, use the mouse and click on the “save data to file” button to save this change. If the change was made correctly and saved, this new name will be seen in the other sections of this controller, such as when a new test is started or a test is programmed.


Below is an example of what the screen would look like if the above-listed change were made. The screen would look like this. To return back to the “Adjust Machine Parameters” page, use the mouse and click on the blue “RETURN” button.


The cabinet’s data-logging and step mode are also set on this page. When both of these features are activated/enabled, the boxes will be green in color. The Data Logging button is self explanatory. If this feature is “Enabled” then the cabinet’s parameters and conditions will be saved to the computer’s hard drive while conducting a test. If “Disabled” then no data logging will take place. As listed above, when Enabled, the box will be green in color. If Disabled, the box will be red in color. To Enable or Disable, simply use the mouse, position the cursor over the box and left-click once. The Manual Step Mode is Enabled and Disabled in the same way. The purpose of the Manual Step Mode is to allow the user to manually advance the automatic cycle from one step to the next. Basically, this feature allows the user to “override” the cycle timer and proceed to the next cycle step. This feature is particularly useful when trouble-shooting a newly written test cycle.


The last section to this “Adjust Machine Parameters” page is the timers and password section. With this feature, the user can change several important timers. Blower Purge Time- This is the time in minutes that the purge blower will remain on when the purge blower button is

ACTIVATED on page F2 (Status of Current Test). When the timer has elapsed, the blower will automatically turn off. This purge blower is used to evacuate fog from the cabinet prior to opening the cabinet cover. Mix Tank Sparger Time – The is the time in minutes that the 60-gallon (227 liter) solution tank air sparger will remain on when the Mixer button is ACTIVATED on page F2 (Status of Current Test). When time has elapsed, the mixer will turn off. There is also a similar timer for the optional immersion tank. Passwords – These four lines allow the user to reset the passwords for the pages that are password protected. The passwords listed above are the default passwords set at the factory. NOTE: If the user changes these passwords, it becomes their responsibility to remember them. Otherwise ATLAS will have to re-program the unit at the user’s expense. Power Loss Code - This Power Loss Code sets the activity of the controller if the electrical power is lost to the cabinet and then returns.

Power Loss Fault Codes 0 = Stop Cycle upon Power Return 1 = Continue Cycle upon Power Return


2 = Enter "Pause" mode with outputs off

F10: PROGRAM TEST SPECIFICATIONS This page is activated from the “MAIN MENU” page. To activate it go to the “MAIN MENU” page, press the F10 key on the key board or, using the mouse, place the cursor over the “PROGRAM TEST SPECIFICATIONS” box on the left side of the screen and left-click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The password for this page is 1. Enter a 1 in the password box and, using the mouse, click on the OK button. The purpose of this screen is to allow the user to review, change or create a test profile used during automatic mode. There are a total of 20 possible test profiles, each up 50 steps long. See the next page for an overview of this screen.


This is the “Program Test Specifications” page. There are several main sections to this page. First, select the test to view, change or create. Use the mouse to position the cursor over the desired test name, and click once on the left mouse key. This will select a test. The blue-green strip represents the step number for the chosen test. The first 18 steps are shown in this main screen. To view steps 19-50 use the mouse and scroll bar to move the test parameters into view. When programming a test, there are several conditions the cabinet can perform, if it was setup for these conditions. For the purpose of this manual, it will be assumed that all conditions are available. These conditions are shown to the right. NOTE: Some displayed features are optional and not on each cabinet. They can be used only if the options were purchased with the cabinet.


Some conditions are exclusive of one another, and some can be combined. This first section (pink background) is exclusive; meaning that only one condition from this list can be activated per step. In this graphic, step one has Salt Fog selected as the desired test condition for this step. Below is a description of each test condition. SALT FOG Atomization of electrolyte in the Solution Reservoir using

the fogging tower(s). DRY CYCLE Activates the cabinet’s purge blower and heater to dry the

exposure zone. FOG HUMIDITY Atomization of DI water using the fogging tower(s),

creating a saturated (95-100%) condensing humidity. WET BOTTOM RH Fills the bottom of the exposure zone of the cabinet with DI

water and heats it using the cabinet heater. This creates a 95-100% non-fogging condensing humidity.

CONTROLLED RH Uses the cabinet’s heaters, blower, and fogging tower(s) to control the RH between 30 – 95%, +/- 5%.

IMMERSION FILL Moves solution from the immersion reservoir into the exposure zone.

DRAIN TO TANK Moves the immersion solution from the exposure zone back to the immersion reservoir.

DRAIN TO WASTE Moves the immersion solution from the exposure zone to the floor drain. (Also useful for cleaning.)

AMBIENT Opens the cabinet cover (if automated cover lifters were installed) to expose the parts being tested to ambient lab conditions.

CUSTOM CYCLE No action is taken with this condition. However, this must be selected to activate other sections.

NOTE: Some displayed features are optional and not on each cabinet. They can be used only if the options were purchased with the cabinet.


The conditions in orange and rose can be selected in conjunction with other conditions after one condition is selected in the first set. SPRAY PUMP Uses a magnetic drive (or similar) pump to pull solution

from the reservoir and send it into the spray bar header for direct spray (impingement) of the test specimens.

TIME IN SEC. Changes the timer for a specific step from minutes to seconds.

IMMERSION HOLD SOAK Holds the cabinet at a specific step in the cycle even if the step time has elapsed until the programmed immersion reservoir temperature setpoint has been attained.

USER OUTPUT Activates an output on the control I/O during that step. The user can connect a device to that output and have the device activated during any specified step.

CHAM HOLD SOAK Holds the cabinet at a specific step in the cycle even if the step time has elapsed until the programmed cabinet exposure zone temperature setpoint has been attained.

CHAM RAMP SOAK Meters power to the cabinet heaters so that the exposure zone temperature setpoint is achieved at the end of the step time.



After the test conditions are chosen for each step, values for temperatures, relative humidity and looping must be set. To the right is an example of setpoints for these conditions. Note – if certain cells are left blank, the controller may ignore that parameter. STEP TIME. This is the time that this step will be run. If it is left blank,

the controller will run the next step. All 50 steps will be run by the controller.

CABINET TEMP. SET PT. The temperature in degrees C that the cabinet’s exposure zone will attain during a given step.

BUBBLE TOWER SET PT The temperature in degrees C that the cabinet’s bubble tower will attain during a given step. It is recommended to use 41oC for any step that does not call for salt fog or high humidity. This will keep the bubble tower warm.

RH SET PT The percent RH that the cabinet’s exposure zone will attain during a given step. The controller will only run this condition if CONTROLLED RH is chosen in the first set of conditions.

IMM TANK SET PT The temperature in degrees C that the cabinet’s immersion solution reservoir will attain during a given step.

LOOP TO STEP The next step the controller will go to after completing the current step. If this is left blank, or has a “0” in it, the controller will go to the next step.

NUMBER OF LOOPS The number of times the controller will repeat the programmed loop for a given step.



The best way to learn this cabinet programming page is to experiment. Below is an example of a programmed test. Notice that as a condition is chosen, the button will “light” up indicating that it is activated for that step. When all of the desired changes have been made to a test, it is required to save the changes. This is done by using the mouse, placing the cursor over the “save changes” button and clicking once with the left mouse key. The computer will ask if the file should be replaced. The file MUST be replaced to save the changes. Use the return button to go back to the MAIN MENU page. NOTE: Some displayed features are optional and not on each cabinet. They can be used only if the options were purchased with the cabinet.


F. Computer Controls Data Logging File PURPOSE: The purpose of this file is to document how the cabinet performed during a test. LOCATION: If the Datalogging feature of the computer controls is activated (see F9 screen) then the controller will create a data-file for every new test started in the automatic mode. By default, these files are saved in a sub-directory of the C hard drive of the computer: C:\Test Directory\Data Log. These files can be saved in other areas of the hard drive, or across a network if the user chooses a new location when prompted. It is not recommended to save the datafile to the computer’s diskette drive (A: drive) because constant use will shorten the life of its mechanical components.. The user assigns the name of the file; if the user does not assign a file name the computer will assign one based on the computer’s time and date. The file extension ends with “.txt”. Although the file is a simple text file, it is formatted in such a way to make the data easy to use in a standard spread sheet program such as Microsoft Excel. This file can also be opened in a word processor program such as Microsoft Notepad, Wordpad or Word. The difficulty with opening the file in a word processor is that all the data in the file will not align correctly like it will in a spreadsheet program. Additionally, in a spreadsheet program, the data is easily graphed and manipulated. If the datalogged file must be moved to another computer, there are two methods to do so. The best way, in terms of file size that can be transferred, is via a Local Area Network, or LAN, which allows direct copying of files between directories/folders from one computer to another. If the laptop is not connected to a LAN, the only way to transfer a datalogged file is to copy it to a 3.5” diskette. Therefore, consideration must be given to the interval at which data is saved, which can be as often as every minute. When saving data to a file every minute, it will reach one megabyte in size after 3-4 days. If data is saved less frequently, such as every 3-4 minutes, it will take longer to reach maximum diskette transfer size. FUNCTION:

The easiest way make use of these data files is with Microsoft Excel. Open Excel, select FILE, and OPEN. Choose the directory in which the file is located. Additionally, on the lower left side of this window, select “ALL FILES.” Next, select the name of the file that is to be opened. Then, click on the OPEN button.

When the OPEN button is activated a TEXT IMPORT WIZARD window will open. There is no need to complete all three steps of the process. Click on the FINISH button to complete the import of this data file.


When successfully imported, the data will be displayed like any other spread sheet. There are 5 main sections to this data file. 1. File information – this section reports

the software version, file name, test number and test name.

2. Calibration Array – this section

documents the calibration settings for the cabinet at the time this test was started.

3. PID parameters – the PID parameters

determine how the controller will ramp temperature and humidity settings.

4. Test Profile – this section documents

the test profile settings that were used for the test that was run. These settings are the test condition, the time of each step, the setpoints for tempera-ture/humidity, and any looping functions. With this information, the user can review the test profile that was running at the time this datafile was generated.

The first three columns in this section are dedicated to the actual events that are running in the test profile. The numbers in these columns correspond to an actual test condition. For example, a number 1 in the Exclusive Event column means that a SALT FOG condition was running during this step in the cycle. These numbers can be added together in the Non-exclusive section to combine test functions. For example, to run a spray cycle in seconds, add 1 + 2 and the result of 3 will signify this combination. The table below lists the event code numbers associated with each test condition. When looking at a data file, use this key to determine how a test profile was programmed.

Exclusive Hold/Ramp soak Event Code # Description Event Code # Description

1 Salt Fog 1 cabinet Hold Soak 2 Dry Cycle 2 cabinet Ramp Soak 4 Fog Humidity 8 Wet Bottom RH

16 Controlled RH Non-exclusive 32 Immersion Fill Event Code # Description 64 Drain to Tank 1 Spray Pump

128 Drain to Waste 2 Time in Seconds 256 Ambient 4 Immersion Hold Soak 512 Custom Cycle 8 User Output

NOTE: Some displayed description are optional and not on each cabinet. They can be used only if the options were purchased with the cabinet.


5. Test Data – this is the “meat” of the datafile. In this section, each row is one data point, and each column is a

piece of data such as cabinet setpoint, cabinet actual temperature, and so on.

Since the time frame for taking a data point is set by the user, each row will reflect that time period. In the case of this example, it is easy to see that the data is taken every minute.

The columns with data are the following. 1. DATE - date this data point was written 2. TIME - time that this data point was written 3. CHAM TEMP - actual cabinet temperature 4. CHAM S P - cabinet temperature setpoint. 5. BT TEMP - bubble tower actual temperature 6. BT S P - Bubble tower setpoint 7. LAB TEMP - laboratory temperature. 8. RH - relative humidity reading (optional) 9. RH S P - relative humidity setpoint (optional) 10. BT OUT PRES - bubble tower output pressure 11. IMM TEMP - immersion reservoir temperature (optional) 12. IMM S P - immersion reservoir setpoint (optional) 13. WET BULB TEMP - wet bulb temperature, actual (optional) 14. JACKET TEMP - air jacket temperature, actual (optional) 15. RTD #7 - actual temperature for RTD #7 (optional) 16. RTD #8 - actual temperature for RTD #8 (optional) 17. BT IN PRES - bubble tower temperature input pressure (optional) 18. BT FLOW - air flow for compressed air into the bubble tower (optional) 19. TEST NAME & STATUS - name of the test being run, and the status of this test 20. CURRENT STEP - the current step number of the test that is being run 21. NEXT STEP - the number of the next step to be run in the test profile 22. STEP TIME - length of time for which this step is set to be run 23. TIME REMAIN - the length of time that is left to run for this step 24. FAULT STATUS - message showing any fault at the time of the data point 25. NOTE PAD - any note that the user typed into the graphing page 26. EVENT - the condition (i.e. salt fog, dry, etc.) that was running during this data point 27. GOTO STEP - the next step that is to be performed after the current one. A 0 means that it

will just go to the next step. 28. TOTAL LOOPS - the number of loops this step is to be repeated


29. 1-8 INPUTS - the position (1=ON, 0=OFF) of inputs number 1-8 30. 9-16 INPUTS - the position (1=ON, 0=OFF) of inputs number 9-16 31. 17-20 INPUTS - the position (1=ON, 0=OFF) of inputs number 17-20 32. 1-8 OUTPUTS - the position (1=ON, 0=OFF) of outputs number 1-8 33. 9-16 OUTPUTS - the position (1=ON, 0=OFF) of outputs number 9-16 34. 17-24 OUTPUTS - the position (1=ON, 0=OFF) of outputs number 17-24 35. 25-32 OUTPUTS - the position (1=ON, 0=OFF) of outputs number 25-32 NOTE: not all cabinets have all of the inputs or all of the outputs. This is dependent on the options purchased with the cabinet. Using input and output positions listed in items 29-35 can be quite useful in determining what the cabinet was doing at the time of the data point. However, since Excel sees this data as a whole number, it will not display leading zeros when it imports the data. To correct this, these eight columns must be reformatted. To reformat these columns, perform the following steps: a. Select columns AC, AD, (directions for AE below), AF, AG,

AH and AI by holding down the CTRL key and clicking on the top of these columns.

b. Next click on FORMAT, then CELLS, and a window will open. c. Click on CUSTOM, and GENERAL will be displayed in the

Type window. d. Overwrite the GENERAL setting with 8 zeros; “00000000” and

then click OK. Repeat steps a-d replacing the columns selected with AE, and replace the GENERAL settings with only 4 zeros “0000”. After all changes are made click on Save and change the file type to EXCEL WORKBOOK. The following two pages show the I/O key to use for deciphering the positions of the inputs and outputs on the data file.


Data Logging Key for Computer Controls for the Koyo I/O Rack Screw Input or Data Log I/0 Data Slot # Description Terminal # Output # File File #

2 16 point sinking/sourcing input Bubble Tower Level Switch 0 X0 Input # 1 cabinet Empty Level Switch 1 X1 Input # 2 cabinet Full Level Switch 2 X2 Input # 3 Salt Tank Full Level Switch 3 X3 1-8 Inputs Input # 4 Salt Tank Low Level Switch 4 X4 Input # 5 Salt Tank Empty Level Switch 5 X5 Input # 6 Internal Reservoir Level Switch 6 X6 Input # 7 cabinet Over Temperature Switch 7 X7 Input # 8 Immersion Heater Over Temperature Switch 0 X10 Input # 9 Lid Switch 1 X11 Input # 10 Trap Level Switch 2 X12 Input # 11 RH Valve in Fresh Position 3 X13 Input # 12 RH Valve in Recirculation Position 4 X14 9-16 Inputs Input # 13 Jet Exhaust Valve Recirculation Position 5 X15 Input # 14 Jet Exhaust Valve Drain Position 6 X16 Input # 15 Control Power 7 X17 Input # 16

3 16 point sourcing output Main Heater Contactor (CON1) 0 Y0 Output #1 cabinet Heat SSR (SSR1) 1 Y1 Output #2 Bubble Tower Heater SSR (SSR2) 2 Y2 Output #3 Blower Motor Relay (CR1) 3 Y3 Output #4 RH Valve Relay (CR2) 4 Y4 1-8 Outputs Output #5 cabinet Drain Relay (CR3) 5 Y5 Output #6 Immersion Heater SSR (SSR 3) 6 Y6 Output #7 Immersion Pump Fill Starter (MS1R) 7 Y7 Output #8 Immersion Drain Starter (MS1R) 0 Y10 Output #9 Spray Pump (CR4) 1 Y11 Output #10 Jet Exhaust Relay (CR5) 2 Y12 Output #11 User output (CR6) 3 Y13 Output #12 Alarm (CR7) 4 Y14 9-16 Outputs Output #13 RH Probe Solenoid Relay (CR8) (Sol. 16) 5 Y15 Output #14 Air Wiper Heater SSR & Solenoid Relay (SSR 4 & CR9)

(Sol. 17) 6 Y16 Output #15

Wet Bottom Drain Relay and Solenoid (CR10) (Sol. 15) 7 Y17 Output #16

4 12 Point Relay output Bubble Tower Air Solenoid # 5 0 Y20 Output #17 Bubble Tower Bypass Solenoid # 12 1 Y21 Output #18 Salt to Tower Solenoid # 8 2 Y22 Output #19 Fog Tower Drain Solenoid # 7 3 Y23 Output #20 Trap Drain Solenoid # 4 4 Y24 17-24

Outputs Output #21

DI to Fog Tower Solenoid # 3 5 Y25 Output #22 DI Water to Trap Solenoid # 2 0 Y30 Output #23 DI to Solution Reservoir Fill Solenoid # 13 1 Y31 Output #24 Lid open Solenoid # 9 2 Y32 Output #25 Lid close Solenoid # 10 3 Y33 Output #26 Solution Reservoir Air Sparger Solenoid # 6 4 Y34 Output #27


DI to Bubble Tower Fill Solenoid # 1 5 Y35 25-32 Outputs

Output #28

7 Combination card, 4 in and 4 out Immersion Reservoir Fill Switch 0 X100 Input # 17 Immersion Reservoir Empty Switch 1 X101 17-20 Inputs Input # 18 Drain Motorized Ball Valve Open 2 X102 Input # 19 Drain Motorized Ball Valve Closed 3 X103 Input # 20 Immersion heater Contactor (Con 2) 0 Y40 25-32

Outputs Output #29

DI to Immersion Reservoir Fill Solenoid # 14 1 Y41 Output #30 Immersion Reservoir Air Sparger Solenoid #11 2 Y42 Output #31 Spare 3 Y43 Output #32


X. OPERATING INSTRUCTIONS

A SALT FOG (SPRAY)

The following instructions are for Salt Fog testing in accordance with ASTM B-117. Refer to the ASTM test specification for exact test instructions. If NOT testing to ASTM B117, refer to the desired test specification.

1. The cabinet temperature has been preset to 35ºC. (Refer to Section VIII Temperature Setting for further details.)

2. Prepare salt solution in accordance with the test specification and transfer it into

the solution reservoir.

3. Make certain that manual ball valve # 1 from the solution reservoir to the Salt Solenoid is open.

4. Check atomizer nozzle to be sure it is functioning properly. To do this, turn on

the Bubble Tower heater switch and make sure compressed air to the Bubble Tower is set to 15 psi (1.03bar). If all conditions are set properly, the cabinet will start fogging. If not, refer to Section XIV Troubleshooting Tips. Turn this off after it is proved that the cabinet is fogging.

5. Place test specimens in the cabinet in accordance with the test specification.

Allow sufficient space between the test pieces for adequate fog circulation. Do not allow condensation from one specimen to fall on another. Most test specifications prohibit stacking specimens. Always refer to the test specification for placement during the test.

6. Place a minimum of 2 condensate collector funnels (80 cm2) and 2 graduated

cylinders (100 ml) in the cabinet so that the horizontal plane of the top of the funnel is at test level. Locate one as close to the dispersion tower as possible and one as far away as possible. (Do not place the funnel so close to the dispersion tower that it collects condensation, which may drip from the adjustable cone.)

7. Rotate the vertical tube of dispersion tower until the 4 holes (1” / 2.54cm) at the

base of the tube are fully open. The holes are used to control the velocity and quantity of the fog. Open holes will result in a higher collection rate. Closed holes will reduce the collection rate.

8. Adjust the inverted adjustable cone at the top of the tower so that the bottom tip

of the cone is even with the top edge of the vertical tube. It may be adjusted at any time to suit testing needs.


9. Close the cabinet cover.

10. If the optional Wet Bottom Drain was purchased, be certain the ball valve is

closed and the bottom of the cabinet is filled with water to 10-15cm / 4-6”.

11. If the Jet Exhaust Assembly is being used, turn on water valve and adjust pressure to 5 PSI (0.34bar) on the gauge.

B END-OF-TEST PROCEDURE At the completion of each test and/or prior to opening the lid, the cabinet must be purged of any fog to avoid exposing the exterior cabinet and components to the corrosive fog. To do this: 1. Turn the air purge toggle valve located on the control panel so that the air is directed

in to the cabinet rather than the Bubble Tower.

2. Allow the cabinet to be completely evacuated of fog before opening the lid. This cabinet purge may take from 15 – 30 minutes depending on the size of the cabinet and venting arrangements.

NOTE: If the cabinet lid begins to bounce, reduce the incoming air pressure slightly via the air purge valve until the lid stops bouncing.


XI. SAMPLE RECOMMENDATIONS, USE OF RACKS, MOUNTS

A simple inspection of the racks and mounts provided shows how easy they are to position inside the cabinet. Don’t crowd samples in the cabinet. Leave 2” or so between each sample. Samples should be loaded uniformly, facing the same way, for example, for the best result. Don’t allow samples above to “drip” solution on samples below. Leave space, accordingly. Load samples, and then examine positioning to make sure that all is right before beginning a test.


XII. FOG COLLECTION PROCESS & PROCEDURES

Testing Rule: Always verify uniformity of the condensation rate of fog (also called fall out or dispersion) before every test, because uniformity and consistency is a key to accuracy in results.

Maintenance-Troubleshooting Tip: Verify the uniformity of fog condensation rate as an important part of the regular maintenance schedule, as well as to provide an alert to indicate potential problem areas. The key indicator for maintenance is variations in collection rates that are not corrected by normal adjustments to control flow and pressure.

A. FOG DISPERSION CONTROL AND CONTROLS

The BCX cabinet delivers excellent fog dispersion control by providing independent controls for the volume of fog and the amount of air pressure. These controls make it easy for the operator to set, test, and adjust flow and dispersion.

1. Control of amount/volume of fog or corrosive: To increase or decrease the amount of solution-

a) Open or close the Throttle Holes in the dispersion tower base, OPEN providing more fog, CLOSED (or partially CLOSED) providing less.

b) Change the position of the inverted cone assembly.

2. Control of dispersion/distance of fog - To increase or decrease the projection - also referred to as “the throw” - of the solution-

a) Adjust the air pressure using the air pressure regulator. Note, when the air pressure is adjusted, so must the Bubble Tower temperature as indicated in the appendix of the ASTM B117 specification.

b) Open or close the Throttle Holes, OPEN providing more fog, CLOSED (or

partially CLOSED) providing less.. c) Change the position (height of the tip above the top edge of the vertical tube/baffle)

of the inverted cone assembly.


B. DETERMINING & MEASURING COLLECTION RATES

The best measure of cabinet performance is the fall out figure, also called the fall out rate or collection rate. Please refer to ASTM B117, or other applicable procedure, for detailed instructions and specific requirements. The collection rate is determined by measuring the amount of solution collected in two collection vessels located inside the cabinet during a given period of time. 1. Place a minimum of 2 condensate collector funnels (80 cm2) and 2 graduated

cylinders (100 ml) in the cabinet so that the horizontal plane of the top of the funnel is at test level. Locate one as close to the dispersion tower as possible and one as far away as possible (do not place the funnel so close to the dispersion tower that it collects condensation which may drip from the adjustable cone).

2. Rotate vertical tube of dispersion tower until the 4 holes (1” / 2.54cm) at the base of

the tube are fully open. The holes are used to control the velocity and quantity of the fog. Open holes will result in higher collection rates. Closed holes will reduce the collection rate.

3. Adjust the dispersion cone at the top of the tower so that the bottom tip of the cone is

even with the top edge of the vertical tube. It may be adjusted later to suit testing needs.

4. A collection rate reading of between 1.0 and 2.0 milliliters of solution each hour

(averaged over a minimum of 16 hours) per 80 cm2 of area should be the correct reading. Note: The fall out figure is the best measure of cabinet performance.

5. To adjust or vary the collection rate, adjust the air pressure (air pressure regulator),

the Bubble Tower temperature, the Throttle Holes, and the inverted cone assembly. Each one will have an impact on the collection rate. Keep in mind the objective when making adjustments.

6. Make sure that the tower and cone assembly is perpendicular to the cabinet floor.

XIII. TEST METHODOLOGY & SPECIFICATIONS

The BCX Series is designed to perform multiple tests to specification. Please refer to the test specification - ASTM B117, for example - for full instructions, considerations, rules, significance, etc. Test specifications supersede this manual. See the section on maintenance on procedures to follow before running each test.


XIV. MAINTENANCE

Regular maintenance is necessary for proper operation, and some maintenance topics and considerations follow. Like any piece of laboratory equipment, the BCX cabinet should have a regular maintenance program to keep it operating properly. Please follow the maintenance recommendations.

A. CHECK BEFORE EACH AND EVERY TEST: THE RULE OF THREE

Check three items before each and every test to ensure reliable results.

1. Is the cabinet clean?

Clean the test cabinet before each test, or major test sequence. Warm water and a sponge should suffice in most cases. Rinse the interior of the cabinet. Be certain that all accumulated salt is cleaned off walls, specimen racks, etc. Rust stains that may occur from dripping condensation should be removed with a mild, non-abrasive cleanser. The fog nozzle* should be inspected for salt build-up which can occur in the orifice. Wipe off temperature probes, and wipe down the exterior of the cabinet and level controls, as needed.

2. Is the fog uniform?

Check fog uniformity (refer to the section on “Fog Collection...”). 3. Is the concentration of the solution and the pH correct?

Check the solution concentration and pH factor. Note: ASTM B117 contains a procedure for measuring pH.

*NOTE: The atomizer nozzle and filter cartridge are the heart of the cabinet, and must

be kept clean and free from obstructions.

B. ROUTINE MOUNTHLY MAINTENANCE

1. Filter Cartridge Replacement a) Check/replace the Dispersion Tower Filter Cartridge (located in line from the salt

solution holding tank to the atomizer nozzle) every 1-2 months. b) Check/replace the DI water line filter cartridge (located in line just after the

customer installed DI water inlet) every 1-2 months.


2. Tubing & Fittings

a) Check the colored poly tubing for signs of oil which may have entered the lines

through the air regulator. If the tubing has discolored, have the compressor checked. Discoloration is typically a sign of oil within the air supply lines.

b) Check all tubing and connectors/fittings for wear. Replace as needed.

3. Atomizer Nozzle Maintenance and Replacement

If clogging of the atomizer occurs, remove it and, with compressed air, blow air into the face of the nozzle, thereby blowing any dirt out the back. Avoid using any instrument to clean the nozzle. Over-cleaning will enlarge the air holes and change the operating characteristics of the nozzle.

4. Cabinet Heaters

The cabinet heaters must be checked on a regular basis, but at least every month. Inspect the heaters for any salt or residue accumulation. If accumulation of any type is present, the heaters must be cleaned. Inspect the heaters for any signs of wear or degradation including but not limited to discoloration of the heater sheath, or breaking down of the coating. If any signs of wear or degradation are present, replace the heater immediately. No further testing should be done until the heater has been replaced. To avoid possible down-time during an important test, it is suggested that cabinet heaters be replaced every year. Should you have any questions please contact ATLAS Tech Service or your authorized Atlas Representative..

5. General Maintenance checklist, below.

Maintenance Area or Item Recommended Action

Compressed air filter Replace, as needed. Solution reservoir filter Clean screen.

DI water filter Replace, as needed. Bubble tower Drain, clean, and refill with clean water.

Aerators in bubble tower Check for fine dispersion of bubbles. Replace, as needed.

Cabinet heaters Remove any salt accumulation. Check heater integrity Deionized water Check for proper purity and for neutral pH.


C. ANNUAL SERVICE

1. Check atomizer nozzle and replace if needed. 2. Drain Salt Solution Reservoirs, and clean the interior. Remove algae build-up. 3. Refill reservoirs with fresh solution. 4. Replace the air bubbler at the base of the Bubble Tower. 5. Replace Bubble Tower O-Rings (2ea). 6. Check calibration of all devices in accordance with normal, accepted, calibration

methods and procedures regarding temperature, pressure, and flow. 7. RTD temperature sensors.

Check the calibration of the cabinet RTDs every year or as required.

8. Check cabinet heater integrity and replace when needed, or at least annually.


D. CALIBRATION

Annual calibration will assure that the BCX cabinet is operating properly. Third party services are available to perform this procedure. 1. Temperature Controls

It is suggested that a certified RTD simulator/reader be used to verify the PLC. To calibrate the controller simply connect the simulator to each channel of the controller (one at a time) and send 3 signals to the controller, 20ºC, 35ºC and 70ºC. If the display screen reads the same as the simulator then everything is fine. If not, contact Atlas Tech Service or an Atlas authorized representative. If the readings are incorrect but linear, then an offset can be used to compensate. If the readings are non-linear, then a component will need to be replaced.

2. RTD Temperature Calibration Procedure

a) Shut down the cabinet as described in the operation manual and relieve any pressure from the Bubble Tower.

b) Prior to removing the RTDs, mark the wires so they can be put back correctly

when calibration is complete. c) The RTDs will unplug and screw out of the plastic fittings. When replacing the

RTDs, use a thin layer of Teflon tape on the threads. d) Heat a 1000 ml beaker of water (tap water is acceptable) to a temperature of

approximately 35ºC. This is close to the operating temperature of the RTDs. e) Stir the water using a magnetic stirrer, and hang or hold the standard

thermometer along with the Thermocouple near the center of the moving water. f) Compare the reading of the RTDs with the thermometer. If the temperature

shown on the controller is more than 1ºC different than the certified thermometer, the RTDs should be replaced.

The RTDs can also be checked using the RTD simulator/reader.

Pressure gauges are calibrated at the factory prior to shipment. They may be returned to ATLAS on an annual basis for re-calibration with certificate. For some items, replacement cost is comparable to the cost of recalibration when shipping and handling are taken into consideration. Contact ATLAS Tech Service or an authorized Atlas representative before returning items for calibration.


XV. TROUBLESHOOTING, NOTES

A. GENERAL

Please note that the controller is a source of information regarding the status of the unit. Check the basics first, as with any piece of equipment. Is there electrical power to the unit or Circuit breaker? Is there water to the unit? Is there compressed air to the unit?

B. SPECIAL NOTE ON SOLUTION PURITY: FILTER, FOG NOZZLE

Attention must be paid to the purity of the chemicals and salt used for various solutions for tests. A clogged filter and a clogged fog nozzle can be the result of impurities. Interruption of the fog, uneven collection rates, and improper flow can be caused by these impurities. Additionally, DI or distilled water that is not of the proper type can invalidate the test as well as damage the equipment. Never use ASTM D1193 type I or II water. Use ASTM D1193 Type IV water. Or as described in ISO3696 or JIS K8150.

C. TROUBLESHOOTING CONTENTS These follow in the order shown below.

No Fog - D. Low Collection Rates - E. High Collection Rates - F. Uneven Collection Rates - G. Low Relative Humidity - H. No Heat in Bubble Tower -I. Cover Bounces - J. Cloudy Bubble Tower -K. Incorrect pH Level - L. Inconsistent Air Pressure in Bubble Tower - M. Bubble Tower Fills Up with Water Over Float Switch - N. Salt Settles in Bottom of Salt Solution Reservoir - O


D. NO FOG

POSSIBLE CAUSES CORRECTIVE ACTION Clogged atomizer nozzle Clean or replace nozzle Clogged solution filter cartridge Replace filter No solution in the internal reservoir Fill reservoir Inadequate air flow to the nozzle Check air flow to nozzle Bubble Tower Air Solenoid Failure Check/replace solenoid Customer supplied Compressed Air failure Check for proper air supply

E. LOW COLLECTION RATES

POSSIBLE CAUSES CORRECTIVE ACTION Clogged atomizer nozzle Clean or replace nozzle Clogged solution filter cartridge Replace filter Air pressure set too low Check air pressure setting Out-of-calibration pressure gauge Check gauge calibration Improper placement of collector funnels Probably located too high Improper positioning of adjustable cone Centrally locate cone height Throttle holes of Dispersion Tower closed Open throttle holes Inadequate air flow to the nozzle Check air flow to nozzle Customer supplied compressed air failure Check for proper air supply Empty nozzle feed reservoir Check floats, solenoids & tubing

F. HIGH COLLECTION RATES

POSSIBLE CAUSES CORRECTIVE ACTION Worn atomizer nozzle Replace nozzle Air pressure set too high Check air pressure setting Out-of-calibration pressure gauge Check gauge calibration Improper placement of collector funnels Probably located too high Improper positioning of adjustable cone Centrally locate cone height Throttle holes of Dispersion Tower opened Close throttle holes Bubble Tower temperature improper Check & correct bubble tower temp


G. UNEVEN COLLECTION RATES

POSSIBLE CAUSES CORRECTIVE ACTION Worn or clogged atomizer nozzle Clean and/or replace nozzle Air pressure setting not accurate Check air pressure setting Out-of-calibration pressure gauge Check gauge calibration Improper placement of collector funnels Probably located too high Improper positioning of adjustable cone Centrally locate cone height Throttle holes of Dispersion Tower opened Close throttle holes Bubble Tower temperature improper Check & correct bubble tower temp Funnel collecting condensation from test specimen Check & correct funnel placement Empty fog nozzle feed reservoir Check floats, solenoids & tubing

H. LOW RELATIVE HUMIDITY

POSSIBLE CAUSES CORRECTIVE ACTION Empty fog nozzle feed reservoir Check floats, solenoids & tubing RTDs are out of calibration Check and calibrate RTDs Controller is out of calibration Check and calibrate controller Wet bulb wick & reservoir empty Clean and fill wick & reservoir Air pressure setting not accurate Check air pressure setting Out-of-calibration pressure gauge Check gauge calibration Throttle holes of Dispersion Tower closed Open throttle holes Bubble Tower temperature improper Check & correct bubble tower temp

I. NO HEAT IN BUBBLE TOWER

POSSIBLE CAUSES CORRECTIVE ACTION Activation of the Low Water Cut-off feature Reset switch on the B.T. heater Bubble Tower RTD is out of calibration Check and calibrate RTD Controller is out of calibration Check and calibrate controller Bubble Tower setpoint too low Check & correct setpoint Bubble Tower is not full of water Check & correct water level Blown fuse for the Bubble Tower heater Check and replace fuses if needed Bubble Tower heater is damaged Check and replace heater if needed


J. COVER BOUNCES

POSSIBLE CAUSES CORRECTIVE ACTION Back pressure in the exhaust line Check exhaust line Back pressure in the drain line Check drain line

K. CLOUDY BUBBLE TOWER

POSSIBLE CAUSES CORRECTIVE ACTION Water is contaminated Check & clean water source Water inlet filter is full Check & replace filter Water cylinder is etched Check & replace cylinder

L. INCORRECT PH LEVEL

POSSIBLE CAUSES CORRECTIVE ACTION Water may not meet specification Check water to ASTM D1193* Water may not meet specification Check salt to ASTM B117 Algae build up in fog nozzle feed reservoir Check & clean reservoir Algae build up in salt or water in line filters Check & replace filters if needed Algae build up in the solution reservoir Check & clean reservoir

M. INCONSISTENT AIR PRESSURE IN BUBBLE TOWER

POSSIBLE CAUSES CORRECTIVE ACTION Air bubbler may be clogged Check & replace if needed Air pressure setting not accurate Check air pressure setting Out-of-calibration pressure gauge Check gauge calibration Customer supplied air filter may be clogged Check & clean if needed Air regulator may be defective Check & replace if needed

*Or equivalent in ISO3696, JIS K8150


N. BUBBLE TOWER FILLS UP WITH WATER OVER THE FLOAT SWITCH

POSSIBLE CAUSES CORRECTIVE ACTION Leak in the Bubble Tower O-rings Replace O-Rings Leak in one of the other fittings in the B.T. Check for leaks & correct Spikes in the air water pressure Check & correct water regulator In coming water pressure set too high Regulate water pressure down Float switch has malfunctioned Check or replace float switch Bubble Tower water fill solenoid stuck open Check, clean or replace solenoid

O. SALT SETTLES IN BOTTOM OF SALT SOLUTION RESERVOIR

POSSIBLE CAUSES CORRECTIVE ACTION Incorrect salt Check salt to ASTM B117 Insufficient mixing time Increase mixing time


XVI. WARRANTY INFORMATION & SERVICE

EQUIPMENT WARRANTY Atlas Material Testing Technology LLC warrants for twelve (12) months from first use or fifteen (15) months from date of shipment, whichever occurs first, that this ATLAS instrument has passed our inspection and tests; that it is free from defects in materials and workmanship; and that it will perform according to the applicable published ATLAS specifications if installed and operated according to our instructions. This warranty is in lieu of any other warranty expressed or implied. In no event will ATLAS be liable for special or consequential damages as a result of any alleged breach of this warranty provision. The liability of ATLAS hereunder shall be limited to repairing or exchanging, at its option, any defective part F.O.B., ATLAS plant, Chicago, Illinois (U.S.A.). Equipment or parts which have been subjected to abuse, misuse, accident, alteration, neglect, unauthorized repair or installation are not covered by warranty. ATLAS shall have the right of final determination as to the existence and cause of the defect. When parts are repaired or exchanged, the warranty on said part shall continue in effect for the remainder of the original equipment warranty period or for six (6) months following the date of shipment by ATLAS, whichever period is longer. ATLAS reserves the right to make changes and improvements in its products without obligation to install these changes in products theretofore manufactured.

PARTS WARRANTY Parts and material supplied by Atlas Material Testing Technology LLC are inspected and tested to ensure that they are free from defects and will operate properly when correctly installed and operated in equipment produced by ATLAS. Parts (excluding consumable components such as light sources, optical components, crock cloth, etc.) are under warranty for a period of six (6) months from date of shipment. This warranty is in lieu of any other warranty expressed or implied. In no event will ATLAS be liable for special or alleged breach of this warranty provision. The liability of ATLAS hereunder shall be limited to repairing or exchanging, at its option, any defective part F.O.B., ATLAS plant, Chicago, Illinois (U.S.A.). Parts which have been subject to abuse, misuse, accident, alteration, neglect, unauthorized repair or installation are not covered by warranty. ATLAS shall have the right of final determination as to the existence and cause of the defect. ATLAS reserves the right to make changes and improvements in its products without obligation to install these changes in products theretofore manufactured.

Atlas Material Testing Technology LLC 4114 North Ravenswood Avenue Chicago, Illinois 60613 USA Phone 773-327-4520 FAX 773-327-5787


XVII. REPLACEMENT PARTS

This is a partial list of typical replacement parts. Part # Description U/M Qty

C261731 Atomizer Nozzle Assy. EA 1.0 C010040 Panel Mount Air Gauge EA 1.0 C010145 NEWLOC 3/8 X 1/4 F/F EA 5.0 C010150 NEWLOC 3/8 Male Connector EA 5.0 C010160 NEWLOC 3/8 Male Elbow EA 5.0 C010170 NEWLOC 3/8 Female Connector EA 5.0 C010185 NEWLOC 3/8 Bulkhead EA 5.0 720650 3/8" O.D. Polyurethane tubing, BLUE FT 25.0 720655 3/8" O.D. Polyurethane tubing, RED FT 25.0 720660 3/8" O.D. Polyurethane tubing, YELLOW FT 5.0

C263300 Air Bubbler, Stainless Steel EA 2.0 C262470 O-Ring, 6" EA 2.0 720445 Bubble Tower Float Switch Assembly EA 1.0

C261240 Bubble Tower Heater EA 1.0 C263280 Dispersion Tower Float EA 1.0 710300 In-line Filter Assembly for DI water EA 12.0 710310 In-line Filter Assembly for Salt Water EA 12.0 720455 RTD - Single for BCX EA 2.0 720350 cabinet Heater 2000W with grounding grid EA 1.0


XVIII. GLOSSARY Words in italic have a separate entry. AASS see Acetic Acid Salt Spray Access Ports holes that can be placed in the side walls of a lab corrosion testing cabinet, through which

compressed air lines, water or hydraulic lines, electrical lines, or mechanical connections can be routed; used to connect to samples being tested.

Acetic Acid a mild acid, chemical formula C2H4O2, used as a corrosive fluid in some test methods, such as ASTM G85 Annex 1 and GM 4466-P; also used in conjunction with sodium chloride in test methods BS7479 and ISO9227.

Acetic Acid Salt Spray (AASS) a test method requiring a corrosive solution of acetic acid and sodium chloride, such test methods include BS7479 and ISO9227.

Acid Rain Test a test method that is intended to duplicate the conditions of outdoor exposure in an industrial area, where rain rinses chemicals from the atmosphere.

Acrylic Cover a clear cover for lab corrosion testing equipment, which sloping angle is designed to prevent condensation from dripping onto samples, and which allows for viewing of ongoing test conditions.

Adjustable Cone an inverted (point down) cone, which deflects the upward-rising fog from the atomizer nozzle, and is the top of an Omni-Fog Tower; also catches any drops or droplets and allows them to drip back into the Internal Reservoir, thus preventing splattering of test samples.

Adjustable Humidity see Variable Humidity, also called Controlled Humidity. Air-actuated Cover an option that provides a mechanical way to lift the cover of a lab corrosion testing cabinet

which, when connected through cabinets controls, allows the cover to be raised at specified times, such as for access to samples, or to automatically create ‘lab ambient’ conditions in the Exposure Zone.

Air Bubbler a component for percolating incoming compressed air located at the base of the Bubble Tower; when air passes through it, the air is separated into small bubbles, which increases the surface area of air in contact with heated DI water, thus increasing both the temperature and the humidity of the air.

Air Compressor a mechanical device that is used to create pressurized air. Air Powered Cover Lifter see Air-Actuated Cover. Air Pressure Gauge a gauge located on the Bubble Tower in Salt Fog cabinets and on the Control Panel of cyclic

cabinets, which shows the pressure of air at the top of the Bubble Tower. Air Regulator a device which allows a specific volume if air to pass, so that air pressure is maintained at a

desired level. Air Relief Valve a safety device located on top of the Bubble Tower with a setpoint to about 5 psi / 34 kPa above

the desired air pressure, which will open and allow air to escape if the air pressure exceeds the setpoint.

Alarm an error condition that cause a corrosion cabinet to stop operation; these are usually removed through manual action by the operator after problem correction.

ASS see Acetic Salt Spray. Atomizer Nozzle a small cylinder, made of acrylic resin, that combines compressed air and a fluid (salt solution,

water, electrolyte) and propels the mixture upward through the Omni-Fog Tower as a fog. Automatic Solution Level Control a system of level switches, solenoids, supply lines and a reservoir that

maintains a set level of fluid (salt solution, water, electrolyte) in the internal reservoir. Back Pressure in a drain line or fluid supply line, pressure that causes movement of fluid in the opposite direction

than which desired. Bubble Tower a vertical cylinder that is 3/4 full of heated water, through which compressed air is forced to make

the air humid; allows compressed air to atomize fluid (salt solution, water, electrolyte). Bubble Tower Heater a resistance heater submerged in water in the Bubble Tower. Building Drain a hole in the floor of a room, such as a laboratory, that is connected to a sewer system; intended

to remove fluids by gravity from the room or building; also called Gravity Drain. C2H4O2 see Acetic Acid


Cabinet Heater a resistance heater used to achieve and maintain temperatures in the exposure zone. In a Salt Fog cabinet, heaters are located in the water jacket. In a cyclic cabinet, heaters are located below the diffuser plate.

Canadian Wiring Package the proper wiring and electrical parts to allow the CSA label to be affixed to a corrosion cabinet operated in Canada.

Carbon Dioxide a colorless, odorless gas, chemical formula CO2, that dissolves readily in water to make a weak acid.

CASS see Copper Accelerated Acetic Acid Salt Spray Casters wheels located on the bottom of a lab corrosion testing cabinet which allow it to be rolled across a floor. CCT see Cyclic Corrosion Test. CE Label the proper wiring and electrical parts to allow the CE (European Conformity) label to be affixed to a

lab corrosion testing cabinet operated in many European countries. Chart Recorder a device that prints, on paper, current conditions of various pre-determined test parameters such

as temperature, humidity, and pressure. Chromasoft™ Software in Salt Fog cabinets, software that performs two-way functions- it communicates

information to the user via an IBM-compatible PC, and communicates instructions from the operator that are input to that PC.

Circular Chart Recorder see Chart Recorder. CO2 see Carbon Dioxide Collection Rate see Condensation Rate. Combination Oil and Water Extractor a device that removes moisture and oil from pressurized air; usually

found on the air supply line just before that line enters a lab corrosion testing cabinet. Compression Fitting a connector for tubing, used in lab corrosion testing cabinets; connection is made by

pushing the proper size tubing into an open end of the fitting; these fittings have been tested at 80 psi / 552 kPa.

Condensation Rate the rate at which humidity condenses from air and falls by gravity through the exposure zone, usually measured as millilitres per hour.

Connectors, Quick, for Tubing see Quick Connectors. Control Cabinet in cyclic cabinets, the right side of the unit, which houses the Bubble Tower and electrical panel,

among other components, and on top of which is placed the Display Panel or NoteBook Computer. Control Panel see Standard Display Panel, or Computer Monitor. Controlled Humidity see Variable Humidity; also called Adjustable Humidity. Copper-Accelerated Acetic Acid Salt Spray (CASS) a test method that combines copper chloride, acetic acid

and salt solution; found in ASTM B368, ISO 9227, GM4476P, Ford BQ5-1. Corrodkote© a test that involves coating samples with a chemical slurry which is allowed to dry before placing

the samples in a humidity cabinet; ASTM B380. Corrosion the degradation of a material, usually the oxidation of iron or other metal, caused by interaction with

its environment. Corrosion Control the attempt to neutralize destructive environmental attacks. Corrosion Testing an important aspect of corrosion control, includes lab and outdoor exposure. Cover Open a message on the display panel that indicates the cover is not completely closed. CSA see Canadian Wiring Package. Cycle a specified sequence of events, called Steps; in cyclic testing, where samples are exposed to various

environmental conditions in a pre-set sequence. Cyclic Corrosion Test a sequence of environmental steps that simulate real-world conditions. Datalogging Software software that performs two-way functions: it communicates information to the user from

the controller via a PC, and communicates instructions from the operator to the controller that are input at the PC.

Deionized Water see DI Water. Deionizer Resin Sack a quantity of resin for ion exchange that is placed inside deionizer systems. DI Holding Tank, 25 gallon in Salt Fog cabinets, a horizontally mounted cylindrical reservoir, used to supply DI

water to the Bubble Tower when no source of pressurized DI water is available. DI Tank, 60 Gallon, with Pressurizing Pump in a cyclic cabinet, a separate reservoir for DI Water, on a stand

with castors, which includes a pump that pressurizes the DI water. See also Extra Solution Reservoir.


DI Water for all corrosion cabinets, water that meets ASTM D1193 Type IV (or equivalent, as found in ISO 3696 or JIS K8150); this water can be created through reverse osmosis, distillation, or filtering with ion exchange.

Diffuser Plate in a cyclic cabinet, the bottom of the exposure zone; it contains holes for the upward movement of air and the downward movement of drips and condensate, and beneath which the heaters are located.

Dispersion Rate see Condensation Rate. Dispersion Tower see Omni-Fog Tower. Display Panel see Standard Display Panel, Computer Monitor. Drain an opening at or very near the bottom of the exposure zone through which condensate and rinse water is

routed to the building drain. See also Drain/Vent and Vent. Drain/Vent in cyclic cabinets, the 4” opening, usually in the center lower back, through which both fluid and gas

exit the exposure zone. Dry Bulb an RTD sensor that measures ambient temperature within an enclosure. Dry-off an environmental cycle during which heaters are energized and the air blower moves air through the

exposure zone to remove moisture. Dual Magnetic Seals matching rubber strips with embedded magnets that attract one another, located (first) on

the top of the exposure cabinet of cyclic cabinets, and (second) on the bottom of the cover where it contacts the top of the exposure cabinet; to prevent conditions in the exposure cabinet from escaping to the laboratory; so that, when closed, the rubber strips are attracted to and held together by the magnetic strips within.

Duo-gas an optional environmental condition with valves and connections to allow two gasses to be used in testing.

Dwell a period of time during which no environmental cycles are activated, although cabinet heaters can be energized to maintain a temperature setpoint above ambient.

Electrolyte a fluid containing a chemical that allows electrical conductance. Environmental Cabinet those test cabinets that are designed to simulate variable conditions that are encountered

in the real world, such as temperature, humidity, etc. Environmental Cycle a condition created in an exposure zone to simulate a real-world condition, such as conden-

sing fog, high humidity, high/low temperature, solution spray, immersion, and variable humidity. Exhaust Recirculation System a vertically mounted cylinder containing a porous material to which corrosive

molecules become attached and are then rinsed off by water that is sprayed from above; this fluid is collected in the built-in reservoir, which is then recirculated again as spray water.

Exposure Cabinet the part of a lab corrosion testing cabinet that includes the exposure zone, cover, rack supports, and Omni-Fog Tower.

Exposure Zone the volume of space inside the exposure cabinet in which samples are exposed to environmental conditions; the top of the exposure zone is the horizontal plane of the entry of vapor, fog, mist, or spray; in cyclic cabinets the bottom is the diffuser plate; in Salt Fog cabinets the bottom is the floor of the cabinet.

External Condensate Collection Package a system of collection funnels, tubing, and valves, which allows a pre-test check of the condensation rate from outside the exposure cabinet; that is, with the cover closed.

Extra Solution Reservoir a second or subsequent holding tank for a mixed chemical solution, connected by gravity lines to the Solution Reservoir. See also DI Tank, 60 Gallon, with Pressurizing Pump.

Fiberglass Bracket see support bracket. Fiberglass Rod see support rod. Filter Assembly, DI Water in cyclic cabinets, a replaceable filter that is installed in the lower front area of the

Control Cabinet; its purpose is to trap all particles in the DI water supply. Filter Assembly, Salt Solution in cyclic cabinets, a replaceable filter that is installed in the vicinity of the lower

front area of the 60 gallon Solution Reservoir; its purpose is to prevent precipitates or other non-dissolved chemical from reaching the atomizer nozzle.

Filter Cartridge in Salt Fog cabinets, a wound filter that is placed in the internal solution reservoir that prevents precipitates or other non-dissolved chemical from reaching the atomizer nozzle.

Flow Meter a meter on a fluid line that measures the volume of fluid that has passed that point. Fog fluid particles in the air as molecules, usually smaller than 50 microns in size. Fog Collection see condensation rate.


Fungus Test an environmental test performed in lab corrosion testing cabinets,using various forms of fungi to attack coatings.

Gas Shocks see Air Actuated Cover Lifters. Type IV Water DI water according to ASTM D1193 for Type IV. Graduated Cylinder a cylinder, closed on the bottom, which has markings for accumulated volume of a fluid; in

a lab corrosion cabinet it is used to check the condensation rate. Gravity Drain see building drain. Grayscale Touchscreen Display see Display Panel. High Humidity Cycle a test cycle in which the air in the exposure zone is saturated with moisture. Horizontal Dispersion System a horizontally-mounted set of pipes that disperses fog, mounted in place of the

inverted cone at the top of the Omni-Fog Dispersion Tower; used when cabinet volume, sample size or operator preference requires movement of the dispersion tower from being located toward the middle of the cabinet to (usually) the back.

Humidifying Tower see Bubble Tower. Humidity Pipe Assembly a plastic pipe, mounted along the floor of Salt Fog cabinets, through which compressed

air is forced through standing water, to make non-condensing humidity for certain tests such as ASTM B380.

Inert Material a material that is non-magnetic, no-corrosive, and non-electrically-conductive. Pneumatic Cover Lifting System see Air-actuated cover. Mist A term for fluid suspended in a gas that is often misused in corrosion testing in place of fog (mist particles

are larger than fog particles). NaCl see Sodium Chloride. Nitric Acid a corrosive fluid, chemical formula HNO3, used as an oxidizing agent in corrosion tests. Nitric Oxide a colorless, poisonous gas, chemical formula NO. NOx see Nitric Acid, Nitric Oxide. O Ring, Bubble Tower replaceable seals, about 5.5-6” / 14-15 mm in diameter, used at the top and bottom of the

Bubble Tower. O Ring, Internal Reservoir a replaceable seal, about 14” / 36mm in diameter, used on both ends of the horizontal

cylinder of the External Solution Reservoir; found in older SF cabinets. Omni Fog™ Dispersion Tower TRADEMARK; a vertical plastic assembly, with velocity ports, Atomizer Nozzle,

and inverted cone, that baffles and distributes fog created at the Atomizer Nozzle. Panel Rak a sample support device, consisting of vertically-oriented slots for holding samples. Panel Tray a sample support device; consisting of a double row of slots, 40 in all at .5” spacing, at a 15º angle. Perspiration Test see Synthetic Perspiration Test. pH Meter Kit a kit consisting of a pH Meter and solutions for adjusting the pH of the chemical solution. Plastisol-coated support Bar see Support Bar. Plastisol-coated Support Rack see Support Rack. PLC Programmable Logic Controller. Pneumatic Cover Lifter see Air-Actuated Cover. Power Exhaust Kit in a cyclic cabinet, a venturi style pump with pipe and connectors to assist in removing

exhaust from the exposure zone. Precision Air Regulator an air pressure regulator that is graduated at 0.1 psi intervals. Precision Control Package see Chromalox Controller. Premium Controls in a cyclic cabinet, an IBM™-PC-compatible notebook (laptop) computer used for cabinet

controls. Prohesion™ TRADEMARK, a cyclic test involving repeated episodes of exposure to corrosive fog followed by dry-

off; this test has been codified as ASTM G85 Annex 5. Quick Connectors, Tubing in lab corrosion testing cabinets, tubing connectors that have a moveable collar that

allows the tubing to be pulled out, usually without tools. Recorder see Chart Recorder. Reinforced Cabinet in a cyclic cabinet, a metal basket that is embedded within the exposure cabinet so that the

weight of immersion solution does not burst the walls. Resistance Temperature Device usually referred to as ‘RTD,’ see temperature probe. RTD Resistance Temperature Device; see temperature probe.


Rust Inhibitor a fluid that is added to water to suppress deterioration caused by oxidation of an iron-containing metal surface that is in contact with that water; in a Salt Fog cabinet, rust inhibitor is added to the water that is placed in the water jacket.

Safety Switch an electrical switch that opens a circuit to stop a test procedure and/or closes another circuit to energize an alarm.

Salimeter see salinity hydrometer. Salinity Hydrometer a hydrometer that measures the specific gravity of a saline solution. Salt see sodium chloride. Salt Fog Adder, Model 300 a set of valves, tubing, nozzles, switches, relays and solenoids that allows the Model

300 to be used for salt fog testing. Salt Spray a remnant term, from the original ASTM B117, which was intended to mean salt fog. Salt Spray Cabinet a cabinet of specific internal volume in which samples are placed and salt solution is sprayed

in order to later check for penetration of seals due to the presence or absence of chemical precipitates; more properly called a salt fog cabinet.

Saturation Tower see bubble tower. SF Start-up Kit see start-up kit. Sight Gauge on a Salt Fog Cabinet, a vertically-oriented, transparent tube mounted on the outside of the cabinet

that is used to indicate the level of water in the water jacket. SO2 see sulfur dioxide. Sodium Chloride a crystalline compound, chemical formula NaCl, which readily dissolves in water and promotes

surfaced oxidation of many metals, especially iron. Solution Collection Funnel a funnel that is used to measure the collection rate of condensing fog. Solution Reservoir a container for salt solution, DI water, or other electrolyte, which fluid is supplied to the

atomizer nozzle. Solution Tank see Solution Reservoir. Specific Gravity Hydrometer a device used to measure the specific gravity of a fluid, with pure water at

standard temperature and pressure having a specific gravity of 1 by definition. Spray a pattern of fluid distributed by pressure through a small opening, which contains droplets. Spray Nozzle a devices that dispenses water in droplets due to water pressure. Spring Cylinder Cover Lifting System in a Salt Fog cabinet, spring-loaded cylinders that assist in lifting the

cover and holding it open. Standard Control Panel in a cyclic cabinet, an operator message and input device through which communication

with the PLC is maintained. Start-up Kit includes 100 pounds /45.4 pounds off ASTM grade salt, a specific gravity hydrometer, a salinity

hydrometer, two 80 cm2 funnels and two 100 ml graduated cylinders. Strip Chart Recorder see Chart Recorder. Sulfur Dioxide a yellowish, foul-smelling gas, chemical formula SO2, a by-product of industrial processes which

can create a type of acid rain; used in test methods that simulate polluted atmospheres, such as ASTM G87, DIN 50017, DIN 50018. Note: cabinets using this gas MUST be vented to the outdoors using a suitable fume hood.

Support Bar a device, made from fiberglass or other inert material, placed within the exposure zone on which samples are placed for testing.

Support Rod a device, made from fiberglass or other inert material, placed at the top of the exposure zone and from which samples are suspended for testing.

Support Rack a device, made from fiberglass or other inert material, placed within the exposure zone on which either samples are placed for testing, or on which support rods are placed.

Synthetic Perspiration Test a test standard for exposure of samples to synthetic perspiration, such as ISO3160 2. Tap Water water suitable for drinking, also called potable water. Temperature and Humidity Recorder see Chart Recorder. Temperature Probe a device that measures temperature as a function of electrical resistance. Temperature Recorder see Chart Recorder. Test Panel Holder see Panel Rak, Panel Tray, Support Bar, Support Rack, Support Rod. Tubing flexible, hollow plastic piping used to route fluid and air; in a cyclic cabinet, tubing is made of

polyurethane, in a Salt Fog cabinet, tubing is made of polypropylene.


Tubing Connectors hollow pieces of plastic that are used to connect sections of tubing. Two Line Display in older cyclic cabinets, the operator message area of the standard Display Panel. UL see Underwriter’s Laboratories. Underwriter’s Laboratories an independent testing laboratory that, among other activities, inspects, tests and

approves electrical items used by consumers. Variable Humidity the ability to achieve and maintain a level of humidity between ambient and saturated. Also

called Adjustable Humidity, Controlled Humidity. VCU Video Control Unit, see Display Panel. Video Control Unit see Display Panel. Water Fog a fog that is comprised of water (usually de-ionized) only. Water Jacket in salt fog and humidity cabinets, the space between the outer wall and inner wall that is filled with

water and heater. Water Trap in a cyclic cabinet, a U-shaped section of pipe in the duct leading from the air blower to the

exposure cabinet which, when filled with water, blocks the backward movement of air from the exposure cabinet to the inside of the control cabinet.

Wet Bottom Drain Assembly a series of pipes and valves that allow water to accumulate in the bottom of an exposure cabinet. In a cyclic cabinet, it includes float switches and solenoids.


INDEX

—A— Air flow diffuser, 16, 17 Air Relief Valve, 19

—B— Bubble tower, 15 Bubble Tower refill, 15

—C— Clogging of the atomizer, 64 Compressed air specifications, 10 Connections, cabinet utilities, 9 Control Buttons, 23 Corrosive fog, 7 Crystalline buildup, 16

—D— Definitions, control panel, VCU, 22 Display Area, 22 Drain connections, 9 Dwell Cycle, 7

—E— Electrical supply, 11 Exhaust fan, vent, roof, 10

—F— Filter Cartridge Replacement, 63 Filter, salt solution reservoir, 16 Floor drain, 9 Fog collection, 4, 61, 62, 68 Fog fall out or dispersion, 61 Fog uniformity, 61 Fog, collection rate, 62 Fog, control of dispersion/distance of fog, 61 Fog, control of fog, 61

—H— Heaters, cabinet, 15 Humidifying Tower, 19

—M— Maintenance, Annual recalibration, 66

Maintenance, Annual Service, 65 Maintenance, nozzle, 64 Maintenance, routine, 63 Maintenance, Temperature Calibration Procedure, 66 Moving your cabinet, 8

—N— Numeric Keypad, 23

—P— Parts listing, 74 Programmable Logic Controller, 7, 15, 21, 66, 68

—R— Racks and mounts, 60 Regular maintenance, 63

—S— Safety, 6 Salt fog, 5, 7, 61, 62, 63, 69, 70 Salt solution, 7 Samples, test, 60 Spray nozzle, 16

—T— Temperature protections, cabinet, 15 Temperature range outside cabinet, 8, 12 Temperature Setting, 20, 21 Testing, utility services to cabinet, 12 Tests, perform multiple tests to specification, 62 Touch Panel, 23 Troubleshooting, 68

—U— Unloading your cabinet, 8

—V— Video Control Unit, 21, 22

—W— Warranty, 73 Water float sensor, 15

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Table of Contents Rev. 4.70 AMTT Oct04