Salt Spray Cabinet Manual Model Ref.: VF7705 (500 liter) VF7710 (1000 liter)
Health & Safety The Manufacturer is required to ensure, for reasons of Health and Safety at Work that, as far as is reasonably practicable, the articles which we design, produce and supply are as safe as possible and of minimal risk to health. We are required to provide information on the safety and handling precautions to be observed when installing, operating and maintaining our product. Such advice is contained in this manual. We should also like to point out, however that you as users have an important responsibility in the provision and maintenance of safe working practices and conditions. Accordingly we draw to your attention the following matters: This apparatus should only be used as intended and within its design parameters by suitably qualified and trained personnel who have read and understood the relevant sections of this manual. ii iii iv This manual should be readily available to such personnel at all times. In addition to that which is written in the manual, normal common-sense safety precautions must be taken at all times to avoid the possibility of accidents. Installation, maintenance and connection to electrical supplies should only be carried out by suitably trained personnel. v. We have undertaken a risk assessment for the hazards we believe are associated with this apparatus (copy attached) However, we would recommend that users produce their own risk assessment for the entire testing process for which this apparatus will be used. Page No.: 1
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Installation CAUTION THE EQUIPMENT SHOULD ONLY BE INSTALLED BY SUITABLY QUALIFIED PERSONNEL. DAMAGE CAUSED DUE TO INCORRECT INSTALLATION WILL NOT BE COVERED BY THE WARRANTY 1. Operating Environment This equipment is designed for internal use only, in an environment controlled to within the following limits:- Ambient Temperature: +15 to +30 C Note: The minimum operating temperature of the cabinet will depend directly upon the actual ambient temperature of the environment in which it is located. Ambient Humidity: 45 to 85% RH (no condensation) 2. External Services Note: All hoses and pipes up to 3 metres (10ft) in length, and the power cable, are supplied with the equipment. Electricity standard IEC socket Compressed air 12.5 mm (½ ) bore hose Salt Water 4 mm (3/16 ) bore hose De-ionised Water 12.5 mm (½ ) bore hose Air Saturator Drain No connection required. (See below) Do not connect anything to the Air Saturator Drain; it is provided for maintenance purposes only. Note: If cabinets are left unused for any length of time it is recommended that the air saturator is drained to prevent the build up of algae which could cause system blockages or of bacteria which might present a potential health risk. Page No.: 3
3. Electrical Supply Connect the mains cable provided to the IEC electrical socket at the rear of the cabinet (see above). Connect the other end of the mains cable to a fused electrical supply in accordance to the rating label at the rear of the chamber via a residual current device (earth leakage circuit breaker) using a non reversible 3 pin plug. 4. Compressed Air Supply Note: The compressed air supply must be clean, dry and oil free. It must have a minimum pressure of 1.4 bar (20 psi) and a maximum pressure of 6.0 bar (87 psi). Between these pressures, the flow rate should be at least 75 litres per minute (2.6 cubic feet per minute) equating to a free flow at atmospheric pressure of approximately 102 standard litres per minute (3.6 standard cubic feet per minute). Connect the 12.5 mm bore air hose provided to the air inlet at the rear of the cabinet (See above). Secure with hose clips provided. Connect the other end of the 12.5 mm air hose to the air supply. 5. De-ionised Water Supply Note: Cabinets must be supplied with deionised or distilled water, either gravity fed or pressurised, provided that the incoming pressure is between 0.5 to 5.0 bar (7 ~ 70 psi). See Operation Manual Paragraph 6.4 (VI) for instructions on manual filling. Connect the 12.5 mm bore water hose provided to the water inlet at the rear of the cabinet (See above). Connect the other end of the 12.5 mm water hose to the de-ionised water supply. 6. Condensate Drain Drain 40 mm diameter pipe Connect the 40 mm diameter push-fit pipe provided to the outlet of the cabinet, situated at the rear of the cabinet. Connect the other end to the service drain or drip tray. 7. Exhaust Vent to Atmosphere Exhaust 40mm diameter pipe Page No.: 4
Connect the 40 mm pipe provided to the exhaust outlet at the rear of the cabinet. If the length of the vent pipe route is greater than 5 metres, a larger diameter pipe should be installed. Route the other end to outside atmosphere, maintaining a straight run-up or run-down to avoid sags where condensate may collect and cause back pressure. This exhaust outlet must be terminated with a covered vent to prevent the fog being sucked out of the cabinet. Page No.: 5
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Operation 8. Cabinet Roof CAUTION THIS EQUIPMENT SHOULD ONLY BE OPERATED BY SUITABLY QUALIFIED PERSONNEL. The cabinet roof is held open using a roof stay; this is stored to the side of the roof when it is not required. Be sure to locate the bottom end of the roof stay in the recess in the cabinet water trap. Be sure to locate the top end of the roof stay in the recess in the roof. 9. Cabinet Control system 2.1 Mains Isolator Isolates cabinet from electricity supply. 0 = Off, 1 = On. 2.2 Configurable Electronic Thermostat The LED screen has a 3 digit display, with 2 dedicated multi-function buttons located to the right of the display, for the adjustment of parameters. Function button UP - Function button DOWN 2.3 Function Buttons: The Configurable Electronic Thermostat has two multi function buttons. Adjustments may be made to the settings and configuration using these buttons. 2.4 Starting / Stopping a Test Page No.: 7
Set Isolator to: 1 = On. Once the cabinet is connected to all required services, operation of the cabinet isolator will immediately start/stop a salt spray test. On starting a test, salt spraying is initiated and the cabinet actual temperature will automatically start to be controlled to match the set point (SV) temperature. The air saturator actual temperature will also be controlled to match the set point (SV) temperature. 2.5 Displaying Cabinet & Air Saturator Temperatures Pressing the button continuously for 5 seconds will display the Air Saturator temperature Set Value. Pressing the button continuously for 5 seconds will display the Cabinet air temperature Set Value. After a few seconds of not pressing the buttons, the display will revert to the actual temperature within the cabinet. Pressing the button for 2 seconds will display the air saturator actual temperature. 2.6 Cabinet Temperature Set Point The cabinet temperature Set Point may be adjusted from within the configuration menu of the Electronic Thermostat. Press and button together for 10 seconds. Press the button repeatedly until parameter 11 is shown on the LED display. Immediately press both and buttons to reveal the cabinet temperature set point. Adjust the cabinet temperature Set Point using both and buttons, DO NOT SET ABOVE 50C. Once set at the desired temperature, press both and buttons at the same time to revert to the configuration menu. Press the button repeatedly until EP is shown on the LED display. Press both and buttons at the same time to revert to the normal mode of operation. 2.7 Air Saturator Temperature Set Point The air saturator temperature Set Point may be adjusted from within the configuration menu of the Electronic Thermostat. Page No.: 8
Press and button together for 10 seconds. Press the button repeatedly until parameter 20 is shown on the LED display. Immediately press both and buttons to reveal the air saturator temperature set point. Adjust the air saturator temperature set point using both and buttons, DO NOT SET ABOVE 63C. Press both and buttons at the same time to revert to the configuration menu. Press the button repeatedly until EP is shown on the LED display. Press both and buttons at the same time to revert to the normal mode of operation. 2.8 Calibrate Cabinet Temperature Display The displayed value for cabinet temperature may be adjusted for calibration purposes from within the configuration menu of the Electronic Thermostat. Press and button together for 10 seconds. Press the UP button repeatedly until parameter 03 is shown on the LED display. Immediately press both and buttons to reveal any offset value for cabinet temperature. Adjust the cabinet temperature offset value using both and buttons. Press both and buttons at the same time to revert to the configuration menu. Press the button repeatedly until EP is shown on the LED display. Press both and buttons at the same time to revert to the normal mode of operation. 2.9 Calibrate Air Saturator Temperature Display The displayed value for air saturator temperature may be adjusted for calibration purposes from within the configuration menu of the Electronic Thermostat. Press and button together for 10 seconds. Press the button repeatedly until parameter 06 is shown on the LED display. Immediately press both and buttons to reveal any offset value for air saturator temperature. iii. vi Adjust the air saturator temperature offset value using both and buttons. Press both and buttons at the same time to revert to the configuration menu. v. Press the button repeatedly until EP is shown on the LED display. Press both and buttons at the same time to revert to the normal mode of operation. 2.10 Air Pressure Regulator and Gauge Regulates and indicates the atomiser air pressure. Page No.: 9
Air pressure gauge Air pressure regulator. Pull the regulator cap and rotate clockwise to increase air pressure and counter clockwise to reduce air pressure. 2.11 Flow Meter Monitor/adjust the flow rate of the salt solution from the reservoir to the atomiser. The salt solution flow rate is controlled by the compressed air flow to the atomiser. The air flow is controlled by a throttle valve positioned to the side of the salt solution flowmeter, to increase flow rate to the atomiser rotate the black cap clockwise, to reduce flow rate rotate the cap counter clockwise. During normal operation, reducing the salt flow to zero while maintaining a normal flow of air to the atomiser will purge the cabinet of salt fog. 2.12 Alarm indicator The chamber control system is capable of identifying a number of alarm conditions. This information is relayed to the user by means of the alarm indicator: Different sequences of flashes of the alarm indicator signify different conditions: Display: Reason: Solution: Alarm indicator illuminated and buzzer sounding for one second periods: Cabinet over temperature thermostat operated. Cabinet has overheated. Check temperature display and temperature set point. Alarm indicator illuminated and buzzer sounding for two second periods: Alarm indicator illuminated and buzzer sounding for three second periods: Air Saturator over temperature thermostat operated. Air saturator has entered low water mode. Air Saturator has overheated. Check temperature display and temperature set point. If the cabinet is connected to a permanent water supply, this alarm will disappear after around 1 minute, if it persists check water is Page No.: 10
turned on the rear of the cabinet, or fill manually see below. Continuous Alarm and buzzer. Multiple Alarms Active More than one alarm condition is active. Resolve one condition to allow diagnosis of remaining alarms. Push Alarm Button to mute buzzer. 2.13 Manual filling of the cabinet air saturator: Moist Air/Dry Air: During normal operation the cabinet operates in Moist air mode, compressed air for the salt spray atomiser is bubbled through the cabinet air saturator. When the level of water in the air saturator falls below a factory set limit, the cabinet automatically switches to a Dry air mode. Salt spray testing continues with air being diverted from the air saturator. This continues until the air saturator refills. (See Alarm indicator). If the cabinet is not connected to a pressurised supply of deionised water for automatic filling of the Air Saturator, fill the Air Saturator manually as follows: Ensure that the air saturator is de-pressurised by turning the pressure regulator counter clock wise until the pressure reading is at the minimum. Open the hand operated ball valve at the manual filler port by rotating it fully anticlockwise. Insert a funnel into the open orifice of the manual filler port and slowly fill with deionised or distilled water. Filling stops when the Air Saturator Alarm LED is no longer illuminated. Remove the funnel and close the ball valve. Reset air pressure once testing starts. 2.14 Cabinet drain weir With the cabinet drain weir in place position, salt fog condensate will accumulate in the cabinet base to a predetermined level, before draining to waste. This assists in maintaining a high humidity during testing, and is the correct position for most continuous salt spray tests. With the cabinet drain weir removed, salt fog condensate will drain away. This also drains the cabinet interior when cleaning is required. Pull the drain weir to remove it. Page No.: 11
2.15 Cabinet Atomiser Air and salt solution are brought together to create a salt fog within the cabinet. The air supply hose (black) is connected to the side of the atomiser. The salt solution hose (blue) is connected to the bottom of the atomiser filter housing. 10. Setting Up Procedure Determine the test parameters Composition of the salt solution. Cabinet temperature. Air saturator temperature Salt fog fall out rate. Test duration. 11. Set up cabinet 1. Ensure that the drain and vent are connected and not blocked. ii. iii. Prepare the salt solution and transfer it to the salt solution reservoir. Fill the cabinet base with water to a depth that just covers the drain weir. The water trap around the base of the roof creates a self replenishing seal. This should be filled with water before testing begins. iv. Set the Salt Fog Fallout Rate The method for measuring the Salt Fog Fallout Rate is specified as being a 100 mm-diameter funnel in conjunction with a measuring cylinder graduated in millilitres. This procedure is used to collect salt fog fallout at various points across the cabinet workspace (no closer than 100 mm from the cabinet walls or atomiser) for set periods of time. From these measurements the average fog fallout rate and the spread of the fog throughout the cabinet can be determined. Generally, the spread of the fog within the cabinet is controlled by the air pressure, and the density of the fog is controlled by the salt solution flow rate. With the atomiser positioned centrally in the cabinet, increasing the air pressure will tend to increase the salt fog fallout at the extremes of the cabinet, whilst decreasing the air pressure will tend to increase the fallout in the centre of the cabinet. Page No.: 12
Increasing the salt solution flow rate will increase the salt fog fallout at any point in the cabinet, whilst decreasing the flow rate will reduce the fallout at any point. Only very small adjustments to the air pressure and flow rate should be made at any one time, before rechecking the results. V. Set the air pressure to according to the test standard. vi. Vii Set the initial flow rate so that the peak flow is approximately 10 to 15 ml/min. The ball in the flow meter may fluctuate very slightly during testing. Adjust the air pressure to obtain an even spread of fog within the cabinet, regardless of the actual amount of fallout collected. viii. Adjust the flow rate to bring the fallout within the limits specified in the test standard. ix. Recheck the Salt Fog Fallout Rate until satisfactory. x. Ensure that the air saturator is full of deionised water. xi. Xii Ensure Cabinet temperature set value is set according to test standard. Ensure Air Saturator temperature set value is set according to test standard. 12. Shut down procedure Turn cabinet Isolator switch to OFF. If the cabinet is not to be used continuously, refer to Care & Maintenance below. Page No.: 13
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Care & Maintenance 1. Routine Maintenance The Manufacturer recommends consistent Annual Servicing of the cabinet but routine maintenance is also recommended to keep the cabinet in good working order. The following maintenance is recommended for a cabinet that is in regular use. 2. Daily Checks Record cabinet variable parameters on the Daily Check Sheet provide at the end of this section. A sample Daily Check Sheet is provided at the end of this manual. Ensure drain is clear. Ensure exhaust is clear. 3. After Use Operate the cabinet with water instead of salt to flush the salt lines and help prevent algae. Clean the cabinet interior and roof by washing with warm water and mild detergent. ii. Check that the cabinet service connections are secure and are not leaking. Switch off the power supply to the cabinet. 4. Storage & Contamination If the cabinet is to stand unused for a period of more than one week, or if contamination by algae growth is detected in the salt solution reservoir, the following procedure is recommended: i. Switch off the cabinet. ii. iii. iv. Drain the air saturator. To drain the air saturator: Switch the electrical isolator to OFF. v. Turn the air supply to the chamber off. vi. Place a collection tank below the air saturator drain (approx 6L) vii. viii. ix. Remove the air saturator drain plug. Open the air saturator manual fill valve. Discard any salt solution remaining in the reservoir. x. Clean the reservoir thoroughly. Page No.: 15
xi. xii. xiii. xiv. xv. xvi. Partly fill the reservoir with a biocidal sterilising agent solution and replace the salt filter housing in the reservoir. Switch on the cabinet and run for approximately five minutes, with the roof closed. This will flush all the salt solution hoses and fittings with the sterilising agent. Switch off the cabinet and leave to stand until required for use. Discard the sterilising agent. Clean the tank thoroughly. Remove Salt Solution Filter from Reservoir and run chamber until remaining solution is purged. 5. Deionised Water Inlet Filter Detach deionised water supply hose from the bulkhead fitting at the rear of the cabinet. Withdraw the wire mesh filter from inside the bulkhead fitting. Scrub the filter clean with a brush under running water, or replace the filter. Re-insert the filter into the bulkhead fitting. Reconnect the deionised water supply. 6. Clean or Unblock Salt Spray Atomiser Salt Solution Inlet Salt Filter Housing Including Filter wadding Salt Filter Sealing Washer Atomiser Sealing Washer Atomiser Nozzle Atomiser Cap Compressed Air Inlet Switch off the power supply to the cabinet. Withdraw the atomiser from its support, taking care not to damage the two hoses. Detach the compressed air inlet hose (1). (1) Page No.: 16
Unscrew the atomiser cap (2). Unscrew the salt solution inlet pipe fitting from the atomiser filter (3). (2) Unscrew the atomiser filter from the nozzle (4). Wash all parts in warm clean water, changing the filter wadding if required. Reassembly of the atomiser is a reverse of the above. (3) (4) Page No.: 17
7. Sample Daily Check Sheet Daily Checks for Month: D ay Cabinet Temp ( C) Air Saturator Temp ( C) Air Pressure (Bar) Fallout (ml/80cm²/hour ) ph of Fallout Water Conductivity(µ s) %Concentratio n of Salt Solution/Specif ic Gravity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Page No.: 18
Optional Accessories Internal base loading platform Picture may differ from actual item supplied Description: Horizontal removable platform, covering the internal base of cabinet, to enable large/heavy test samples to be accommodated directly on the internal base of the cabinet. Installation: This equipment is supplied with the cabinet and can be removed if required. Maintenance: No specific maintenance required. Art. Nr.: VF7805 (500 liter); VF7806 (1000 liter) Page No.: 19
Installation kit Picture may differ from actual item supplied Description: A bottle trap to connect between the drain outlet of cabinet and local drain facility, to prevent any smells from entering the cabinet via the drain. Also 3m of drain/exhaust tubing with a selection of couplers and 3m compressed air hose with hose clips Installation: All component within this kit are covered by the installation section of the instruction manual, with the exception of the Bottle Trap. To install the Bottle Trap; Inaster the drain pipe from the cabinet into the inlet of the bottle trap, connect the outlet of the bottle trap to waste. Operation: The Bottle Trap will prevent unpleasant smells from the waste system entering the cabinet. Maintenance: No specific maintenance required. Art. Nr.: VF7807 (500 liter); VF7807 (1000 liter) Page No.: 20
Insulated roof Picture may differ from actual item supplied Description: An insulated non-transparent roof (supplied as standard). Improves thermal efficiency to increase cabinet maximum operating tem and salt spray fall-out range. Installation: Place the insulated over on top of the clear transparent cabinet roof to achieve higher temperature and / or salt spray fallout. Maintenance: No specific maintenance is required. Art. Nr.: VF7803 (500 liter); VF7804 (1000 liter) Page No.: 21
Additional saline reservoir Picture may differ from actual item supplied Description: An additional 90L (23 US Gal) reservoir to the one supplied as standard. Installation: No installation required. Operation: Feed salt solution pipe through pre-drilled whole inside of reservoir. Maintenance: Keep the reservoir clean at all times and if it is not to be used for a while, it should be cleaned with a sterilizing solution. Art. Nr.: VF7800 (500 liter); VF7800 (1000 liter) Page No.: 22
Spares Kit Picture may differ from actual item supplied Description: A kit of 1 x Air Solenoid Valve, 1 x Water Solenoid Valve, 1 x Drainage Weir for Sump, 1 x Salt Solution Primary Filter Unit and 10m of Salt Solution Hose. Installation: Refer to separate instructions within the spare kit for each of the components supplied. Art. Nr.: VF7801 (500 liter); VF7801 (1000 liter) Page No.: 23
Extra sample holders Picture may differ from actual item supplied Description: Additional sample holders Installation: Place the sample holders in the position required within the cabinet test space Operation: Load the samples to be tested referring to the test standard being performed. Maintenance: Clean off any contamination between tests to prevent cross contamination. Art. Nr.: VF7808 (500 liter); VF7809 (1000 liter) Page No.: 24
Fall-out measuring kit Picture may differ from actual item supplied Description: Two 80cm 2 funnels and two 0-100mm measuring cylinders, for monitoring fall-out rates. Installation: Position the collection vessels in the desired location within the test space, ensuring they are not obstructing, or being obstructed by the test samples. Operation: Ensure the measuring cylinders are empty prior to each test starting. Art. Nr.: VF7802 (500 liter); VF7802 (1000 liter) Page No.: 25
Study book Corrosion handbook This study book about corrosion testing gives trained and untrained users further insight in the required techniques for corrosion testing. Corrosion principles just as possible interferences in and around the cabinet are discussed. Interpretations and reporting are also tackled. Efficiently operating and using a corrosion test cabinet leads to great savings. Unnecessary waiting time from sample transport to external laboratories is no longer an issue. Correct assessment of the results is also one of the discussed issues. Picture may differ from actual item supplied Art. Nr.: VF7101 Handbook Corrosion (English version) VF7100 Corrosie handvat (Dutch version) Page No.: 26
Natriumchlorid Bag of 25 kg Natriumchlorid Picture may differ from actual item supplied Art.nr. VF7600 Page No.: 27
Attention! Please read the enclosed instruction manual before connecting this cabinet to its external service utilities and attempting to use it. This cabinet has been dispatched with its air saturator emptied of water in order to reduce weight. As a consequence, when power is first applied the cabinet will display an alarm condition. Page No.: 28