Atlas BCX Series Operating Manual Download Page 1

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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

Summary of Contents for BCX Series

Page 1: ...__ 13 I Utility Services Testing___________________________________________________________________ 13 J Lab Temperature and Humidity ____________________________________________________________ 13 K Component Valves ______________________________________________________________________ 14 L Solenoid Valve Assignments______________________________________________________________ 15 VII BCX SERIES ...

Page 2: ...AMPLE 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_________...

Page 3: ...BCX Series Operating Manual Page 3 XVII REPLACEMENT PARTS 116 XVIII GLOSSARY 117 INDEX 123 ...

Page 4: ...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 ...

Page 5: ...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 o...

Page 6: ... 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 li...

Page 7: ...icals 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 ...

Page 8: ...ration 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 t...

Page 9: ... 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...

Page 10: ...ine 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 ...

Page 11: ...e 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 ve...

Page 12: ...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 line to this port and run it to an o...

Page 13: ...e 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 ...

Page 14: ...ing 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 ...

Page 15: ...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 N...

Page 16: ...he 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...

Page 17: ...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 blocka...

Page 18: ...n 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 ...

Page 19: ...s 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 loc...

Page 20: ...he 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 T...

Page 21: ... 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 À 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 ...

Page 22: ...e 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 a...

Page 23: ...me 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 choic...

Page 24: ...anel 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 abbr...

Page 25: ...ine 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 ...

Page 26: ...sword 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 2...

Page 27: ...ST 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...

Page 28: ...ea 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 Cycl...

Page 29: ...etpoints 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 C...

Page 30: ...rt 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 T...

Page 31: ...leting 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 LOOP3 From...

Page 32: ...st 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 Thi...

Page 33: ...bble Tower Temperature Setpoint is 41o C 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 c...

Page 34: ... will show The screen shows that all looping information is 0 zero since the controller is not in cycle 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 LOOP2 From 0 To 0 Set 0 Togo 0 LOOP3 From 0 To 0 Set 0 Togo 0 ASTM B11...

Page 35: ...AY 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 ...

Page 36: ...osen 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 ...

Page 37: ...ature 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 t...

Page 38: ...OTE 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 s...

Page 39: ... 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 AS...

Page 40: ...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 t...

Page 41: ...c 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 param...

Page 42: ...here 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 wi...

Page 43: ... 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 avai...

Page 44: ...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 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 fron...

Page 45: ...eys 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...

Page 46: ...ure 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 the...

Page 47: ...d 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 Contin...

Page 48: ...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...

Page 49: ...torial 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 t...

Page 50: ... 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 Passwo...

Page 51: ...uld 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 ...

Page 52: ...page the DISPLAY area should show Now PUSH the right arrow key five 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 5 key and then the ENTER Key once If the password was entered correctly the screen will show Select Operting Mode 1 AUTO Select Operting Mode 5...

Page 53: ...t 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 bac...

Page 54: ... the HOME Key one time When at the first page the DISPLAY area should show 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 1 AUTO Select...

Page 55: ... 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 TO...

Page 56: ...e 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 BUTT...

Page 57: ...le 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...

Page 58: ...ar 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 ONL...

Page 59: ...ut 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 perfor...

Page 60: ...ylic 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 contro...

Page 61: ...NS 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 tha...

Page 62: ... 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 rev...

Page 63: ...estigating 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 o...

Page 64: ... 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 nam...

Page 65: ...resent 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 F...

Page 66: ... 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 t...

Page 67: ...ser 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 ...

Page 68: ...e 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 ove...

Page 69: ...rcome 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 ...

Page 70: ... 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 ope...

Page 71: ...in 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 z...

Page 72: ...he 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 latchin...

Page 73: ... 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 i...

Page 74: ...tures 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 setpoin...

Page 75: ...h 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 ...

Page 76: ... 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 wo...

Page 77: ...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 w...

Page 78: ... 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...

Page 79: ... 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 personne...

Page 80: ...t 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 authoriz...

Page 81: ...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 F...

Page 82: ...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 ea...

Page 83: ...nce 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 para...

Page 84: ...roller 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 cha...

Page 85: ...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...

Page 86: ...anual 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 ...

Page 87: ...ta 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 th...

Page 88: ...er 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 ...

Page 89: ...nd 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 dur...

Page 90: ...ep 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 ri...

Page 91: ...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 re...

Page 92: ...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 zo...

Page 93: ... a given step It is recommended to use 41o C 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 ...

Page 94: ... 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 ea...

Page 95: ...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 copyin...

Page 96: ...ents 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 ...

Page 97: ...on 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 te...

Page 98: ... 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 Ne...

Page 99: ... 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 ou...

Page 100: ...0 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 ...

Page 101: ...ecimens 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...

Page 102: ...o 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 minu...

Page 103: ...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 ...

Page 104: ...e 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 con...

Page 105: ...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 ...

Page 106: ...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 sol...

Page 107: ...tion 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...

Page 108: ...tion 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 ...

Page 109: ...ark 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 stirre...

Page 110: ... 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 s...

Page 111: ...ge 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 ...

Page 112: ...oir 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 T...

Page 113: ...er 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 replac...

Page 114: ...rect 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 Ins...

Page 115: ...ths 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 proper...

Page 116: ...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 Assemb...

Page 117: ...ble 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 F...

Page 118: ...ur 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 A...

Page 119: ...le 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...

Page 120: ...ter 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 Atomi...

Page 121: ...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 operato...

Page 122: ...umidity 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 blow...

Page 123: ...ance 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 ...

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