Operating Manual

AUTOMATIC WATER CONDENSATION TEST CHAMBER WITH THE MANUAL GAS

DOSING SYSTEM FOR THE KESTERNICH TEST CABINET
Type CON 300-FL AIR CWC AWRF KES with DosiCORR MD
Issue: 18.02.2015

VLM GmbH | Heideblmchenweg 50 | D-33689 Bielefeld | Germany

p: +49 5205 87 9630 | f: +49 5205 87 96350 | e: info@vlm-labtec.com | www.vlm-labtec.com

Operating Manual CON 300-FL AIR CWC AWRF KES

Contents
1.

2.

3.

Introduction.......................................................................................................................................... 4
1.1.

Purpose of this document ............................................................................................................... 4

1.2.

Operators ......................................................................................................................................... 4

1.3.

Note to the Reader .......................................................................................................................... 4

Basic Safety Instructions .................................................................................................................... 5

2.1.

Safety Symbols ................................................................................................................................ 5

2.2.

Obligations and liabilities ............................................................................................................... 5

2.3.

Safety First....................................................................................................................................... 5

2.4.

Correct Use ...................................................................................................................................... 5

2.5.

Authorized Operators ..................................................................................................................... 6

2.6.

Protective Equipment ..................................................................................................................... 6

2.7.

Conduct in the Event of Emergency ................................................................................................ 6

Transport and Installation ................................................................................................................ 7

3.1.

Transport ......................................................................................................................................... 7

3.2.

Aligning the Cabinet ....................................................................................................................... 7

3.3.

Requirements and Accessories ....................................................................................................... 7

4.

Technical Description ......................................................................................................................... 8

5.

Installation, Connections and Key System Components ............................................................ 12

5.1.

Overview Connections .................................................................................................................. 12

5.2.

Demineralized Water Supply ........................................................................................................ 12

5.3.

Electrical Power Supply ................................................................................................................. 13

5.4.

Compressed Air Supply (required for AWRF and AIR option) ...................................................... 14

5.5.

Drain Water................................................................................................................................... 14

5.6.

Power Supply and Safety .............................................................................................................. 14

5.7.

Key System Components ............................................................................................................... 15

5.7.1.
6.

The Controller ........................................................................................................................ 15

Operation of the JUMO dTRON Controller and Conducting the Kesternich Test .................. 16
6.1.

Basic Functions .............................................................................................................................. 16

6.2.

Setting Controller Parameters for the Water Condensation Test (CON) .................................... 16

6.3.

Operation of the Kesternich Test with Manual Dosing System (DosiCORR MD) ...................... 19

6.3.1.

Principle of Operation........................................................................................................... 19

6.3.2.

Putting KES System in Operation ......................................................................................... 19

6.3.3.

Setting the Needle Valve ...................................................................................................... 20

2

Operating Manual CON 300-FL AIR CWC AWRF KES

6.3.4.
7.

8.

Commissioning ................................................................................................................................... 22
7.1.

Preparation for Tests ..................................................................................................................... 22

7.2.

Conducting Condensed Water Test ............................................................................................... 22

Maintenance and Troubleshooting ................................................................................................ 23

8.1.

9.

Operating the Multi Directional Valve ................................................................................. 21

Maintenance ................................................................................................................................. 23

Spare Parts and Consumables ......................................................................................................... 24

9.1.

Spare Parts List.............................................................................................................................. 24

9.2.

Accessories for Placing the Specimens ......................................................................................... 24

9.3.

Other Accessories .......................................................................................................................... 25

1. Introduction
1.1. Purpose of this document
This operating manual introduces the users/ operator of the VLM Corrosion Test Cabinet with:
-

the working principle of the test device

the operation of the cabinet
safety instructions
maintenance

The operation manual should be always at hand.

This type of the corrosion test cabinets have been developed to carry out condensed water tests pursuant
to ISO 6270-2 (CH, AT, AHT) in combination with forced drying and automatic water refill. Please see further
details in the corresponding standard specifications.
Please read this operation manual thoroughly before starting using the unit.
The operating manual instructs the operator to handle this test cabinet with safety and only for the purpose
it is designed for. Knowledge of the relevant chapters is an imperative for the safe and correct use. For this
reason operators are obliged to get familiarized with the safety instructions and operating conditions in
order to avoid personal injury and material damage. All claims and liabilities will be rejected if their cause
is incorrect operation and/or incorrect use.
Necessary maintenance works may only be carried out by personnel of VLM or their representatives.
Otherwise all claims and liabilities will be rejected.
Our indications are based on the state of our current knowledge.
The information in this manual is subject to technical alterations!

1.2. Operators
VLM corrosion testing instruments may only be operated by personnel instructed and authorized by the
owner.

1.3. Note to the Reader

Dear reader,
Our operating instructions are updated regularly. You will find the latest version on our website
www.vlmgmbh.de. You help us with your suggestions for improvement to form a most user-friendly
operating manual.
Let us know your suggestions by e-mail info@vlm-labtec.com or fax +49 5205 87 963-50.
2015 VLM GmbH Innovative Korrosionsprftechnik, Labortechnik & Dienstleistungen
D-33689 Bielefeld, Heideblmchenweg 50, Germany
All rights reserved
No parts of this publication, nor extracts of it, may be reproduced without the prior permission of the
publisher.

Operating Manual CON 300-FL AIR CWC AWRF KES

2. Basic Safety Instructions

2.1. Safety Symbols
The following designations and symbols are used for safety indications throughout this manual:
DANGER!
Immediate danger to life and health of persons. Ignoring these indications can result in severe
health hazards.
WARNING!
Possibly dangerous situation. Ignoring these signs may result in slight injuries or causes
material damages.
IMPORTANT!
Important indications for the correct use of the unit and other useful information. Ignoring
these signs may result in material or surrounding damages.

2.2. Obligations and liabilities

Please observe the indications in this operating manual!
A precondition for the safe and trouble-free use of the VLM corrosion test instrument is the
knowledge of the basic safety instructions. This operating manual, especially the safety
indications, have to be followed by all persons who work with this unit. Furthermore, the local
regulations and instructions of accident prevention apply as well.

2.3. Safety First

The devices are equipped with electrical and mechanical protectors. They were subjected to a strict safety
rules and they all passed acceptance test.
However, incorrect use can:
-

threaten life and body of the operator

damage the instrument and the operators property
diminish the instruments operating efficiency

All persons concerned with the installation, commissioning, operation, maintenance and repair of the
instrument must:
-

be appropriately qualified
respect follow the rules and instructions provided in this manual

Please resolve any problem that can affect the safety immediately.

2.4. Correct Use

The unit is intended exclusively for conducting Water Condensation test according to DIN EN ISO 6270-2
(CH, AT, AHT) as well as for the Kesternich test.
The instrument was specifically developed for this purpose and must not be operated in a manner in which
it was not intended to be used.
Important!
The conditions mentioned in this manual concerning operation and maintenance must be
strictly obeyed.

Operating Manual CON 300-FL AIR CWC AWRF KES

2.5.

Authorized Operators
- Only approved persons are allowed to operate the instrument
- The minimum age of operators is 18
- The operator is responsible for third parties within working area
- The areas of responsibility for the different activities in the relation with the
instrument must be clearly defined and observed. Ambiguous areas of competence are
a safety risk

The owner of the test device must:

- Make this manual accessible to the operator
- Check that the operator has read and understood this manual
- Provide the necessary personal protective equipment
- Make sure that the operating manual is kept nearby the test unit at all times
- The general as well as the local regulations for accident prevention must be accessible and followed
- All safety and danger instructions must be kept nearby the test unit in a readable condition and
renewed if necessary
2.6. Protective Equipment
The unit has the following protective equipment:
- Lockable door of the test chamber
- Main switch with thermal overcurrent protection
The protective equipment:
- has been installed for the safety of the operator and the surrounding area
- must, under no circumstances, be changed, removed or by-passed as a result of changes to the
instrument
Important:
Attention is drawn to the possible existence of additional local statutory requirements of
national institutions responsible for the health and safety of the operators

Opening and closing mechanism of the chamber door is done manually by

pulling the handle of the lock.
Please do not loosen the hinges of the door without supervision of VLM
personnel or authorised service personnel. Unproper handling may result
in equipment damage or human injuries
Should the door not be closing properly please check if the supporting
cabinet is fully aligned and in horizontal position.

Figure 1 The door hinge

2.7. Conduct in the Event of Emergency

In case of emergency turn the main switch immediately OFF and disconnect the mains plug.

Operating Manual CON 300-FL AIR CWC AWRF KES

3. Transport and Installation

3.1. Transport
VLM corrosion test cabinets and accessories are packed into
fumigated wooden crates and carefully protected against
mechanical damages.
Nevertheless, upon reception of the package please check the
outer surface of the package for damages such as scratches, cracks,
holes which may indicate an impact on the goods. If so accept the
consignment only under protest.
Be careful, when you take the cabinet and accessories out of the
crate. If you use a fork lifter you can take the cabinet from the front
side as the forks are longer than the depths of the cabinet (Figure
2).
However, if you want to transport the cabinet through narrow
doors you should take it with the fork lifter from the left hand
(heavier) side. In this case we strongly recommend to use wooden
bars transversely to the longitudinal axis of the cabinet
protect the bottom of the cabinet.

Figure 2 Transport with a fork lift

If the cabinet is stored for a longer period of time make sure that the storage room is dry. The temperature
should not fall below 0C.
Important: Remove all packaging materials such as foam particles from all inlets and outlets.
Be aware of all components under the bottom of the cabinet when you transport the cabinet by
a forklifting or hand pallet truck.

3.2. Aligning the Cabinet

Follow the following procedure for aligning the cabinet:
1. Align the cabinet such as that there is a slight downward slope
towards the drain. This will allow the condensate to flow freely
and completely out of the test chamber. This should be done by
adjusting the height of the feet (Figure 3).
2. Close the drain by a rubber stopper.
3. Put water into the chamber so the base is covered. Pull the
stopper out of the drain outlet. Watch the water if it is running
evenly and completely off the base to the drain. If necessary
adjust the feet.
Make sure, that the cabinet / chest is placed tension free.

Figure 3 Adjusting the length of feet

3.3. Requirements and Accessories

Table 1 shows an overview of basic requirements for installing corrosion test equipment and conducting
corrosion tests.
Table 1 Basic requirements for conducting corrosion tests
Standard
1
Compressed air1)
Particle and oil-free
(DIN EN ISO 9227)
2
Demineralized water1) < 5 S/cm (DIN EN ISO 9227)
4
Drain water1)
5
Air exhaust2)
1)

Required for AWRF option

2)

Pressure
6-8 bar

Connection
Nipple size. 5

2-5 bar
No pressure

male thread
PVC hose 25 mm
PU hose 50 mm

Required for AIR option

7

Operating Manual CON 300-FL AIR CWC AWRF KES

4. Technical Description
4.1.

Operating Range

Temperature range: Ambient < T< + 50C

Note that it is not possible to have lower temperature in the
test chamber than the environmental one.
Relative humidity (RH) inside the test chamber during the
Water Condensation test:
- ca. 100 % RH condensation on the specimens

4.2.

Water Condensation Test (CON CH) According

to ISO 6270-2/50014

For compliance with these conditions, the test chamber should

be located in a room with normal ambient conditions and
without any corrosive ingredients (e.g. not in a chemical
laboratory). The room temperature should be between 18C
and 28C (according to DIN 50014) and the relative humidity not
higher than 75%. Also the test chamber should be protected
from draft and direct sun radiation.
In comparative studies, the temperature in the test chamber
should be the same as the ambient temperature (23 2C
according to DIN 50014.

Relevant Test Standards

Condensation water test:
DIN EN ISO 6270-2 (CH, AT, AHT)
BS 3900F2, BS 3900 F15,
ASTM D2242

Literature:
Standards are available from:
Beuth Verlag GmbH,
Burggrafenstr. 6,
10787 Berlin
ASTM International, 100 Barr Harbor
Drive,
PO Box C700, West Conshohocken,
PA 19428-2959
United States
Annual Book of ASTM Standards Vol
03.02

Note: A decrease in ambient temperature leads to the increase of the amount of water
condensation

According to ISO 6270-2 three phases (Table 2) are defined in the Cyclic Climate test being:
- Water condensation Constant humidity (CH)
- Water Condensation Alternating humidity and temperature (AHT)
- Water condensation Alternating temperature (AT)
The water condensation test (CH) is commonly conducted in the following way:
The trough of the test chamber is filled with purified water such as all four corners of the chamber are
covered and then the water is heated up uniformly to 40C. This allows all test specimens in the chamber
to have a uniform and constant temperature (tolerance is 0,2C).
Option AWRF
The CON test chambers with the AWRF option (Automatic Water Refill) can beside the constant (high)
humidity (CH) phase also facilitate the cooling phase (AT) where the chamber is cooled down to the
environmental temperature with humidity at nearly 100% (with or without water in the chamber).
Option AIR
The CON test chambers with the AIR option can also perform the forced ventilation phase (AHT). The test
chambers without AIR option can perform the AHT phase only by (manually) opening the front door. The
AHT phase can run with or without water in the test chamber.
Table 2 shows the parameters of the water condensation test in more details.

Operating Manual CON 300-FL AIR CWC AWRF KES

Table 2 High humidity test procedures

VLM
Cyclic Climate test chambers with AIR option are equipped with solenoid valves and a pneumatically
controlled ball-valve which is closing and opening the ventilation system. For this reason all VLM chambers
fully comply with the DIN 50014 requirements in terms of the ventilation and cooling of the ambient air.
The specification of the chosen ventilators is selected such as to resemble the storage conditions in normal
environmental conditions. The air can flow into the lower rear part of the test chamber through a specially
designed air duct which can be adjusted such as to ensure uniform drying of the test specimens.
The test chamber with AIR option is equipped with fans with adjustable speed in order to meet specific test
standards. The AIR system allows the fastest way for ventilate and cool down the test chamber by
establishing forced ventilation. This replaces the requirement for opening the door
Option: Controlled Water Condensation (CWC)
VLM has developed an innovative water condensation system featuring the patented CWC concept
(Controlled Water Condensation system - Figure 4). This system allows an accurate regulation of preselected condensation parameters such as the temperature difference between the bottom and the roof
of the test chamber. This allows a maximum reproducibility and comparability of test results.

Figure 4 VLMs patented CON AIR CWC method for water condesation

During the salt spray phase, the air under the roof saturated with salt fog acts as a heat insulator. This
insulation is removed after switching to water condensation phase. The battery of fans installed in the roof
construction are pumping the ambient (room) air through the double shelled roof which cools down the air
under the roof in order to keep the required vertical temperature gradient of 1C between the air under
9

Operating Manual CON 300-FL AIR CWC AWRF KES

the roof and the air above the water bath in the test chamber. In this way a uniform and reproducible
condensation temperature in the test sample zone is controlled to very tight tolerances.
Prerequisites for having such a highly sensitive temperature control system are an advanced software
control and a stainless steel construction of the test chamber coated with PTFE. This makes possible to have
a fast and uniform heat transfer from the heating grid under the floor and behind the back wall of the
chamber. As a result the CWC concept allows a very good horizontal temperature stability and
reproducibility of climate conditions.

4.3.

General View of CON 300-FL AIR CWC AWRF KES

Figure 5 and on the next page show the front and the rear view of the CON 300-FL AIR CWC AWRF
Roof with CWC
system

Door

Control panel
Test chamber
Tap for drain water (not
applicable for chambers
with AWRF option)

Adjustable foot

Figure 5 Front view of the test cabinet

4.4.

Technical Drawings with Dimensions

Figure 6 Mechanical schematics

10

Operating Manual CON 300-FL AIR CWC AWRF KES

4.5.

Technical Specification
Model
Test Chamber (mm):
Volume test chamber
Dimensions test chamber W/D/H1/H2 (mm)

CON 300-FL AIR CWC AWRF KES

300 liter (dm3)
800/600/520/733

Outer Dimensions Casing W/D/H (mm):

Width (mm)
Door opening (mm)
Heating andregulated humidity
Operating temperature
Constant Humidity
Temperature stability
Protection
Heating system
Sensors
Other:
Demineralized water (connection type)
Tap water (connection type)
Electrical supply
Compressed Air
Waste water, drain
Power socket for climate module
Communication
Total weight including the bench
Material
CWC System
Opening mechanism

1100/700/900
740 x 400

Ambient < T < +50 C

100% RH
0,5 %
Over-temperature protection
Micanite surface heating under the floor
- corrosion resistant and highly sensitive temperature
sensors above the floor and under the roof

< 5 S/cm ( outer diameter)

Always via Ion-exchangeing cartridge ( outer diameter)
230V, 700 W (Schuko)
6-8 bar (connection nipple size 5)
Pipe fittings (spiral hose ID 32mm)
230V (Schucko)
RS232 (option)
80 kg
Stainless steel coated with ECTFE (Halar), polypropylene
side panels, stainless steel rods coated with plastic, dry
cover seal made of EPDM Foam
Double-shell roof with built-in fans for cooling in
accordance with the CWC
Manual lock

11

Operating Manual CON 300-FL AIR CWC AWRF KES

5. Installation, Connections and Key System Components

5.1. Overview Connections
All inlets for electricity (mains, control) and fluids (purified water and compressed air) are located at the
rear side of the test chamber. Also the water drain outlet is located there (Figure 7).

Fans for CWC

system
(CWC option)

Air exhaust
(AIR option)

Below fittings only for AWRF option !

Air inlet
(AIR option)
(AIR

Figure 7 Connections at the rear of the test cabinet

All connections for water supply / water drain as well as electrical connections are in the lower part of the
rear panel.

5.2. Demineralized Water Supply

Fitting for the cabinet with AWRF option: 3/4 (outer thread)
Water purity: max. 5 S/cm
The plant for water purification is not a standard part of the
delivery. However, it is strongly advised to use demineralized water
for DIN EN ISO 6270-2 test. If there is no central supply of
demineralised water a water purification plant should be installed
Figure 8 Leakage safety unit
(Figure 9). For this purpose a stop cock (with male thread) for the
fresh water supply should be installed in the vicinity of the test
cabinet / chest. If there is no floor drain a leakage safety unit (Figure 8) has to be
installed in order to avoid flooding in case of a break of the tubing.
A 230 V socket must be also installed in the vicinity of the test cabinet / chest.
It is recommend to always have a spare ion-exchanger cartridge at hand with a quick
coupling system. This will prevent interruption of tests when the exhausted cartridge
requires replacement.
Very Important!
Any connection pipe or hose between the water purification plant and the
corrosion test cabinet must either be made of stainless steel or plastic for
demineralised water is very aggressive to brass, iron or copper.

Figure 9 Water
purification plant

Check if all parts are delivered before starting the installation of the water purification plant. Pay attention
to the instruction manual of the manufacturer of the ion-exchanger cartridges.

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Operating Manual CON 300-FL AIR CWC AWRF KES

Figure 10 Splitter for the purified

water supply

Figure 11 Digital
conductivity meter

Figure 12 Analog conductivity

meter

Important!
If there is no drain in the floor a leakage water safety unit (Figure 8) has to be
installed to prevent any damages caused by flooding. In case of a leakage or
burst of a hose the sensor located on the floor will immediately close the
magnetic valve and the water supply will be shut down.

Please follow the following procedure to set up the plant for water purification:
1. Mount the splitter for the purified water on the wall so that it is convenient
Figure 13 Ion-exchange
to be connected and operated.
cartridge
2. Mount the quick connector nipples on the threads on the outlet / inlet of
the ion exchange cartridge.
3. Connect the water outlet of the ion exchanger to the inlet of the splitter. Connect one of the splitter
outlets to the inlet of the test chamber.
4. Connect the water inlet of the ion exchange cartridge to the tap water supply with a supplied hose.
The safety unit should be mounted on the water tap.
5. Screw the second female quick connector on the plastic double-nipple and the conductivity meter
on the other side. Press this unit on the pure water outlet of cartridge (indicated on the cartridge).
Connect this unit with the delivery unit by a hose.
6. Mount the stop-cock on the splitter and connect the hose to it.
7. Put the plug of the conductivity meter into a socket (230 V).
Important!
Note, that the actual conductivity will only be indicated when the water is flowing.
Conductivity meters are shown in Figure 12 and Figure 11
Once you put an ion exchanger cartridge Figure 13 into use pay attention to the fact that the
air will be completely displaced by the water. Open the venting screw at the top of the
cartridge thus the air can escape. Close this screw after there is only water coming out of the
cartridge.

5.3. Electrical Power Supply

The cabinet is equipped with 3 m electrical cord with a plug. For more information please refer to the table
with technical data.
Voltage: 230 V, frequency: 50-60 Hz, fault-current circuit breaker,
Recommendation: pursuant to the requirement 3-5 sockets

13

Operating Manual CON 300-FL AIR CWC AWRF KES

5.4. Compressed Air Supply (required for AWRF and AIR option)
The pressure of the compressed air should be between 6 and 8 bar which is required to operate ball valves.
Make sure that the compressed air entering the cabinet is oil free (0,2 mg/m) and particle free (< 5 m).
Be aware of shavings in case new pipes have been installed. These particles may enter the inlet valve and
block it. We strongly recommend the installation of a compressed air maintenance unit which is available
as an accessory (Figure 15).
There is a female connector Size 5 to connect the hose (Figure 14).
In case there is no clean supply of compressed air available VLM can supply a silent compressor which meets
the requirements of the corrosion tests (Figure 16).

Figure 16 Air compressor

Figure 14 Compressed air

inlet

Figure 15 Air filter

5.5. Drain Water

The drain pipe should have a downward slope in order to allow a free flow of
the drain water. Should this not be possible (e.g. the drain inlet siphon is on a
higher level than the test chamber) it is recommended to install a sewage water
pump which is available as an accessory (Figure 17).
Moreover, make sure that over pressure or under pressure will not occur when
connecting to the sewage system since this might affect the climate conditions in
the testing chamber.

Figure 17 Drain pump

5.6. Power Supply and Safety

Make sure that there are enough sockets to connect the cabinet and the conductivity meter (if
a water purification unit is installed). The electrical installation may only be carried out by an
expert. The rated voltage of the unit has to be corresponding to the mains voltage. In order to
reach the maximum electrical safety a current-operated earth-leakage protection/tripping
current 30 mA is recommended.
The following are electrical requirements for this type of test cabinet:
-

1 phase, 230 V mains (50 Hz) supply and consumes 700 W of the electrical power
The conductivity meter in the ion exchange cartridge 230 V
The water leak detector 230 V
Air compressor 230 V

14

Operating Manual CON 300-FL AIR CWC AWRF KES

5.7. Key System Components

5.7.1.

The Controller

Figure 18 shows the main control panel with the touch screen, pilot lamps and main switches. The
controller is based on an advanced Jumo dTRON microprocessor controller.

LED screen Jumo

controller

Control light roof

cooling (CWC option)

Control light heating

chamber (Micanite heaters)
Control light fan
(AIR option)
Control light over
temperature chamber
Fan speed regulator
(AIR option)

Control light
compressed air (AWRF
and AIR option

Switch for internal

illumination

Toggle switch Start/Stop

/Water Drain (AWRF
option)

Main switch
Toggle switch
Aeration/AT/AHT
(AIR option)

RS232 interface
(option)

Figure 18 Control panel

Control Panel /Symbols:

Temperature regulation (controller)

Temperature regulation (test chamber)

Temperature limitation (over temperature protection)

15

Operating Manual CON 300-FL AIR CWC AWRF KES

6. Operation of the JUMO dTRON Controller and Conducting the

Kesternich Test
6.1. Basic Functions
Figure 19 shows the control panel of the Jumo dTRON controller.

Figure 19 Jumo controller

Display Actual/Set Value Temperature Chamber C

Set value
in Program mode the remaining test time (days:hours) is shown
Programming Key, up and down key, exit key
Indicating active system components:
LED indicator 1 = automatic water refill (AWRF option)
LED indicator 2 = fan (AIR option)
LED indicator 3 = Heater chamber on (blinking)
LED indicator 4 = Roof cooling active (CWC option)
6. Segment-Display indicating temperature unit [C]

2.
3.
4.
5.

Attention:
During the filling up of the test chamber with demineralized water the message niv appears
in the green display. When the water level reaches the normal value this message will
disappear. If for any reason the water level during the test drops below the default level this
message will appear again. In this case please check the water supply.

6.2. Setting Controller Parameters for the Water Condensation Test (CON)
Test chamber operates only common water condensation tests (CON). The test starts by pressing the Start
toggle switch (Figure 18) into the upper position. The test can be put on hold (timer is stopped but not
reset) by pressing the toggle switch into Stop position (0). Pressing the toggle switch again into the Start
position will continue the test (timer will continue counting down).
If the AWRF option is available (Automatic Water Refill system) the chamber will be automatically filled
with demineralized water to the required level.
After the CON test is finished the water can be drained from the test chamber by pressing the toggle switch
Start /Stop/Water Drain (Figure 18) into the lower position (Water Drain).
All parameters needed for the standard CON CH test are already stored (preconfigured) in the Jumo dTron
controller. These values are as follows:

16

Operating Manual CON 300-FL AIR CWC AWRF KES

CON CH test:
The default temperatures are (factory setting):
- Test chamber:
40 C
- Roof temperature:
always 1 C less than the chamber temperature
Important Note: In case the CWC option is available (VLMs patented Controlled Water
Condensation system) the control system will maintain a constant temperature gradient in
the test chamber of exactly T=-1 C between the bottom and the roof of the test chamber.
This gradient temperature is stored in the controller as a parameter (SPdA) and should not
be changed by the operator (should this be required please contact VLM). This implies that
the operator can/should change only the set temperature in the test chamber (SP). The roof
temperature will automatically follow and the temperature gradient of T=-1 C will be kept.
After setting the operating temperature there are two ways run the programmed tests. The first one is in
the so called User mode of the controller and the second one is in the Program (Pro) mode of the controller.
User mode:
In this mode the time of the test duration cannot be set and the test will run as long as the operator does
not stop the test manually. Please note that in this mode only CON CH test can be conducted! In case the
test parameters (chamber temperature) should be changed the operator must do it manually. There is no
time display showing either how long has the test been active or how much time until the end of the test.
During the normal operation of the test chamber the orange pilot lamps are illuminated and blinking.
Table 3 describes the procedure necessary to program the controller in the user mode.
Table 3 Programming procedure in User mode

Step

Mode

Press
PGM

Press

Display
indicator

CON CH
1

Name of the controller mode

PGM

User

PGM

In2

CON CH
2

Actual roof temperature

CON CH
3
4

Meaning

SP1

SP

CON CH

Set chamber temperature in CON mode

(press PGM and then or to change
the set value SP1)
Control of the temperature set point for
CON mode

CON CH

trun

Set temperature difference between the

roof and the bottom of the chamber
(normally is this parameter -1C; press
PGM and then or to change the set
value SPdA). Only for CON mode.
Elapsed program time

CON CH

trest

Remaining program time

CON CH
5

SPdA

17

Operating Manual CON 300-FL AIR CWC AWRF KES

Program (Pro) mode:

In this mode the test can be run according to a user defined program. Both the chamber temperature and
the duration of a test can be programmed and the remaining test time is displayed in the main screen (green
LED display). In the Program mode all three CON test modifications can be configured (CON CH, CON AHT
and CON AT)!
Table 4 shows how to access the Program mode and how to define / configure a new program.
Table 4 Configuration of the Program mode

Step

Mode

Press
PGM

Press

Display
indicator

Meaning
Name of the controller mode

CON CH

CON CH

PGM

User

2x

PGM

Pro

CON CH

SPP1

CON CH

tP1

CON
AHT/AT

SPP2

CON
AHT/AT

tP2

Name of the controller mode

(Program)
Set Point Program 1 for chamber
temperature in CON mode (press PGM
and then or to change the set
value SPP1)
Set Time Program 1 defines the time
duration for SPP1 temperature in CON
mode (press PGM and then or to
change the set value tP1)
Set Point Program 2 for chamber
temperature in CON AHT/AT mode
(press PGM and then or to
change the set value SPP2)
Set Time Program 2 defines the time
duration for SPP2 temperature in CON
AHT/AT mode (press PGM and then
or to change the set value tP1)

Once the program has been configured it can be started by pressing the upper arrow on the controller.
The double point on the green part of the display will start blinking indicating that the test (time) runs. The
program can be stopped by pressing the same button on the controller once again.
Please note that normally the water remains in the chamber during the CON AHT/AT phase. Should CON
AHT/AT phase be conducted without water in the test chamber the Water Drain switch should be pressed
on the control panel.
The choice between the AHT and AT phase is made by pressing the toggle switch Aeration / AT/ AHT into
desired position.

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Operating Manual CON 300-FL AIR CWC AWRF KES

6.3. Operation of the Kesternich Test with Manual Dosing System (DosiCORR MD)
VLM offers a cost effective system for conducting the Kesternich test by means of manual gas dosing system
DosiCORR MD). In principle this specific system can be fitted to any type of front loading VLM test chamber
designed to conduct (among more) Water Condensation test (CH, AT, AHT).
The Kesternich test is an extended version of the Water Condensation (CON CH) test in which the
predefined volume of the SO2 gas is introduced in the test chamber.
6.3.1. Principle of Operation
The lower container of the glass dosing unit is filled
with the Paraffin oil. This part is connected with the
upper part of the glass container by means of a
multi directional valve. After (manually) opening
the valve (red mark showing upwards) the SO2
flows under pressure into the lower part of the
glass container and the paraffin oil is displaced into
the upper glass container. When the Paraffin oil in
the upper container reaches the level mark
(typically 2 L volume mark) the needle valve has to
be closed.

Multi directional
needle valve

Paraffin oil

After above process is finished the needle valve has

to be turned (manually) such as to show the green
mark upward. This will allow the Paraffin oil to flow
freely into the lower container and displace the
whole volume SO2 gas from the lower container
into the test chamber.
Pay attention to the safety regulations
set up for the handling of hazardous
gases such as SO2 in laboratories!
You should only work in good ventilated
rooms. Read the safety-sheet attached
to the gas-bottle by your supplier.

Figure 20 System for conducting manually Kesternich test

Be aware that sulphur dioxide (SO2) is liquid under pressure inside the steel bottle (gascylinder). Always put the gas-cylinder in an upright position and fix it tightly so that it cannot
under no circumstances topple over.
Never place the cylinder in a horizontal position! The liquid sulphur dioxide will flow out of
the bottle instead of the gas when opening the needle valve. The liquid SO2 will expand
instantly in the tubing and the glass container (gas metering device). This handling may result
in severe health hazards.
6.3.2. Putting KES System in Operation
Place the glass container (gas metering device) in the vicinity of the test cabinet. Make sure that it is in a
stable position and cannot topple over. Remove the multidirectional valve and fill the complete volume (ca.
2,5 L) of the Paraffin oil (use a funnel) into the lower part of the glass container (until the oil level reaches
the zero mark. Screw the multi directional valve back and connect the inlet and outlet hoses accordingly.
Connect the vent pipe at the top with the venting system, safety hood or directly to outdoor environment
so that SO2 gas can escape without any danger in case it bubbles through the paraffin oil.

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Operating Manual CON 300-FL AIR CWC AWRF KES

Gas inlet on the side wall of

the test chambver

Figure 21 Set for conducting Kesternich test

Multi directional valve

Needle valve

6.3.3. Setting the Needle Valve

Connect the needle valve to the gas bottle and push the
rubber hose on the tubing fitting. Make sure that there is a
tight hose connection to the gas bottle and the glass gas
metering device without any leakage.

Figure 22 Needle valve

Before starting the very first dosing of the sulphur

dioxide (SO2) make absolutely sure that all
connections are tight and the lower vessel of the
gas metering device has been filled up with
paraffin. Never open the needle valve when the inlet stopcock of
the metering device is still closed. Otherwise the full pressure of the
gas will effect on the rubber hose which may be disconnected or
burst.

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Operating Manual CON 300-FL AIR CWC AWRF KES

6.3.4. Operating the Multi Directional Valve

1.

Open the inlet to the glass dosing device. Turn the multi
directional valve into the position RED up.

2.

Open the valve of the steel bottle.

3.

Open the needle valve carefully until the SO2 starts slowly
flowing into the lower part of the glass container whilst the
Paraffin oil is being displaced to the upper container.

4.

As soon as the level of the paraffin reaches the 0,2 L or 2,0 L

mark, close the needle valve as well as the valve of the steel
bottle.

5.

Turn the multidirectional valve into the position GREEN up

so that the Paraffin oil displaces the SO2 into the test chamber

6.

Close the multi directional valve as soon as the Paraffin oil has
completely filled the lower container.

Figure 23 The image shows the position

RED of the multidirectional valve
when the SO2 is flowing from the steel
bottle into the gas metering device

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Operating Manual CON 300-FL AIR CWC AWRF KES

7. Commissioning
7.1. Preparation for Tests
Important!
Make sure that all supply and drain hoses have been connected properly and the fresh water
tap is open.
Press the green main switch and make sure that:
- The door is tightly closed
- The green pilot lamp is illuminated (compressed air supply)
- The chamber heater is on indicated by the orange pilot lamp.
Purity of the water
As mentioned before it is strongly advised to use demineralized water (ion-exchange cartridges) for DIN EN
ISO 6270-2 test. Always watch the conductivity on the measuring gauge and timely replace the cartridge by
a regenerated one.
Regard and treat this cabinet as a testing device. Keep it clean and make sure, that it will be serviced within
the set intervals.
Note that the inside of the test chamber is coated with ECTFE (Halar) which may only be cleaned by a soft
cloth and non-abrasive cleaning agent.
Remove any salt residues on the outer case with a wet cloth.
Protect the surfaces by applying cleaning and protecting sprays.
General Test Procedure
Never put specimens directly on the floor of the chamber.
Attention:
- Make sure that the compressed air at the required pressure is permanently available
(AIR and AWRF option).
- Check if the fresh water tap is open and the pure water supply is guaranteed all the
time

7.2. Conducting Condensed Water Test

1. Clean the testing chamber so that no salt residues are left.
2. Adjust the chamber temperature at 40C
3. Close the drain port by a rubber stopper if no AWRF option
is available
4. Pour demineralised water into the test chamber so that:
- All four corners of the bottom of the test chamber are
covered completely with water.
5. Put the specimens on the supporting rods. Note that in case
of test panels a rack with slits at 15 has to be used
6. Firmly close the door
7. Watch the water level and refill the chamber manually if no
AWRF option is available.
Figure 24 VLMs patented CWC method
for water condesation

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Operating Manual CON 300-FL AIR CWC AWRF KES

8. Maintenance and Troubleshooting

8.1. Maintenance
What ?

When ?

Clean the test chamber, but do not scratch the ECTFE coated base.
Check the door sealing for leakage and if necessary change it
Check the water filter inside the water inlet fitting at the back of the test
cabinet and change it if necessary
Check the filter inside the unit for compressed air, change it if necessary
Clean the drain system by rinsing pure water through the drain
Clean the outer case

Who?

monthly
monthly
quarterly

Operator
Operator
Operator

quarterly
monthly
monthly

Operator
Operator
Operator

In the course of time the elasticity of the silicon foam seal can decrease. Consequently there may be not
enough even surface pressure against the door / lid so the chamber will not be hermetically closed
anymore.
If the seal is damaged for chemical or mechanical reasons it has to be replaced. The seal can be removed
easily as it is not fixed in the gap by adhesives.

It is strongly recommend to mount an air filter (Figure

25) unit to guarantee the supply of oil free and particle
free compressed air (AWRF and AIR option).

Figure 25 Air filter unit

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Operating Manual CON 300-FL AIR CWC AWRF KES

9. Spare Parts and Consumables

9.1. Spare Parts List
Article Nr.
V.272.202.710
V.272.202.610
V.272.102.002
V.277.017.404
V.277.017.434
V.277.017.473
V.277.017.414
V.277.017.424
V.282.412.000
V.271.103.004
V.271.103.002
V.271.103.003
V.287.500.010
V.273.231.010
V.273.231.012
V.285.110.020
V.275.402.033
V.475.111.005
V.576.100.000

Description
Main switch 12 A
Switch air purge / spraying
Switch lightning
Clip connector 2 poles
Clip Connector 5 poles
Connector pin block 12 poles
Clip connector 3 poles
Clip connector 4 poles
Temperature controller JUMO dTRON 304
Pilot lamp green (pressure/ air
Pilot lamp yellow (heating/ventilation)
Pilot lamp red (over temperature/low level.
Filter for controller and timer
Relais
Relais
Solid State Relais (ELR/SSR)
Compact fluorescent lamp
Heater testing chamber
Temperature sensor testing chamber Pt 100

Description in the
circuit diagram
Q1
S2
S1
X2-X11
X2-X11
X2/X3/X5/X11
X2/X3/X5/X11
X2/X3/X5/X11
D1A/D1B/D1C
H 13
H1/H2
H3/H4
Z1
K5/K8
K2
V1/V2
E2
E1
B1

9.2. Accessories for Placing the Specimens

Article No.
V.851.210.300
V.851.210.100

V.851.212.000
V.851.212.001
V.851.200.820
V.851.200.010
V.851.220.000

Accessories
Specimen rack 20 acc. To ISO 9227, 26 slits
gap 3,5 mm, length 550 mm
Specimen rack 15 acc. To ISO 6270-2 (High
Humidity CH Constant Humidity, 26 slits gap
3,5 mm, length 550 mm
S-hooks straight (10 Pcs/Unit)
S-hooks twisted by 90 (10 Pcs/Unit)
Specimen support rods
Cross connector
Special specimen holder for steel-discs
Specimen holder for very small specimens
Further individual holder, hooks upon
request
Accessories

24

1 Pc
11 Pc

1U
1U
1 Pc
1 Pc.
1 Pc.
-

1 Pc

Operating Manual CON 300-FL AIR CWC AWRF KES

9.3. Other Accessories

Order-No.
V.852.250.028
V.852.250.020
V.852.250.1500
V.852.250.1506
V.852.250.1601
V.852.250.1805
V.852.250.1402
V.852.250.1400
V.852.901.000
V.852.901.001
V.852.901.005
V.852.211.101
V.852.211.000
V.852.211.100

V.852.210.100
V.852.221.003

Water purification plant

Ion exchanger stainless steel cartridge DI 2800
Ion exchanger stainless steel cartridge DI 2000
Adapter for quick release coupling Pack. 2 Pc.
Quick release coupling Pack. 2 Pc.
Conductivity meter, analog mountable on top of the cartridge
Conductivity meter, digital, mountable on the wall
Distribution unit 1 inlet port 3 outlet ports
Stop cock straight, plastic
Hose 1,50 m length with 3/4 connectors
Hose 2,00 m length with 3/4 connectors
Extension hose 2,00 m
Compressed Air Supply
Screw compressor
Laboratory compressor
Capsuled laboratory compressor
Coupling No. 5
Plastic hose
Purification unit for oil- and particle free clean air
GFK Grid to protect the base

25