Ascott Corrosion

Chamber Service
Manual:
Issue I

Ascott Analytical Equipment Limited,

Unit 6 Gerard, Lichfield Road Industrial Estate,
Tamworth, Staffs. B79 7UW Great Britain
Telephone: +44 (0) 1827 318040 Fax: +44 (0) 1827 318049
E-Mail: info@ascott-analytical.com Website: www.ascott-analytical.com

1
 FILE NOTE
Ascott Service Manual Issue I March 2015

Issue Date First Description Of Amendments

Issued
A October 2013 Original Issue
B Feb 2013 Revised contents page, navigation and layout
C Feb 2014 Maintenance and H&S items updated
D March 2014 Pictures, Layout, and navigation updated
E May 2014 Updated more pictures, layout and table borders
F June 2014 Updated Electrical plugs, atomiser pictures, layouts and table
justifications.
G July 2014 RH sensor details amended
H Jan 2015 Updated installation/Training
I March 2015 Updated Layout & services quality warning added

2
Contents
Part 1 - Installation 6
1.1 Positioning 6
1.2 External Services 8
1.2.1 Electricity 9
1.2.2 Water 11
1.2.3 Compressed Air 11
1.2.4 Exhaust 12
1.2.5 Drain 12
1.2.6 Air Saturator Drain 13
1.2.7 Salt Solution Reservoir 14
1.2.8 Installation – ‘Maintenance’: 15
Part 2 - Chamber Controls 18
2.1 Human Machine Interface (HMI) Screen 18
2.2 Emergency Stop 19
2.3 Mains Isolator 20
2.4 Air Pressure Gauge & Regulator 20
2.4.1 Resetting the air saturator safety valve: 21
2.5 Flow Meter(s) & Peristaltic Pump(s) 21
Part 3 - Chamber Inner 22
3.1 Atomiser 22
3.2 Sump / chamber base 25
3.3 Immersion heating element – IP chambers only 26
3.4 Temperature probes 28
3.5 Humidity sensor – IP chambers only 28
3.6 Air saturator vent / warm air inlet / purge inlet 32
3.7 Canopy 32
Part 4 - Chamber Functionality 35
4.1 Salt spray 35
4.1.1 Moist Air / Dry Air 36
4.1.2 Air saturator 36
4.1.3 Salt solution 37
4.2 Ambient air drying – Cyclic Corrosion IP Chambers 37
4.2.1 Ambient air drying Fan 38
4.3 Air Purge - Cyclic corrosion IP chambers 39
4.4 Air drying – Salt Spray IP chambers 39
4.5 Air purge – Salt Spray chambers 40
4.6 Condensation humidity – Cyclic corrosion IP chambers 40
4.7 Condensation humidity – Salt spray IP chambers 43

3
4.8 Controlled humidity – Cyclic corrosion IP chambers 44
Part 5 - Service & Calibration 45
5.1 Portable Appliance Test. 45
5.2 Calibration Procedures 45
5.2.1 Calibrating chamber temperature: 45
5.2.2 Calibrating chamber relative humidity: 45
5.2.3 Calibrating chart recorder or similar devices: 46
5.2.4 Calibrating chamber air saturator temperature: 46
5.2.5 Calibrating chamber air pressure: 46
5.3 Component and Functional checks 47
5.3.1 Record Total Hours run: 47
5.3.2 Check for compressed air leaks at solenoid valves: 47
5.3.3 Check Air pressure regulator and gauge function correctly:
47
5.3.4 Check air saturator heater operating: 48
5.3.5 Check Moist air/Dry air operating: 48
5.3.6 Check Pump speed control operation: 49
5.3.7 Check individual wall heaters by hand: 49
5.3.8 Check temperature controllers’ function and control correctly:
50
5.3.9 Check Purge outlet not blocked by salt: 50
5.3.10 Check HMI battery condition (IP chambers only): 50
5.3.11 Check PLC battery condition: 51
5.3.12 Check/clean water inlet solenoid: 51
5.3.13 Check for blow back in water inlet line (air saturator): 52
5.3.14 Check Moist air outlet check valve: 52
5.3.15 Check ‘Pressurise air saturator’ non-return valve: 53
5.3.16 Check moist air solenoid valve for contamination: 54
5.3.17 Check for oil in air lines: 54
5.3.18 Check for signs of water/oil in pneumatics/water filter: 54
5.3.20 Check function of over temperature thermostats: 55
5.3.21 Check/clean flow meter: 56
5.3.22 Change salt hoses: 57
5.3.23 Change peristaltic pump tubing: 57
5.3.24 Change salt filters and clean salt filter housing: 58
5.3.25 Check, tighten braided hose connections: 59
5.3.26 Check air saturator safety valve is not leaking: 59
5.3.27 Drain Air Saturator: 60
5.3.28 Remove, clean air saturator sight glass: (Chamber turned off)
61
5.3.29 Refill air saturator checking the function of all optical sensors:
61
4
5.3.30 Check pneumatic cylinders hold canopy stable when open:
62
5.3.31 Check canopy for function and leaks: 62
5.3.32 Check canopy hinges for signs of corrosion and oil as required:
63
5.3.33 Check canopy cylinder brakes: 63
5.3.34 Check for any leakage to drains including through plastic ball
valve: 64
5.3.34 Clean base water level sensor & check that it operates
correctly: 65
5.3.35 Check main program function: 65
5.3.36 Check humidity sensor assembly: 66
5.3.37 Check condition of pneumatic hoses: 66
5.3.38 Check alarm record and note frequent alarms: 67
5.3.39 Check Immersion Element terminals 67
5.3.40 Cyclic Corrosion chambers – Header Tank: 68
5.4 Consumables spares kit 71
5.5 Ascott approved service checklist 73
Part 6 - Service Action Points 74
6.1 PLC Monitor (IP chambers) 75
6.2 Humidity sensors (IP chambers only) 76
6.3 Humidity Header Tank (CC IP chambers only) 77
6.4 Air Saturator Sight Glass 79
6.5 Drain system blockages 80
Notes: 81

5
Part 1 - Installation
CAUTION

ASCOTT CORROSION CHAMBERS SHOULD ONLY BE INSTALLED BY

SUITABLY QUALIFIED PERSONNEL. DAMAGE CAUSED DUE TO
INCORRECT INSTALLATION WILL NOT BE COVERED BY THE WARRANTY.

1.1 Positioning
Move the Salt Spray Test Chamber into position as shown:

Chamber

The site for installation of all equipment must be flat and level.

6
Operating Environment

This equipment is designed for internal use only, in an environment controlled to within
the following limits:-

Storage
Ambient Temperature: +5 to +30°C (no icing)

Ambient Humidity: < 85% RH (no condensation)

Operation
Ambient Temperature: +18 to +23°C (no icing)

Ambient Humidity: <50% RH (no condensation)

Note: The minimum operating temperature and operating humidity achievable inside
a basic chamber (without accessories) will depend directly upon the actual ambient
temperature of the environment in which it is located.

The rear castors can be locked when

the chamber has been positioned.

7
 1.2 External Services
Warning! - connecting an Ascott chamber to poor quality external service utilities (ie; water and
compressed air) and/or a failure to maintain Ascott products regularly in accordance with Ascott
recommended maintenance procedures, could lead to a catastrophic and potentially dangerous
failure of the product safety systems.

Overview of chamber rear

Inspection Hatch for

atomiser hose
Circuit breakers
connections
Electrical
Exhaust
connection
Inspection Hatch for
Salt solution hose over-temperature
thermostats
Humidity system
water inlet (CCT Breather for drain
chambers only)
Air saturator water
Drain outlet
inlet
Lockable castors
Compressed air inlet
(x2)
Basic 450L CCT Chamber pictured
Forklift truck mounts
Air saturator drain
(x2)

The following external service utilities must be provided in the immediate vicinity of an
Ascott corrosion test chamber installation.

8
 Electricity – single phase or 3 phase, with neutral
& earth (model dependent – see below).

Salt Solution – 4 mm (3/16”) bore hose (only

applies to 450L, 1000L & 2000L chambers).

Humidity system water inlet (CCT chambers

only) – 12.5 mm (½”) bore hose

Air saturator water inlet – 12.5 mm (½”) bore

hose

Air saturator drain (no connection to this)

Compressed air – 12.5 mm (½”) bore hose

View of back left of typical
chamber Note: All hose and cable is provided by Ascott.

If optional SO2 gas dosing facility (ACC46) has been ordered, the following external
service utility connection will also be provided.

SO2 gas inlet – 4 mm (3/16”) bore hose for

connection to separate SO2 gas cylinder (not
supplied)

1.2.1 Electricity

As standard, Ascott chambers are configured for the following electrical supplies.
Other electrical supply connections can be considered on request.

Max.
1 phase/ Single Phase Three Phase Current Plug 3
Model Frequency 2
3 phase 1 Voltage Voltage per Style
phase
S120iS 1 phase 220-240 VAC - 50 Hz 5 Amps A
S450iS 1 phase 220-240 VAC - 50 Hz 7 Amps A
S1000iS 1 phase 220-240 VAC - 50 Hz 9 Amps A
S2000iS 1 phase 220-240 VAC - 50 Hz 13 Amps B
S120iP 1 phase 220-240 VAC - 50 Hz 5 Amps A
S450iP 1 phase 220-240 VAC - 50 Hz 12 Amps B
S1000iP 1 phase 220-240 VAC - 50 Hz 12 Amps B
9
 Max.
1 phase/ Single Phase Three Phase Current Plug 3
Model Frequency 2
3 phase 1 Voltage Voltage per Style
phase
S2000iP 3 phase - 380-440 VAC 50 Hz 11 Amps C
CC450iP 3 phase - 380-440 VAC 50 Hz 20 Amps D
CC1000iP 3 phase - 380-440 VAC 50 Hz 20 Amps D
CC2000iP 3 phase - 380-440 VAC 50 Hz 25 Amps D
ACC04 1 phase 220-240VAC 50Hz 3 Amps A

Note 1 - All models, whether 1 or 3 phase, require both neutral and earth connections.
Note 2 – Ascott chambers will also work with a 60Hz supply frequency, but certain
optional accessories will only work with a 50 Hz supply. Please check before ordering.
Note 3 – For non-European customers, electrical plugs will only be fitted if readily
available in the U.K. For European customers, standard electrical plugs will usually be
fitted as follows, unless otherwise agreed.
Note 4 – Always check that the supplied power meets the chamber requirements for
voltage and connections. If in any doubt do not connect the chamber as it is likely to
be damaged if not connected correctly.

Type A
Single phase plug (3 pole; Phase, Neutral & Earth) – various styles fitted
depending on country. Generally rated up to 10 Amps.

Type B
Single phase plug (3 pole; Phase, Neutral & Earth) – industrial style to
European standard; IEC-EN60309-2. 16 Amp rated size.

Type C
3 phase plug (5 pole; 3 phases, Neutral & Earth) - industrial style to
European standard; IEC-EN60309-2. 16 Amp rated size.

10
 Type D
3 phase plug (5 pole; 3 phases, Neutral & Earth) - industrial style to
European standard; IEC-EN60309-2. 32 Amp rated size.

Ascott recommend the electrical supply is protected by a residual current device

(R.C.D.) also known as an earth leakage circuit breaker.

WARNING: ASCOTT APPLIANCES MUST BE EARTHED

A rotary electrical isolator switch is mounted in a prominent position on the chamber.

This isolates the chamber from the incoming electrical supply (live and neutral) when
the switch is rotated to the '0' position, and can be padlocked in this position if required.
The electrical supply is connected when this switch is rotated to the '1' position.

1.2.2 Water

Deionised or distilled water is required for topping up the chamber air saturator and for
making up the salt water solution to be sprayed. We recommend a maximum electrical
conductivity of 5.0µS at 25°C for both.

Due to the volume of water required when cyclic corrosion testing, CC450/1000/2000xp
chambers must be connected to a continuous deionised or distilled water supply
pressurised to within the limits 0.5 – 6.0 bar.

The water consumed by the air saturator is approximately 1-2 litres per 24 hours of
continuous testing, in the moist air mode of operation. The water consumed creating the
salt spray is approximately 20 litres per 24 hours of continuous testing.

Where a local deionised water supply is unavailable Ascott offer an in-line mains water
deioniser as an optional accessory (ref.: ACC06).

1.2.3 Compressed Air

A clean, dry and oil free compressed air supply pressurised to within the limits 4.0 to 6.0
bar (58 to 87 P.S.I.). Between these pressures the air supply should be capable of
delivering a flow rate of at least 240 Litres (8.5 cubic feet) per minute.

Care is needed to ensure that the selected compressor is capable of a high duty cycle
as the consumption of air is constant!

Where a local supply is either unavailable or unsuitable Ascott offer an independent oil
free air compressor as an optional accessory (ref.: ACC04). This requires connection to
a 220-240VAC, 50Hz, 13 A switched single phase electrical supply.
11
1.2.4 Exhaust

Exhaust vent outlet

Nominal Nominal
Chamber exhaust pipe exhaust pipe Height above
size diameter Salt diameter floor to centre
Spray Cyclic of outlet
Chambers Corrosion Test
Chambers
120 Litre 55mm (2.2”) N/A 360mm
(14.1”)
450 Litre 55mm (2.2”) 110mm 800mm
(4.4”) (31.5”)
1000 Litre 55mm (2.2”) 110mm 845mm
(4.4”) (33.3”)
2000 Litre 55mm (2.2”) 110mm 845mm
(4.4”) (33.3”)
Note: 3m (10ft) of exhaust pipe and a selection of
View of back right of typical chamber couplings are provided by Ascott

An exhaust vent to atmosphere, i.e.; the chamber should ideally be located adjacent
to an outside wall, and a hole made through the wall to accommodate the exhaust
pipe. The end of this pipe should be shielded from the wind to prevent any disturbance
to the conditions inside the chamber.

It is recommended that the diameter of the exhaust pipe is increased if the vent pipe is to
exceed 3m (10 ft). If In any doubt please consult Ascott for further advice.

1.2.5 Drain
Drain outlet
Chamber size Nominal drain Height above
pipe diameter floor to centre of
outlet.

12
 120 Litre 22mm (7/8”) 83mm (3.25”)
450 Litre 22mm (7/8”) 100mm (4”)
1000 Litre 22mm (7/8”) 100mm (4”)
2000 Litre 22mm (7/8”) 100mm (4”)
Note: 3m (10ft) of drain pipe and a selection of
couplings are provided by Ascott

View of bottom centre of typical

chamber

A floor level drain to remove salt fog condensate etc. from the chamber interior.
Manual Base Drain - Salt spray chambers only

Drains the chamber completely.

With the tap handle in the vertical (closed)
position, salt fog condensate will
accumulate in the chamber base to a
predetermined level, before draining to
waste. This assists in maintaining a high
humidity during testing, and is the correct
position for most continuous salt spray
tests.
With the tap handle in the horizontal
(open) position, salt fog condensate will
drain away. This drains the chamber
interior for cleaning.

1.2.6 Air Saturator Drain

Air Saturator Drain

Do not connect anything to the Air
Saturator Drain; it is provided for
maintenance purposes only.

To drain when required:

Set to Dry air mode.. Then use
a flat blade screwdriver to open the
drain tap.

Note: If chambers are left unused for any length of time it is recommended that the air
saturator is drained to prevent the build-up of algae which could cause system
blockages or of bacteria which might present a potential health risk.

13
1.2.7 Salt Solution Reservoir

Position the Salt Solution Reservoir to the side of the chamber.

(120 litre chambers have an integral salt solution reservoir)

Salt Solution Reservoir – The side wall

has a hole to allow the salt solution
hose to pass through.

14
 Salt solution inlet hose

120L
Only

Feed the end of the 6 mm salt

solution hose that is fitted with a
filter, into the Salt Solution Reservoir
ensuring that the filter unit lies at the
bottom of the reservoir.

1.2.8 Installation – ‘Maintenance’:

Once a chamber is installed, the chamber services should be inspected for leaks,
blockages and general condition periodically. Ideally before starting, during and upon
completion of a test program.
Correct installation is vitally important for the correct operation and long term reliability of
Ascott corrosion chambers. Below are examples of poor installations and problems that
arose as a result:

15
 Chamber exhaust connected to
drain:

Canopy opens during salt spray

mode due to build-up of pressure.

Result: Corroded/seized pneumatic

cylinders and salt fog
contamination of local area.

Poor water quality:

Air saturator sight glass

contaminated. Optical sensors
unable to detect correct water
level.

Result: Air saturator heating element

remains ON during ‘low water’. Air
saturator damaged.

Poor water quality:

Immersion heating element coated

in deposits.

Result: Immersion element

damaged.

Poor air quality:

Oil/water getting into pneumatic

system.

Result: Pneumatic faults due to

solenoid valve failure.

It is therefore very important that the De-ionised water and air supplies are regularly
checked by the user.

1.2.9 Installation / Training

16
It is often required to provide customer training in the use and maintenance of Ascott
chambers, whether at the time of installation of a new chamber or when a new
employee is introduced to the chamber.

Although not designed to replace the chamber instruction manual, customers do

benefit from having the chamber demonstrated by an experienced engineer.

The checklist below will assist in aiding such demonstrations, ensuring that important
aspects of the chamber are remembered.

INSTALLATION / TRAINING SCHEDULE

Installation Requirements Programming

Electrical connection Steps
Compressed air supply Function
DI water connection and supply Temp
Salt solution connection Time
Drain connection Humidity
Exhaust outlet and path Repeats / save / save as

Controls explanation Global settings

Moist air/dry air

Isolator
Automatic drain settings
E Stop

Pneumatic gauge and regulator Interpreting test standards

Pump and flow meter Importance of reading whole standard

Drain valve - tap/switch Create / implement a program from a test

standard
Ethernet connection
Control system (IS)
Chamber inner
Setting / Run modes
Atomiser
Timed stop
Sump / Heating element
Care & Maintenance - User
Temperature probes
Atomiser salt filter
Humidity sensor
Cleaning inner
Air saturator vent
Not used / clean salt lines
Purge / warm air inlet
Algae prevention
Canopy / gasket
Peristaltic pump tube
Chamber functionality
Humidity sensor
Salt spray
Optional Accessories
Condensation humidity
ACC46 – SO2 facility (dangers and use)
Ambient air drying
ACC01 – ECC-1
Controlled humidity
ACC90 – Dehumidifier
Off
ACC30 – Salt spray (vertically down)
Test set-up
ACC112 – Midi unit
Atomiser set up
ACC29 – Refrigeration
Salt solution reservoir
ACC120 – Logging software
Test pieces

Air pressure

Signed: ........................................... Position: ...............................................

Print: ........................................... Date: ...............................................

17
Signed on behalf of Ascott Analytical Equipment Limited

Signed: ........................................... Date: ...........................................

Print: ...........................................

Part 2 - Chamber Controls

2.1 Human Machine Interface (HMI) Screen

The chamber control system utilises a Human Machine Interface (HMI) screen mounted
in the chamber control panel. This operates in conjunction with a Programmable Logic
Controller (PLC) mounted within the chamber. The HMI screen is touch sensitive and
uses ‘virtual’ push buttons for the selection of various functions.

Display
LCD screen with backlight.

Salt Spray IS

Display
Colour LCD screen with backlight.

Salt Spray IP and Cyclic Corrosion IP

Maintenance:

18
IP HMI’s may require replacement internal batteries. The HMI will display an alarm when
this needs to take place.

Apart from keeping clean, the HMI screens do not require further maintenance.

2.2 Emergency Stop

Pressing the chamber emergency

stop button during canopy opening
or closing will ‘freeze’ the canopy in
its current position.

An audible alarm sounds. When the emergency stop button is returned to its normal
position, the HMI screen will return to the canopy Open/Close screen.

Maintenance:

Occasionally, the switches on the rear of the emergency stop button can work loose,
causing them to stick during use. (As this is directly linked to the canopy function it can
lead to the canopy being unable to operate or a permanent E-Stop alarm)

The E-stop micro switches may

need to be realigned and
tightened.

19
2.3 Mains Isolator

Isolates the chamber from the

electricity supply.

Maintenance:

No Maintenance required

2.4 Air Pressure Gauge & Regulator

Air pressure gauge and air pressure

regulator

These indicate and control the pressure of the compressed air supply to the atomiser(s).
They will only operate when air is supplied to the atomisers.

2.4.1 To adjust the air pressure:

20
Pull out the regulator knob to unlock.
Rotate anticlockwise to decrease the pressure and clockwise to increase it.
Push in the regulator knob to lock.

Maintenance:
The air pressure should not be decreased below normal settings (15-20psi) as this can
lead to the air saturator being over pressurised. This would result in the air saturator
pressure release valve operating. This would need to be reset. Otherwise, these items
do not require maintenance.

2.4.2 Resetting the air saturator safety valve:

With chamber operating in salt spray

mode open the ‘front’ regulator to
maximum

Locate the safety valve on the air

saturator. (Shown here with plastic
tubing removed) Reset by lifting &
releasing the small nipple until it stops
venting air.

Locate regulator with hoses P1/P2

connected. Adjust until pressure
gauge on the front of the chamber is
at 22psi. Lock the regulator.

2.5 Flow Meter(s) & Peristaltic Pump(s)

21
 Flow meters and Peristaltic
pumps
(2000L- pictured)

450L and 1000L chambers are fitted with one flow meter and one peristaltic pump.
2000L chambers are fitted with two flow meters, and two peristaltic pumps, one of each
for each atomiser. The flow meter(s) monitor the flow rate of salt solution from the
reservoir to the atomiser(s). The peristaltic pump(s) draw salt solution from the reservoir
and pass it to the atomiser(s).

Maintenance:

Peristaltic pump tubing should be replaced by the user regularly. (See instruction
manual) Generally lasting many years, replacement of the pump motor would be
required if the pump does not operate or the rotor cannot be rotated by hand.

Part 3 - Chamber Inner

3.1 Atomiser

Atomiser positioned in mounting

holder

The atomiser is mounted in a PVC holder located on the rear wall of the chamber. It is
locked into position using plastic thumbscrews. Position and lock the atomiser so that
when atomising, the spray impacts in the centre of the inside of the canopy viewing
window when the canopy is closed. This position can be adjusted to achieve even
fallout results during salt spray testing.

22
 Compressed Air
Atomiser ‘salt Inlet Hose & Atomiser Cap
Atomiser Body
in’ Luer fitting Atomiser ‘air in’
& filter spacer
assembly Luer fitting
assembly

Salt solution
Salt Solution
Filter Housing Plastic spacer Atomiser Nozzle
Inlet Hose
(filter fitted)

Maintenance:

The salt filter should be cleaned on a week by week basis to prevent the build-up of
dirt/algae. The atomiser should be checked to ensure that it is firmly assembled and all
hoses are securely attached.

The effectiveness of an atomiser can be checked with the canopy open and the
chamber operating in salt spray ‘test mode’.

23
 Remove the salt supply line from
the bottom of the atomiser and
place the open salt filter into a
cup of clean water.

The atomiser should draw the

water through the filter to create
a strong plume of fog. If this
does not happen or if the
atomiser blows bubbles back
into the cup, inspect the
atomiser for damage or
blockages.

Open the chamber canopy

Switch off the power supply to
the chamber.
Withdraw the atomiser and filter
assembly from its support, taking
care not to damage the two
hoses.
Detach the compressed air inlet
Hose (1).

(1) Unscrew the atomiser cap (2).

Wash the atomiser cap in warm

running water.

Unscrew the atomiser body,

nozzle and cap from the salt
solution filter housing.

Wash the atomiser body and

nozzle in warm running water.
(2)
If the nozzle is blocked, clear the
obstruction by operating the
chamber (canopy open) and
place atomiser assembly,
without the filter attached, into a
cup of clean water (3). Water
should be drawn through the
atomiser to create a spray.

(3) Place finger over atomiser outlet

to blow air/water back through
the atomiser, clearing any
obstruction (4).

24
 Only if this does not work should
the atomiser cone be cleaned
with a fine wire.
Take care not to damage the
cone!

Reassemble the Salt Spray

(4) Atomiser and test once again
(5).

(5)

3.2 Sump / chamber base

The chamber sump is the small tank located in the floor of the chamber. Chamber
sumps are connected to the chamber drains. 450L and 1000L chambers have one
sump. 2000L chambers have two sumps.

Immersion heating element and

float switches in chamber sump.
(Cover removed)
(Pic = Salt spray IP)

The base of the chamber will fill to different levels during use:

Drying:
In cyclic corrosion chambers, the base/sump will automatically empty during a drying
phase.
In salt spray chambers, the base/sump will only empty if the manual base drain is
opened.

25
Salt spray:
In salt spray mode, the chamber base will fill with water so that the whole base is
covered in approximately 3cm of salt solution. (This can be overridden to have a dry
base/sump in the settings of a cyclic corrosion chamber or by opening the manual
base drain of a salt spray chamber.)

Condensation humidity:
In cyclic corrosion chambers, the sump will fill with fresh water and will maintain this
level automatically. (This can be overridden in the settings menu to allow the build-up
of solution on the chamber floor). In salt spray chambers (with the manual base drain
closed) the sump will fill with fresh water and maintain this level. If a period of salt spray
follows this, the water level will rise and may cover the whole base of the chamber.

Controlled humidity:
Cyclic corrosion chambers only. The sump will fill with fresh water. This level will be
maintained automatically.

Maintenance:

The sump contains float switches that need to be kept clean.

(iP Models)

The drain outlet also needs to be kept free of debris as this is also used as a water inlet
on cyclic corrosion chambers.

In addition it is worth noting that corrosion waste can have an effect on the corrosivity
of the chamber and this may affect test results.

3.3 Immersion heating element – IP chambers only

The immersion heating element is a 2KW Titanium element designed to withstand the
corrosive environments it is exposed to.

(A 2000L IP chamber would have one element & associated float switches in each of its
two sumps.)

26
 Immersion element removed
from chamber.

Maintenance:

The chamber base and sump should be regularly drained and flushed with clean water.
This will help to prevent the build-up of acidic/corrosive elements in the base of the
chamber. It will help to keep the drain system, float switches and heating element free
of debris and prolong the life of these components.

Immersion element removed

from a poorly maintained
chamber. Coated in corrosion
deposits and permanently
submerged in an acidic ‘sludge’

Note: if the heating element requires replacement, the internal thermostat and
controlling solid state relay should also be considered for replacement.

Immersion element removed

from chamber. Showing position
of thermostat bulb. (This
thermostat will give an
Immersion Over-temperature
alarm when tripped)
When fitting, apply a small
quantity of Thermal transfer
paste/heat sink compound to
the ‘bulb’.

27
 Solid state relays used to control
heating elements

3.4 Temperature probes

The two probes on the rear wall of the chamber are the chamber PT100, used for the
chamber temperature display and a thermostat. (This thermostat will give a Chamber
Over-temperature alarm when tripped.)

Chamber temperature probes.

Maintenance:

Unless physically damaged, both PT100 and thermostat are maintenance free.

3.5 Humidity sensor – IP chambers only

IMPORTANT!

The humidity sensor is a delicate instrument that is continually exposed to the conditions
within the chamber. To protect the sensor from acidic conditions during testing the user
must select what type of test they are performing before salt spray testing can start. If
any of the ’acidic’ options are selected the chamber will automatically create a curtain
of fresh air around the sensor during salt spray phases.

There is a known degradation over time of ALL manufacturers’ humidity probes if they
are exposed to humidity levels above 90%RH.

28
Humidity probes should be considered a consumable item and should be considered
for replacement on an annual basis. This is particularly the case in chambers that
operate at levels ABOVE 90%RH as part of any test procedure.

Selecting one of the acidic options when loading a profile that includes salt spray will
help to prolong the life of a humidity sensor as the air curtain will be active and will help
to prevent the sensor from being exposed to very high levels of humidity.

The sensor is fitted with a blue ‘filter’ cap. This will help to prevent salt from getting to the
delicate sensor element.

Humidity probe assembly

Sensor in normal position, within

protective plastic sheath, revealing
only the tip of the sensor, to minimise
the number of water droplets
running over the sensor.
The hose attachment supplies
compressed air forming an air
curtain during acidic salt spray tests.
It is important to protect the sensor
from salt accumulation. Selecting an
acidified option when starting the
test will ensure that the air curtain is
used
Filter cap – MUST BE KEPT CLEAN to
ensure good chamber performance
and reliability.

The chamber is also supplied with a ‘solid’ cap that should be used in place of the blue
filter cap to further protect the sensor element when humidity display or control is not
required in the current test profile.

Maintenance:

The humidity sensor must be regularly inspected and the filter cap cleaned. Carefully
remove the filter cap and inspect the internal element for signs of damage or corrosion.
Fit the solid cap while cleaning of the white filter is in progress. DO NOT operate the
chamber without a cap on the humidity sensor.
It is suggested that this is carried out once every month!

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 MONTHLY PROCEDURE For cleaning
the humidity sensor cap:

Protective plastic sheath removed to

reveal entire humidity sensor probe.

Filter cap unscrews from sensor to

reveal electronic sensing element
inside.
This filter can be removed for
cleaning or replacement. In either
case, the chamber must not be
operated until the filter has been
correctly screwed back into position
(finger tight only).

Rinse the cap in warm water to

dissolve any salt deposits.
Dry with clean, compressed air
before replacing.
Take care not to lose the small ‘o’
ring!

Typically, a humidity sensor filter cap blocked with salt deposits will give rise to over
temperature alarms during controlled humidity tests. As the chamber attempts to
generate high humidity, the salt deposits prevent the humidity within the chamber
getting through to the sensor. The chamber compensates by applying more power to
the immersion heater in order to try to generate more humidity. This results in an
increase in chamber temperature. Eventually, this can give rise to a chamber over
temperature alarm.

30
The air curtain assembly should be inspected regularly to ensure that salt deposits do
not build up on or around the assembly.

3.5.1 Fitting a Humidity Sensor Cover (Protects humidity sensor from exposure to
acidic solutions, eg; ASS, CASS, SO2)

Note:
In salt spray chambers, the humidity sensor is only used as an indicator and has no
effect on chamber performance. Therefore the protective cover can be left in place
unless a humidity reading is required.

In cyclic corrosion chambers, the humidity sensor is used as a part of the mechanism
for controlled humidity, the sensor cover should only be fitted when SO2, ASS, CASS
testing or similar. For all other modes of operation the humidity sensor MUST be free to
operate normally.

Isolate the chamber from its electrical supply

Carefully remove the blue humidity sensor cap by

unscrewing clockwise, ensuring the little black ring
is inside it.
Do Not Use The Chamber With This Cap Removed.

Carefully screw on the grey protective sensor cover

anti-clockwise as shown by the directional arrow.

(no picture) The blue humidity sensor cap and o ring should be
kept in a safe place. These should be replaced in
the chamber when the humidity probe is required
for use.
The delicate sensor element should only ever be cleaned using a can of dry
compressed air such as ‘duster gas. Under no circumstances should it be scratched or
rubbed. Avoid contact with finger tips.

If the sensor element is seen to be corroded or damaged in any way it should be

considered for replacement.

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3.6 Air saturator vent / warm air inlet / purge inlet

Square warm air inlet (CC IP

Chamber) and air saturator
vent.

Compressed air inlet. Salt spray

chambers only.

Maintenance:

None required.

3.7 Canopy
Ascott chambers have pneumatically actuated canopies. When operating, an audible
alarm will sound for a few seconds before the canopy starts to move and throughout
the opening/closing process.

32
As a safety precaution, the user must maintain pressure on the ‘canopy close button’
for the canopy to close.

The clear polycarbonate viewing window should be wiped clean using a damp cloth.
Other cleaning agents should NOT be used as these may damage the surface of the
window and may also affect salt fog distribution.

The pneumatic cylinders and hinges should only require cleaning and a light coating of
(none mineral) oil during scheduled maintenance visits.

The canopy gasket provides an effective ‘wet seal’ that retains the corrosive conditions
within the chamber.

Gasket material may become

flattened in use. This should not
pose a problem if kept clean of
salt deposits.

The gasket can dry out, making

opening of the canopy difficult.
Simply lift the lower edge of the
canopy manually to assist in
opening.

The gasket should be regularly inspected and cleaned of salt deposits. Unless
damaged, replacement is not recommended.

When the chamber is operating the canopy is pneumatically pulled down and held
closed.

A proximity sensor detects the

position of a screw mounted in
the face of the canopy.

If the canopy opens during

testing, a ‘canopy open during
run’ alarm will occur.

Usually this would be due to a

blocked or restricted exhaust –
these are the first things that
should be checked.

33
It is possible that the sensor
screw may need adjusting. This
can be checked using a mirror.
The screw should not touch the
sensor, but should have a small
(2mm) gap during salt spray
testing. Adjust the screw a little if
required.

34
Part 4 - Chamber Functionality

4.1 Salt spray

Salt spray is created by the atomiser in the centre of the chamber. Compressed air is
fed to the side of the atomiser assembly; salt solution is fed to the bottom of the
atomiser. The air flowing through the atomiser creates suction that draws the salt
solution through the supply hose to the atomiser.

The RED dotted line shows the path of

compressed air through the
chamber.

Air inlet on rear of chamber

Air saturator
Air pressure regulator & gauge
Atomiser

The Blue dotted line shows the path

of salt solution through the chamber.

Salt solution reservoir

Peristaltic pump
Salt solution flow meter
Atomiser filter

During salt spray testing, the chamber is heated using the ‘wrap around’ heating
elements that are bonded to the floor of the chamber only.
It is usual for the entire floor of the chamber to fill with gathered condensate during salt
spray testing. Some test standards do not require this. To ensure that the base of the
chamber does not fill with condensate, the base drain valve can be opened manually
on salt spray chambers and set to open automatically on cyclic corrosion chambers.

35
4.1.1 Moist Air / Dry Air
Compressed air used by the atomiser is passed through a vessel (air saturator)
containing a column of heated water. This allows the air to be moistened and heated
before it reaches the atomiser. This is known as ‘Moist Air’.

Some test specifications do not require ‘moist air’ (ASTM G85 A5). The chamber can be
set so that the air saturator is not used. In this mode, the incoming air bypasses the air
saturator. This is known as ‘Dry Air’.
It should be noted that if the chamber is switched off, when switched back on the
chamber will default to the ‘Moist Air’ setting.

4.1.2 Air saturator

The air saturator is a pressure vessel containing deionised water. With the chamber
connected to a permanent, pressurised supply of water, once the set value for
temperature has been input, its operation is completely automatic.

The water level within the air saturator is

controlled using a series of optical level
sensors mounted on a transparent sight
glass, located alongside the air
saturator.

The sensors show an illuminated red LED

when water is NOT detected.

Maintenance:

If provided with deionised water, the air saturator only requires the minimum of
maintenance, usually carried out during an annual service.

The air saturator should be drained of water. (Set the chamber to ‘dry air mode’ and
open the air saturator drain valve on the rear of the chamber. Use a suitable vessel to
capture the water)

The sight glass can then be cleaned using a long, narrow brush, or by pushing a wad of
tissue paper through it, having removed the pneumatic fittings at each end.

36
Problems can occur if the water supply is not deionised sufficiently. Deposits within the
water supply can build up within the air saturator and sight glass.

If the sight glass is contaminated, the level sensors can fail to detect the changes in
water level. The heating element could, potentially remain switched on leading to
damage of the air saturator.

In severe cases, pneumatic fittings in the base of the air saturator can become blocked
with deposits. This can lead to the water within the sight glass, not falling in line with that
in the air saturator, again leading to heaters remaining on when no water is present
within the air saturator.

4.1.3 Salt solution

Salt solution is drawn from the salt solution reservoir; it passes through the peristaltic
pump and salt solution flow meter before passing to the filter assembly at the bottom of
the atomiser.

4.2 Ambient air drying – Cyclic Corrosion IP

Chambers
Ambient air flushing / drying is created by a fan blowing ambient air through a heating
element into the chamber. The ‘wrap around’ heating elements that are bonded to
the floor of the chamber also operate at this time.

In cyclic corrosion chambers, during

a drying phase, the chamber base
drain will open automatically.

37
The chamber temperature probe (PT100) detects the chamber temperature, sending a
‘value’ to the PLC. Power to the ‘wrap around’ heating element and fan heating
element is switched using a solid state relays controlled by the PLC.

4.2.1 Ambient air drying Fan

The chamber uses a 240VAC, variable speed, brushless fan to blow ambient air into the
chamber. The speed of the fan is controlled by a variable DC voltage signal from the
PLC. (Programmable Logic Controller)
A 240VAC heating element is attached to the outlet of the fan housing.

Variable speed fan/heater assembly.

Note: Wiring terminals for the fan and

heater are located beneath the fan

A 50mm diameter hose connects the fan assembly to the chamber via a pneumatically
actuated (open/close) ball valve.

Pneumatically actuated ball valve.

Note: The primary purpose of this valve

is to close off the connection between
the chamber and the variable speed
fan / heater assembly.

This will prevent corrosive conditions

from reaching the fan / heater and
escaping the chamber.

Note: 2000L chambers have two fan/heater assemblies and two pneumatically
actuated ball valves. One set of each at either end of the chamber.

38
Maintenance:

During an annual service, the ball valve should be checked for function and full closure.
The fan and heater assembly should be checked for full function and for signs of
corrosion and ingress of dust/dirt.

The fan should be checked for minimum fan speed function during annual service.

Setting a controlled humidity test with a high set value for humidity (higher than the
current Process Value) will result in the fan operating at its lowest speed. If the fan does
not start (allow 20 seconds) the minimum voltage must be increased. The minimum
speed/voltage of the fan is set in the Service Engineers menu on the HMI. (Go to -
Controlled Humidity Settings, increase the minimum value by 1. (So, if set at 10, now set
at 11) This corresponds to an increase of 0.1VDC to the signal voltage. (10 = 1VDC,
11=1.1VDC)
This can be verified by measuring the voltage between the yellow/black wires at the
fan assembly.

Measure the speed control voltage

supplied to the variable speed fan
between the yellow and black wires.

4.3 Air Purge - Cyclic corrosion IP chambers

The variable speed fan and ball valve are also used to provide an automatic ‘air
purge’ to clear the chamber of any salt fog before the canopy is opened. No heat is
applied during purging of the chamber.

4.4 Air drying – Salt Spray IP chambers

Salt spray IP chambers perform air drying in a different way to cyclic corrosion
chambers. Compressed air (cold) is released into the chamber circulating the air and
causing any ‘fog’ to condense. The chamber is heated using the ‘wrap around’
heating elements that are bonded to the floor of the chamber. To perform drying, the
customer must open the manual base drain valve.
The chamber temperature probe (PT100) detects the chamber temperature, sending a
‘value’ to the PLC. Power to the ‘wrap around’ heating element is switched using a
solid state relay controlled by the PLC.

39
 Compressed air inlet. Salt spray
chambers only.

4.5 Air purge – Salt Spray chambers

Salt spray chambers are purged using compressed air. Compressed air (cold) is
released into the chamber circulating the air and causing any ‘fog’ to condense.

4.6 Condensation humidity – Cyclic corrosion IP

chambers

During condensation humidity (Wetting), the chamber sump will automatically empty of
any condensate and fill up with fresh water. This ensures that the water being heated in
order to generate humidity is not acidic as this could prove harmful to the humidity
sensor and also allows the chamber to fill with a regulated volume of water. (This can
be overridden to allow liquid to be retained in the base of the chamber for tests such as
the SWAAT test) The air curtain, used to protect the humidity sensor automatically turns
off during this mode.

40
 The water level in the base of the chamber is
controlled by a ball cock in a small header
tank located behind the front panel of the
chamber.

For effective generation of high humidity, the

chamber set value for temperature must be at
least 10C above ambient.

The primary heating element used during condensation humidity testing, is the
immersion heating element located in the chamber sump.

Immersion heating element and

float switch in chamber sump.
(Cover removed)

The single float switch is used as

a safety precaution. The heating
element will not operate unless
the float switch detects that
enough water is present to
completely immerse the heating
element with water.

The float switch does NOT have

any effect upon the level of
water in cyclic corrosion
chambers.

If the sump does not fill with water within a pre-set period, (typically 20 minutes) the float
switch does not close and a ‘Humidity Low Water’ alarm will occur.

The chamber temperature probe (PT100) detects the chamber temperature, sending a
‘value’ to the PLC. Power to the heating element is switched using a solid state relay
controlled by the PLC.

Note: During ‘rapid heating’ (where a rapid change in temperature is required) the
wrap around heaters will also be active. This would be the case in ‘single programs’
and in main programs where a 1 min step has been programmed. To ‘turn this off’ so
that the wrap around heaters are not used, create the required program using a
‘ramped’ increase in temperature.

41
Maintenance:

The immersion heating element and float switch should be cleaned regularly to prevent
the build-up of corrosion waste. If left unchecked, it is possible for the float switch to fail
to operate correctly leading to ‘false’ Humidity Low Water alarms, or the heater
remaining ON when water is not present.

The humidity header tank should be inspected during annual service.

It is possible for algae to grow within this tank which can lead to problems with water
level control and possible ‘Humidity Low water’ alarms.

Removing the end panels of the

chamber will reveal the fixings for the
front panel. These are located on the
vertical section of the chassis.

Unscrewing and removing these nuts

will allow the front panel to be
removed.

Remove the cover from the header

tank to inspect / clean the inside.

42