CON300FL-AIR-CWC-AWRF-KES_ev3da18022015.pdf

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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:[email protected]|www.vlm-labtec.com
mailto:[email protected]:[email protected]:[email protected]://www.vlm-labtec.com/http://www.vlm-labtec.com/http://www.vlm-labtec.com/http://www.vlm-labtec.com/mailto:[email protected]


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Operating Manual CON 300-FL AIR CWC AWRF KES

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Contents1. Introduction.......................................................................................................................................... 4

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

1.2. Operators ......................................................................................................................................... 4

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

2. 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

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

6. 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........................................................................................................... 196.3.2. Putting KES System in Operation......................................................................................... 19

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


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

7. Commissioning................................................................................................................................... 22

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

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

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

8.1. Maintenance................................................................................................................................. 23

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

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

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

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


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1. Introduction

1.1.Purposeof 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 [email protected] 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.
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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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.


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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 EquipmentThe 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.

2.7. Conduct in the Event of Emergency

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

Figure 1 The door hinge


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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.

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.

3.3. Requirements and AccessoriesTable 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 Pressure Connection

1 Compressed air1) Particle and oil-free

(DIN EN ISO 9227)

6-8 bar Nipple size. 5

2 Demineralized water1) < 5 S/cm (DIN EN ISO 9227) 2-5 bar male thread

4 Drain water1) No pressure PVC hose 25 mm

5 Air exhaust2) PU hose 50 mm

1)Required for AWRF option 2)Required for AIR option

Figure 2 Transport with a fork lift

Figure 3 Adjusting the length of feet


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4. Technical Description

4.1. Operating Range

Temperature range: Ambient < T< + 50C

Note that it is not possible to have lower temperature in thetest 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 chemicallaboratory). 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 2 C

according to DIN 50014.

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 condensationConstant humidity (CH)

- Water CondensationAlternating humidity and temperature (AHT)

- Water condensationAlternating 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.

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


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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 pre-

selected 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.

During the salt spray phase, the air under the roof saturated with salt fog acts as a heat insulator. Thisinsulation 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

Figure 4 VLMs patented CON AIR CWC methodfor water condesation

Table 2 High humidity test procedures


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Roof with CWC

system

Test chamber

Control panel

Adjustable foot

Door

Tap for drain water (not

applicable for chambers

with AWRF option)

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 5and onthenext page show the front and the rear view of the CON 300-FL AIR CWC AWRF

4.4. Technical Drawings with Dimensions

Figure 6 Mechanical schematics

Figure 5 Front view of the test cabinet


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4.5. Technical Specification

Model CON 300-FL AIR CWC AWRF KES

Test Chamber (mm):

Volume test chamber 300 liter (dm3)

Dimensions test chamber W/D/H1/H2 (mm) 800/600/520/733

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

Width (mm) 1100/700/900

Door opening (mm) 740 x 400

Heating andregulated humidity

Operating temperature Ambient < T < +50 C

Constant Humidity 100% RH

Temperature stability 0,5 %

Protection Over-temperature protection

Heating system Micanite surface heating under the floor

Sensors- corrosion resistant and highly sensitive temperature

sensors above the floor and under the roof

Other:

Demineralized water (connection type) < 5 S/cm (outer diameter)

Tap water (connection type) Always via Ion-exchangeing cartridge (outer diameter)

Electrical supply 230V, 700 W (Schuko)

Compressed Air 6-8 bar (connection nipple size 5)

Waste water, drain Pipe fittings (spiral hose ID 32mm)

Power socket for climate module 230V (Schucko)

Communication RS232 (option)Total weight including the bench 80 kg

Material

Stainless steel coated with ECTFE (Halar), polypropylene

side panels, stainless steel rods coated with plastic, dry

cover seal made of EPDM Foam

CWC System Double-shell roof with built-in fans for cooling in

accordance with the CWC

Opening mechanism Manual lock


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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).

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 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.

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.

Figure 7 Connections at the rear of the test cabinet

Figure 8 Leakage safety unit

Figure 9 Water

purification plant

Air exhaust

(AIR option)

Air inlet

(AIR option)

Fans for CWC

system

(CWC option)

Below fittings only for AWRF option !


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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 themagnetic 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

to be connected and operated.

2. Mount the quick connector nipples on the threads onthe 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 inFigure 12 andFigure 11

Once you put an ion exchanger cartridgeFigure 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

Figure 12 Analog conductivity

meterFigure 11 Digital

conductivity meter

Figure 13 Ion-exchange

cartridge

Figure 10 Splitter for the purified

water supply


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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).

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.

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

Figure 15 Air filterFigure 16 Air compressor Figure 14 Compressed air

inlet

Figure 17 Drain pump


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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.

Control Panel /Symbols:Temperature regulation (controller)

Temperature regulation (test chamber)

Temperature limitation (over temperature protection)

Figure 18 Control panel

LED screen Jumo

controller

RS232 interface

(option)

Main switch

Switch for internal

illumination

Control light over

temperature chamber

Control light heating

chamber (Micanite heaters)

Control light

compressed air (AWRF

and AIR option

Control light roof

cooling (CWC option)

Toggle switch Start/Stop

/Water Drain (AWRF

option)

Toggle switch

Aeration/AT/AHT

(AIR option)

Fan speed regulator

(AIR option)

Control light fan

(AIR option)


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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.

1 Display Actual/Set Value Temperature Chamber C2. Set value

3. in Program mode the remaining test time (days:hours) is shown

4. Programming Key, up and down key, exit key

5. 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]

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 Stopposition (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 dTroncontroller. These values are as follows:

Figure 19 Jumo controller


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CON CH test:

The default temperatures are (factory setting):

- Test chamber: 40C

- Roof temperature: always 1C 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 inthe test chamber of exactlyT=-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 ofT=-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 Usermode 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 doesnot 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

StepMode Press

PGM

Press Display

indicator

Meaning

1CON CH

PGM UserName of the controller mode

2

CON CH

PGM In2

Actual roof temperature

3

CON CH

SP1

Set chamber temperature in CON mode

(press PGM and thenorto change

the set value SP1)

4 CON CH

SP

Control of the temperature set point for

CON mode

5

CON CH

SPdA

Set temperature difference between the

roof and the bottom of the chamber

(normally is this parameter -1C; press

PGM and thenorto change the set

value SPdA). Only for CON mode.

6 CON CH trun Elapsed program time

7 CON CH trest Remaining program time


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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

StepMode Press

PGM

Press Display

indicator

Meaning

1 CON CH PGM User

Name of the controller mode

2 CON CH 2x Pro

Name of the controller mode

(Program)

3 CON CH PGM SPP1

Set Point Program 1 for chamber

temperature in CON mode (press PGM

and thenorto change the set

value SPP1)

4 CON CH tP1

Set Time Program 1 defines the time

duration for SPP1 temperature in CON

mode (press PGM and thenorto

change the set value tP1)

5 CON

AHT/AT

SPP2

Set Point Program 2 for chamber

temperature in CON AHT/AT mode

(press PGM and thenorto

change the set value SPP2)

6 CON

AHT/AT

tP2

Set Time Program 2 defines the time

duration for SPP2 temperature in CON

AHT/AT mode (press PGM and then

orto change the set value tP1)

Once the program has been configured it can be started by pressing the upper arrowon 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 CONAHT/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/ AHTinto

desired position.


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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 SO2gas 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 inthe upper container reaches the level mark

(typically 2 L volume mark) the needle valve has to

be closed.

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 regulationsset 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.

Be aware that sulphur dioxide (SO2) is liquid under pressure inside the steel bottle (gas-

cylinder). 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 environmentso that SO2gas can escape without any danger in case it bubbles through the paraffin oil.

Figure 20 System for conducting manually Kesternich test

Multi directional

needle valve

Paraffin oil


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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.

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 orburst.

Figure 21 Set for conducting Kesternich test

Gas inlet on the side wall of

the test chambver

Multi directional valve

Needle valve

Figure 22 Needle valve


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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 slowlyflowing 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 SO2into 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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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.

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.

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

Figure 24 VLMs patented CWC method

for water condesation


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8. Maintenance and Troubleshooting

8.1.Maintenance

What ? When ? Who?

Clean the test chamber, but do not scratch the ECTFE coated base. monthly OperatorCheck the door sealing for leakage and if necessary change it monthly Operator

Check the water filter inside the water inlet fitting at the back of the test

cabinet and change it if necessary

quarterly Operator

Check the filter inside the unit for compressed air, change it if necessary quarterly Operator

Clean the drain system by rinsing pure water through the drain monthly Operator

Clean the outer case monthly 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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9. Spare Parts and Consumables

9.1. Spare Parts List

Article Nr. Description Description in the

circuit diagramV.272.202.710 Main switch 12 A Q1

V.272.202.610 Switch air purge / spraying S2

V.272.102.002 Switch lightning S1

V.277.017.404 Clip connector 2 poles X2-X11

V.277.017.434 Clip Connector 5 poles X2-X11

V.277.017.473 Connector pin block 12 poles X2/X3/X5/X11

V.277.017.414 Clip connector 3 poles X2/X3/X5/X11

V.277.017.424 Clip connector 4 poles X2/X3/X5/X11

V.282.412.000 Temperature controller JUMO dTRON 304 D1A/D1B/D1C

V.271.103.004 Pilot lamp green (pressure/ air H 13

V.271.103.002 Pilot lamp yellow (heating/ventilation) H1/H2V.271.103.003 Pilot lamp red (over temperature/low level. H3/H4

V.287.500.010 Filter for controller and timer Z1

V.273.231.010 Relais K5/K8

V.273.231.012 Relais K2

V.285.110.020 Solid State Relais (ELR/SSR) V1/V2

V.275.402.033 Compact fluorescent lamp E2

V.475.111.005 Heater testing chamber E1

V.576.100.000 Temperature sensor testing chamber Pt 100 B1

9.2. Accessories for Placing the Specimens

Article No. Accessories

V.851.210.300 Specimen rack 20 acc. To ISO 9227, 26 slits

gap 3,5 mm, length 550 mm

1 Pc

V.851.210.100 Specimen rack 15 acc. To ISO 6270-2 (High

Humidity CH Constant Humidity, 26 slits gap

3,5 mm, length 550 mm

11 Pc

V.851.212.000 S-hooks straight (10 Pcs/Unit) 1 U

V.851.212.001 S-hooks twisted by 90 (10 Pcs/Unit) 1 UV.851.200.820 Specimen support rods 1 Pc

V.851.200.010 Cross connector 1 Pc.

V.851.220.000 Special specimen holder for steel-discs 1 Pc.

Specimen holder for very small specimens -

Further individual holder, hooks upon

request

Accessories 1 Pc


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9.3. Other Accessories

Order-No. Water purification plant

V.852.250.028 Ion exchanger stainless steel cartridge DI 2800

V.852.250.020 Ion exchanger stainless steel cartridge DI 2000

V.852.250.1500 Adapter for quick release coupling Pack. 2 Pc.

V.852.250.1506 Quick release coupling Pack. 2 Pc.

V.852.250.1601 Conductivity meter, analog mountable on top of the cartridge

V.852.250.1805 Conductivity meter, digital, mountable on the wall

V.852.250.1402 Distribution unit 1 inlet port 3 outlet ports

V.852.250.1400 Stop cock straight, plastic

V.852.901.000 Hose 1,50 m length with 3/4 connectors

V.852.901.001 Hose 2,00 m length with 3/4connectors

V.852.901.005 Extension hose 2,00 m

Compressed Air SupplyV.852.211.101 Screw compressor

V.852.211.000 Laboratory compressor

V.852.211.100 Capsuled laboratory compressor

Coupling No. 5

Plastic hose

V.852.210.100 Purification unit for oil- and particle free clean air

V.852.221.003 GFK Grid to protect the base

CON300FL-AIR-CWC-AWRF-KES_ev3da18022015.pdf

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