Atlas Model CCX Advanced Cyclic Corrosion Cabinet

Transcription

1 Corrosive Fog/Humidity Cabinet Atlas Model CCX Advanced Cyclic Corrosion Cabinet CCX2000 CCX3000 CCX4000 CCX9000 CCX11000 USER INTERFACE MANUAL Standard Controls Computer Controls Doc. P/N Rev. 0 Atlas Material Testing Technology LLC 4114 North Ravenswood Avenue Chicago, IL USA Phone: (773) Fax: (773) CCX Training Manual 1 Rev kas

2 Doc. P/N Rev. 0

3 GENERAL EQUIPMENT SPECIFICATIONS This page is a record of your equipment specifications. This information is found on the serial number plate of your instrument. Please fill in the blanks below when you receive your unit. When contacting the sales or service department to order parts or obtain information, refer to this page. This will allow us to respond quickly and accurately to your request. MODEL NO. SERIAL NO. VOLTS PHASE CYCLES WIRING DIAGRAM NUMBER REV# DATE MAIN FUSE (time delay, or slow blow ) SINGLE PHASE AMPS 3 PHASE, 3 WIRE AMPS 3 PHASE, 4 WIRE AMPS INSTRUCTION BOOKLET NUMBER MODEL CCX TYPE Advanced Cyclic Corrosion Cabinet Doc. P/N Rev. 0

4 Table of Contents 1.0 SAFETY 1.1 Symbols Operational Precautions QUICK START GUIDE OPERATION STANDARD CONTROLS 3.1 Overview Start a Test Display Cycle Status Mix and Purge Controls Monitor Test Page 1 Cycle Advance, Pause and Stop Monitor Test Page 2 Level, Limit and Lid Switch Indicators Monitor Test Page 3 and 4 Test Loop Parameters Manual Control Page Test Profile Setup Machine Setup Display Setup Calibration Contact Us Power Loss/Resume and Cycle Stop Buttons OPERATION COMPUTER CONTROLS 4.1 System Overview Introduction to Computer Operation Controller Pages Main Menu Select a Test Data Logging Setup Status of Current Test (F2) Current Test Data (F3) Current I/O Status (F4) Historical Test Data (F5) Calibration (F6) Manual Control (F7) Review Maintenance (F8) Adjust Machine Parameters (F9) Program Test Specifications (F10) Data Logging File PREPROGRAMMED TESTS 5.1 Preprogrammed Tests (Standard Controls) Preprogrammed Tests (Computer Controls) TROUBLESHOOTING 6.1 Standard Controls - Status and Fault Messages Computer Controls Status and Fault Messages Doc. P/N Rev. 0

5 1.0 SAFETY This section introduces safety symbols that will appear throughout this manual. It also provides a list of operational precautions and guidelines to operate the CCX cabinet safely. 1.1 Safety Symbols HIGH VOLTAGE! Indicates precautionary information for avoiding electric shock due to high voltage levels. DANGER! Indicates instructions for avoiding hazardous conditions that if not obeyed will result in operator injury. WARNING! Indicates instructions for avoiding hazardous conditions that if not obeyed may result in operator injury. CAUTION! INSTRUMENT DAMAGE Indicates instructions for avoiding conditions that if not obeyed may result in instrument damage. NOTE! Indicates procedural tips and special information. Doc. P/N Rev. 0

6 1.0 SAFETY 1.2 Operational Precautions This list contains the safety precautions that must be followed to safely operate the CCX advanced cyclic lab corrosion exposure cabinet. Follow these precautions when installing and operating the instrument. Safety Disconnect Switch: Connect the electrical supply through a fused safety disconnect switch with appropriately rated slow-blow fuses. Locate the switch as close to the instrument as possible and in view of the operator when standing in front of the instrument. Hot Surface!: Condensation may cause hot water to accumulate on the inside of the cabinet walls, cover and floor during test. Use caution when opening the test cabinet cover after a test is complete. Cover: Each CCX has an exposure cabinet cover. It is shipped on the cabinet in a closed position. Always open the cover by lifting in the center of the lid. Failure to do so can damage the cover and void any warranty the cover may have. If the instrument is equipped with automated air cover lifters, the cover should be opened using the controller after the proper compressed air connection has been made. Drains: Cabinet drains must be laid over the facility drain and not directly connected into the facility drain. This will prevent back pressure from forcing drainage back into the exposure zone. Exhaust: Instrument exhaust must be vented to the outside of the customer s facility unless an factory approved internal venting system is installed. NEVER directly connect multiple corrosion cabinets in the same vent. If multiple corrosion cabinets are vented together, the exhaust from one cabinet can leak into another, causing harm to the test as well as other cabinets. Oil/Water Separator: To prevent contamination of test specimens, supply compressed air to the instrument only through an industrial-grade oil/water filter (user-supplied) Compressed Air Regulator / Filter: The instrument may be equipped (option dependent) with a small air regulator that includes a secondary oil/water trap (sediment bowl). Do not depend only on this trap for compressed air filtering; it is included as a secondary device. Install an industrial-grade filter on your facility supply just before it enters the CCX cabinet. Doc. P/N Rev. 0

7 2.0 QUICK START GUIDE 1. Utility Checks 1.1 Air pressure to unit On 95 PSI (655 kpa). Be sure that it is clean, dry, oil free air. Check to ensure that any customer-supplied oil-water separator is drained and has a clean filter. 1.2 Pressurized deionized water (conforming to ASTM D1193 type IV only) to unit On PSI ( kpa). 1.3 Power to the unit On turn on customer supplied wall switch. 1.4 Power On at the unit ensure that the circuit breaker mounted on the electrical panel is On. 1.5 Control power On pull out (turn ON) the control power. This is a green plunger switch usually located on the right side of the cabinet. 1.6 If this is a computer controlled cabinet, turn the computer On. 1.7 Ventilation fan On turn on any customer supplied and installed exhaust fan. 1.8 Exposure Cabinet drain Open open the customer supplied & installed drain valve. 1.9 Drain line 3/4 (19.05 mm) from back of exposure cabinet must be routed to an Open drain. Ensure that there are no valves or distortions in the line to impede the flow Solution reservoir drain Closed close the customer-supplied 60-gallon (227 liter) salt solution reservoir drain valve. 2. Instrument Checks 2.1 Close the bubble tower drain ball valve, labeled Ball Valve #2 located on left front bottom corner of the bubble tower 2.2 Salt solution reservoir prepared 60-gallon (227 liter) reservoir filled with desired solution for corrosive fogging. 2.3 Open salt solution filter ball valve labeled Ball Valve #1 located behind the access panel on front of the 60-gallon (227 liter) solution reservoir. 2.4 Adjust the air bleed system into the electrical enclosure area to ensure a slight positive pressure into that enclosure. 2.5 Check the position of all other manual ball valves as listed in the operation manual. 2.6 Adjust fogging tower cone (or louvers) to the proper location. If a cone is present, it is suggested to adjust the bottom tip of the cone to be even or slightly below the top of the vertical dispersion tube. The throttle holes are normally left open. 3. Start-up 3.1 If unfamiliar with the operation of this instrument, review section 3.0 OPERATION of the separate Cabinet Operation and Optional Equipment Manual prior to starting an actual test. 3.2 Verify that the test to be run is programmed correctly 3.3 Place parts into the exposure zone of the cabinet (refer to Cabinet Operation/Options Manual. 3.4 Close the cabinet covers. 3.5 Start the desired test. 3.6 Adjust bubble tower air pressure to 15 PSI (103 kpa) if the test requires a fogging cycle. 3.0 OPERATION STANDARD CONTROLS Doc. P/N Rev. 0

8 3.1 Overview There are two different controller options on the CCX, the STANDARD and COMPUTER control package. Both packages consist of an input/output (I/O) block and a display screen. The controller for all CCX Series Cabinets is fully programmable, with an easy-to-use PLC operation (Programmable Logic Controller) accessed from a touchscreen. Standard industry test specifications are pre-programmed so the user can begin testing immediately after installation and setup procedures are followed. Standard tests can be modified, and custom tests and procedures across multiple parameters can easily be programmed into the controller, providing flexibility, meeting multiple needs, and placing real control into the hands of the user. The touchscreen appears throughout this section for reference. The touchscreen allows input to the PLC and displays outputs. The actual cabinet control is performed by the PLC, however, the touchscreen operator interface allows the user to communicate to the PLC for selecting a program to run, changing a program and so on. All operations, cycles, temperatures, times, set points, dry times, etc., are available for the operator to control. The purpose of the cabinet controller is to activate the CCX cabinet components. These components include such items as heaters, blowers, pumps, air solenoids, D.I. water solenoids, salt solution solenoids and so on. The controller will operate the items for the desired lengths of times to produce the environmental conditions (cycles or steps) such as Salt Fog, Humidity, Dry off, Solution Spray, and Immersion. The controller also stores the test profiles ready to be run at the operator s discretion. The controller monitors temperatures, solution levels and other conditions to keep the cabinet running in a safe and repeatable manner. STANDARD CONTROLS PACKAGE The standard control package consists of a rack style micro PLC with 8 inputs, and 16 outputs. This PLC has enough memory to allow for all cabinet function programming and to hold 15 programs, each up to 16 steps. It is adequate to control the CCX in the basic modes with standard cycling and nested looping. The operator interface for this standard package is a 6 monochrome touchscreen display. This package comes standard with the CCX. An optional color display is available for ease of viewing. Doc. P/N Rev. 0

9 3.0 OPERATION STANDARD CONTROLS 3.1 Overview (cont.) 1. Monitor Test in Progress 2. Select test to run. 3. Manual Control 4. Profile setup 1. ASTM B CCT-I 3. CCT-IV 4. ASTM G85 A P 6. Test Test ASTM B CCT-I 3. CCT-IV 4. ASTM G85 A P 6. Test Test 15 NOTE: When viewing the touchscreen please note that the display area for this standard controller is limited to 20 characters including spaces. Therefore, many words are abbreviated. Lid Open/Close Solenoid Cabinet Heater Bubble Tower Heater Spray Pump Moist Air Mix Air Air Blower D.I. to Fog Salt to Fog Air Blower Fill Trap Trap Drain Nozzle Drain User Output 1 Purge ON Time Mixer ON Time Bubble Tower Temp. SP #1 Bubble Tower Temp. SP #2 Bubble Tower Temp. SP #3 Enable Manual Step Power Loss Code Mixer On Time Doc. P/N Rev. 0

10 3.0 OPERATION STANDARD CONTROLS 3.1 Overview (cont.) 5. Machine Setup 6. Calibration 7. Contact US Purge ON Time Mixer ON Time Manual Step (enable / disable) Power Loss Code Bubble Tower Temp. SP #1 Bubble Tower Temp. SP #2 Bubble Tower Temp. SP #3 Alarm Page Display setup Dry Bulb, Read Display Bub Twr, Read Display Wet Bulb, Read Display NOTE: When viewing thetouchscreen please note that the display area for this standard controller is limited to 20 characters including spaces. Therefore, many words are abbreviated. Atlas Material Testing Technology LLC 4114 N. Ravenswood Ave. Chicago, IL Tel: (773) Fax: (773) Web: Doc. P/N Rev. 0

11 3.0 OPERATION STANDARD CONTROLS 3.2 Start a Test Instructions for starting a test in automatic mode Start from the MAIN MENU page of the operator interface. If not already there, PUSH the MAIN MENU Key screen) one time and the controller will be routed the first page, the DISPLAY should show: (on the top left corner of any sub back to the main menu. When at Now PUSH on the SELECT TEST TO RUN Key once. The DISPLAY area, will change to a new screen as shown below: If no test is running, it will be shown on the status bar. The selected test name will show up on the status bar. There are 15 tests to choose from as shown on the left. Five tests are pre-programmed, and the rest (user test 6 15) may be programmed by the user. Using a finger (or other suitable device for actuating a touch screen) select the test to be started. For this example, choose the 9540P test. When a test is selected, PUSH the green START key located in the lower right corner of the screen. Doc. P/N Rev. 0

12 3.0 OPERATION STANDARD CONTROLS 3.2 Start a Test (cont.) When pushed, the start key will start up the test selected and change the display to; PUSH the MAIN MENU key to leave this page and return to the main menu. The display should now be at the MAIN MENU. Note that now the status bar on the main menu displays the name of the test running, and the step that it is Doc. P/N Rev. 0

13 3.0 OPERATION STANDARD CONTROLS 3.3 Display Cycle Status This section instructs the user on how to display the cycle status of the cabinet. From the main menu, PUSH the MONITOR TEST IN PROGRESS button located on the left side middle of the display. The first of three different MONITOR TEST pages will be displayed. The top center blue display area indicates which page is being displayed NOTE: the red ALARM button will only be displayed up if there is an alarm condition This screen will show the operator the following information; 1. what test was selected in this example P 2. what step the cabinet is in in this example - STEP 1 3. the condition of the solution tank in this example - SALT FULL 4. the name of the step running in this example - SOLUTION SPRAY 5. the cabinet temperature set point in this example the dry bulb (cab.) actual temperature in this example the wet bulb actual temperature in this example mixing tank control status in this example - the MIX tank is OFF 9. purge blower control status in this example - the purge blower is ON 10. the bubble tower temperature set point in this example the bubble tower actual temperature in this example the time set for this step in this example 1 minute 13. the time left for this step in this example 1 minute Doc. P/N Rev. 0

14 3.0 OPERATION STANDARD CONTROLS 3.3 Display Cycle Status (cont.) The words shown in this DISPLAY area will change depending on the test name/number running, the step the cycle is in, and the status (In Cycle, Stopped Cycle, Alarm condition) that the cabinet is in. The CYCLE RESUME, CYCLE PAUSE, STEP CYCLE and CYCLE STOP buttons at the bottom of the screen do not all show at the same time. The buttons shown depend on the condition of the test, and the options chosen. For example, the STEP CYCLE button only shows if the user sets up the cabinet this way. 3.4 Mix and Purge Controls The purpose and function of the features on this page are discussed below. MIX White button labeled MIX If the cabinet includes this option, this CONTROL BUTTON will be activated. The time specified in the MACHINE SET-UP section of the controller for the MIX TANK feature can be pre-set and changed. If this timer was set for 30 minutes, for example, the CONTROL BUTTON will change to a green color when pressed, display MIX ON, and the air sparger in the solution tank will be activated and stay on until the time has elapsed, or the operator pushes this button again, whichever comes first. This feature allows the operator to start mixing a salt solution at the touch of a button and walk away knowing that the controller will automatically turn off the mixer. PURGE White button labeled PRGE The purpose of the PURGE CONTROL BUTTON is to evacuate the inside of the cabinet exposure zone of its current environment. Once this button is pushed, the button will change to a green color, the display will show PRGE ON, and the cabinet s Air Blower will turn on and stay on for the amount of time specified in the MACHINE SET-UP section of the controller or until the operator pushes this button again, whichever comes first. A common reason for using this button is turn on the PURGE blower and evacuate salt fog prior to opening the cabinet cover for parts examination. This can help prevent corrosive salt fog from damaging the surrounding areas. Doc. P/N Rev. 0

15 3.0 OPERATION STANDARD CONTROLS 3.5 Monitor Test Page 1 Cycle Advance, Pause and Stop STEP CYCLE The purpose of the STEP CYCLE CONTROL BUTTON is to manually advance an automatic cycle from one step to the next. Basically, this feature allows the operator to over ride the cycle timer and proceed to the next cycle step. This feature is particularly useful when troubleshooting a newly written test cycle to ensure the intended next cycle is achieved. CYCLE PAUSE The purpose of the CYCLE PAUSE CONTROL BUTTON is to put the cabinet into a pause mode during an automatic cycle. When this button is pushed, the test currently running will be temporarily suspended. The button will disappear, and the CYCLE RESUME button will appear and flash, indicating a pause mode. To restart the test, push the CYCLE RESUME button. CYCLE STOP This button will stop a test that is being run in the automatic mode. PUSH the NEXT Key in the top right corner once to show page 2 of the MONITOR TEST page. Doc. P/N Rev. 0

16 3.0 OPERATION STANDARD CONTROLS 3.6 Monitor Test Page 2 Level, Limit and Lid Switch Indicators This is page 2 of the MONITOR TEST sequence. Just to the left of the NEXT key is a key labeled PREV. If the user activates the PREV key, the display will backup one screen. In this case, it will display MONITOR TEST PAGE 1. As on the previous page, the test name, and current step is displayed. Additionally, as before, the current step condition is shown. The eight inputs installed on this cabinet are shown in the center of the display. 1. Lid Switch 2. Bubble tower level switch 3. Solution tank full level switch 4. Solution tank empty level switch 5. Fog reservoir level switch 6. Wet bottom level switch 7. High temp. limit switch 8. Water trap level switch. A green color indicates the switch is UP, or CLOSED, or MADE. A red color indicates the switch is DOWN, or OPEN, or in a BREAK status. In the case of the gray scale display, black color indicates the switch is UP, or CLOSED, or MADE. A white color indicates it is DOWN, or OPEN, or in a BREAK status. At the bottom of this screen, the looping settings and status is displayed. This screen shows what the looping parameters are for LOOP #1 of this test cycle. From - is the step the cycle will start the looping To - is the step the cycle will go to after completing the FROM step Set - is the number of times the controller will repeat this loop SoFar - is the number of times the controller has performed the loop PUSH the NEXT Key at the top right corner of this page. Doc. P/N Rev. 0

17 3.0 OPERATION STANDARD CONTROLS 3.7 Monitor Test Page 3 and 4 Test Loop Parameters This is page 3 of the MONITOR TEST PAGE 3 screen. As on the previous page, the test name, and current step is displayed. Additionally, as before, the current step condition is shown This screen shows what the looping parameters are for LOOP #2 of this test cycle. From - is the step the cycle will start the looping To - is the step the cycle will go to after completing the FROM step Set - is the number of times the controller will repeat this loop SoFar - is the number of times the controller has performed the loop PUSH the NEXT Key at the top right corner of this page. The DISPLAY shows page 4 of the MONITOR TEST PAGE 4 screen: As on the previous page, the test name, and current step is displayed. As before, the current step condition is shown. Additionally, the NEXT key in the top right corner has disappeared, because there is no next page in this sequence. This screen shows the looping para-meters for LOOP #3 of this test cycle. From - is the step the cycle will start the looping To - is the step the cycle will go to after completing the FROM step Set - is the number of times the controller will repeat this loop SoFar - is the number of times the controller has performed the loop PUSH the MAIN MENU Key at the top left hand corner of this page. Doc. P/N Rev. 0

18 3.0 OPERATION STANDARD CONTROLS 3.8 Manual Control Page This section provides instruction on how to use the manual pages of the controller. This section of the controller will allow the user to turn individual cabinet components on and off with the touch of a button. From the main menu, PUSH the MANUAL CONTROL button located on the left side near bottom of the display. The MANUAL CONTROL page will be displayed. There are 13 different output items that can be manually actuated from this screen. They are as follows; 1. Lid (cover) open/close solenoid 2. Cabinet Heater solid state relay 3. Bubble Tower Heater solid state relay 4. Spray Pump relay 5. Moist Air Solenoid 6. Mix tank Air Solenoid 7. D.I. to fog tower Solenoid 8. Salt water to fog tower Solenoid 9. Air blower motor relay 10. Fill Trap Solenoid 11. Trap Drain Solenoid 12. Nozzle Drain Solenoid 13. User Output relay The purpose of each of these items is discussed elsewhere in this manual. However, by the descriptions, it is self-evident what they do or provide. Doc. P/N Rev. 0

19 3.0 OPERATION STANDARD CONTROLS 3.8 Manual Control Page (cont.) The eight (8) inputs installed on this cabinet are shown at the bottom of the display. 1. Lid Switch 2. Bubble tower level switch 3. Solution tank full level switch 4. Solution tank empty level switch 5. Fog reservoir level switch 6. Web bottom level switch 7. High temp. limit switch 8. Water trap level switch. A green color indicates the switch is UP, or CLOSED, or MADE. A red color indicates the switch is DOWN, or OPEN, or in a BREAK status. In the case of the gray scale display, a black color indicates the switch is UP, or CLOSED, or MADE. A white color indicates the opposite. The user can turn these devices on and off individually. For example, to turn off the LID SOLENOID, and open the cover (if option present), press the square key labeled LID SOL OFF. The display will turn off the square button, and turn on a round button just to the right labeled LID SOL ON. This screen shot shows several items in an ON position, and several in an off position. NOTE, these items can be actuated from this screen only if the cabinet is NOT running a cycle. If a cycle is running, this page only displays the status of the outputs. This entire section is only active for a preset amount of time. That is, when the user enters this section of the controller, an internal timer is activated. When the pre-set amount of time elapses, all components that were turned on in the MANUAL mode by the user are turned off, and the DISPLAY area is changed back to the first screen. PUSH the MAIN MENU Key at the top left hand corner of this page. Doc. P/N Rev. 0

20 3.0 OPERATION STANDARD CONTROLS 3.9 Test Profile Setup This function allows the user to set-up a new test profile, or edit an existing one. From the main menu, PUSH the PROFILE SETUP button. CAUTION! When practicing profile changes to the preprogrammed test, DO NOT touch the Enter key or the test will be changed. TO exit from a page and back up, press the Cancel key. The PROFILE SETUP page 1 will be displayed. There are 15 tests to choose from as shown on at right. Five tests are already pre-programmed (but can be edited), and the rest (user tests 6 15) are to be programmed by the user. Using a finger (or other suitable device for actuating a touch screen) select the test to be edited. For this example, choose the 9540P test. The selected test name will show up on the status bar. Once a test is selected, PUSH the aqua color EDIT SELECTED TEST key located in the lower right corner of the screen. Once selected, the screen will change to page two (2) of the PROFILE SETUP screen. As on the previous page, the test name, and current step is displayed. Additionally, as before, the current step condition is shown. From here, all of the test profile setups can be changed. 3.0 OPERATION STANDARD Doc. P/N Rev. 0

21 CONTROLS 3.9 Test Profile Setup (cont.) Start by choosing the step # to be edited. The default is step #1 as shown there. PRESS the STEP # button on the screen, and the KEY PAD display will appear. Using the key pad area in the top left section of the screen, PRESS the number of the step that will be changed first. The value selected will show up here. PRESS the CLEAR key if a mistake is made and a new value is to be entered. The MINIMUM, MAXIMUM and CURRENT values for this function are shown in the boxes on the right side of the display near the center. To exit this page without making a change, PRESS the CANCEL button. No value will be changed, and the display will back up to the PROFILE SETUP PAGE 2. Once the correct value is entered in, PRESS the ENTER key in the lower right corner of this page to make the change. Practice using this numeric keypad display page. It will be used in all other areas of the control where user definable numbers are entered. Although the LABEL (example is STEP # for this screen), MINIMUM, MAXIMUM and CURRENT will change from screen to screen, the functionality of this page remains the same. PRACTICE ONLY! MAKE SURE TO CHANGE THE SETTING BACK TO ITS ORIGINAL VALUE. 3.0 OPERATION STANDARD CONTROLS Doc. P/N Rev. 0

22 3.9 Test Profile Setup (cont.) Using the method explained previously, enter the settings for the rest of this step: a. TIME period for this Step. b. TEMPERATURE (in C) under which this step will run. Remember that this cabinet has no cooling equipment, therefore, a number entered into this area that is lower than the actual temperature surrounding the equipment will not be achieved. This controller works in metric and uses temperature inputs in Celsius. c. EVENT, or condition to be run. Now the actual test condition must be set. Event Codes correspond to actual test conditions as listed in this table. Description Event Code Salt Fog 1 HIGH HUMIDITY (FOGGING) 2 Dry Cycle / purge 4 Solution Spray 8 SET CURRENT STEP IN SECONDS 16 SALT FOG + TIMER IN SECONDS 17 High Humidity + timer in seconds 18 Dry cycle + timer in seconds 20 Solution Spray + timer in seconds 24 Guaranteed Soak 32 Dry cycle + Guaranteed Soak 36 Cover Open - Ambient 64 Cover Open + timer in seconds 80 User output ON 128 Salt Fog + user output ON 129 High Humidity + user output ON 130 Dry Cycle + user output ON 132 Solution Spray + user output ON 134 User output ON + timer in seconds 144 Dry Cycle + user output ON + timer in seconds 148 Solution Spray + user output ON + timer in seconds 150 Cover Open + user output ON 192 Cover Open + user output ON + timer in seconds 208 Doc. P/N Rev. 0

23 3.0 OPERATION STANDARD CONTROLS 3.9 Test Profile Setup (cont.) For example if the number selected in the Event input box is 1, then the cabinet will run a Salt Fog cycle. These numbers can also be added to combine test conditions. For example, if a Dry cycle (Event Code number 4) with the Guaranteed Soak feature (Event Code number 32) enabled, add these two numbers ( = 36) and enter this number as explained above. NOTE: Take care in adding numbers when combining events. If events are combined that conflict with one another (for example Salt Fog and Dry ) the cabinet will not give usable testing results. When the proper TIME, TEMPERATURE, and EVENT CODE have been established and entered into the programmer for each of the 16 steps, it is time to establish the looping schedule. Using the key-pad method explained on the previous pages, enter the settings for the looping schedule. To program a sample LOOP, read the following. For example, if after running Step #11 of the test it is desired to run Step number 1 and repeat this LOOP 79 more times, then enter the following data as shown in the display to the right. Now Loop number 1 is complete. If a Loop number 2 or 3 is needed, PRESS the LOOP # key and change the value to 2 or 3. Follow the above listed instructions to set the Looping parameters for Loop 2 and/or 3. Doc. P/N Rev. 0

24 3.0 OPERATION STANDARD CONTROLS 3.10 Machine Setup This section shows how to use the cabinet setup pages of the controller. These controller pages allow setting of certain functions of the controller to customize testing. From the main menu, push the MACHINE SETUP button located on the right side center of the display. The MACHINE SETUP page will be displayed. Using the key-pad method explained on the previous pages, enter the settings for each of these seven items listed to the right. Factory settings are preprogrammed into the controller, however, all of these numbers can be adjusted by the user. PURGE TIME is the amount of time (in minutes) that the purge blower will operate when it is activated on the front of the control panel. When the time has elapsed, the blower will turn off, and the cabinet is now safe to open for parts inspection or service. The factory preset is 10 minutes. MIXER TIME sets the time (in minutes) that the optional air sparger in the salt solution mixing tank will stay on. The factory preset is 90 minutes. MAN STEP - Manual Step function allows the operator to step from one step in a test to the next with the push of a button. If this function is enabled, then the operator can execute the manual step; if not, then the test cycle will only proceed automatically. To enable this feature a 1 must be entered in the controller; to disable this feature, the 0 (zero) is used. The factory preset is 1. Doc. P/N Rev. 0

25 3.0 OPERATION STANDARD CONTROLS 3.10 Machine Setup (cont.) PWR LOSS - The Power Loss Code sets the activity of the controller if the electrical power is lost to the cabinet and then returns. Below is a list of the codes, and their meaning. Power Loss Fault Codes 0 = Stop Cycle 1 = Continue Cycle upon Power Return 2 = Enter "Pause" mode with outputs off The factory preset Power Loss Code is 1. This value can be changed using the key-pad feature explained earlier in this document. B. TWR SP X (X 1, 2, or 3) - Bubble Tower Temperature Set Points change depending on the test condition being run. These set-points are pre-programmed at the factory and are changeable by the user. Bubble Tower Temp. SP #1 is activated during a Salt fog test = 48 o C Bubble Tower Temp. SP #2 is activated during a Humidity test = 62 o C Bubble Tower Temp. SP #3 is activated during all other test conditions = 41 o C These values can be changed using the key-pad feature explained earlier in this document. NOTE: This controller operates in degrees Celsius, the standard SI units in which most test specifications are written. Doc. P/N Rev. 0

26 3.0 OPERATION STANDARD CONTROLS 3.10 Machine Setup (cont.) ALARM If an ALARM condition occurs, a RED ALARM button at the top right of this screen will display and flash between RED and YELLOW. If the optional color display is not purchased, and the standard grayscale display is installed, this button flashes white and gray. Should an ALARM condition exist, the user will navigate to the MACHINE SETUP page as discussed earlier in this manual, and then push the ALARM PAGE key on the bottom left hand section of the display. When activated, the ALARM STATUS page will be displayed. There are seven alarm conditions that are displayed on this page. 1. Cabinet Temperature - Cabinet exceeded Max Temp allowed - The cabinet s exposure zone exceeded the maximum temperature allowed for this machine. In most cases, this maximum cabinet set point is 75 O C 2. Cabinet Heat up time - The cabinet s exposure zone failed to reach the specified temperature set point in the maximum allowed time. The maximum allowed time is set by the factory in the control code. This is a safety feature to help stop the machine from creating too much heat if there is a mechanical condition preventing the cabinet from reaching a specific temperature. This maximum allowed time will vary with machine type and options. 3. Trap level - The Trap Level Fell Below the Level Switch - The air blower assembly of this machine is equipped with a trap that is filled with type IV D.I. water during a fogging cycle to prevent fog from backing up out of the blower assembly and into the component area during a fogging cycle. If the sensor that monitors this water level detects a condition that would allow the fog to back up, then this fault will display, and the machine will enter a pause condition. Doc. P/N Rev. 0

27 3.0 OPERATION STANDARD CONTROLS 3.10 Machine Setup (cont.) 4. Bubble tower Temperature - Bubble Tower exceeded Max Temp allowed - The cabinet s bubble tower exceeded the maximum temperature allowed for this machine. In most cases, this bubble tower set point is 70 O C. 5. Bubble tower heat up time - The bubble tower failed to reach the specified temperature set point in the maximum allowed time. The maximum allowed time is set by the factory in the control code. This is a safety feature to help stop the machine from creating too much heat if there is a mechanical condition preventing the bubble tower from reaching a specific temperature. This maximum allowed time varies with machine type and options. 6. Salt tank level - Salt Tank is EMPTY - The 60-gallon (227 liter) solution tank is empty. Solution must be added and the fault cleared for testing to continue. 7. Bubble tower fill - Bubble Tower Failed to Fill in allowed Time - The bubble tower failed to fill with pressurized type IV D.I. water in the maximum allowed time. This time is usually set for two minutes. If a condition exists such as low water pressure, no water pressure, or a mechanical failure of the fill solenoid or tubing that would prevent the filling of the bubble tower within this time, then this fault would activate. Green indicates there is no alarm condition. Red/yellow flashing indicates a problem. In the case of the gray scale display, black indicates there is no alarm condition. Flashing white indicates a problem. A fault will cause the cabinet to stop its current testing and requires the condition to be corrected before any further testing can proceed. When the condition that created the fault is corrected, the fault must be reset. This is accomplished by pressing the yellow RESET ALARM button on the bottom left hand corner of the ALARM STATUS page. If the condition is corrected, the condition will return to the OK or green condition message. Once the condition is corrected, and all alarms are reset, the CYCLE RESUME button must be pushed to re-start the cycle. Doc. P/N Rev. 0

28 3.0 OPERATION STANDARD CONTROLS 3.11 Display Setup This section instructs on how to change the contrast on the controller. From the main menu, press the MACHINE SETUP button located on the right side middle of the display. The MACHINE SETUP will be displayed. Press the DISPLAY SETUP button located on the right side bottom of the display. The DISPLAY SETUP page will be displayed. Doc. P/N Rev. 0

29 3.0 OPERATION STANDARD CONTROLS 3.11 Display Setup (cont.) On this page, the user can adjust the contrast on the screen as needed. Several conditions change way the display looks, including over head lighting, temperature of this display, and viewing angle of the user. The contrast will change with the temperature of the unit. Therefore, after the display has attained working temperature, it will be necessary to readjust this contrast to maximize readability of the display. Pressing the left Up arrow key will lighten up the display. Pressing the right Down arrow key will darken down the display. When the display area is adjusted properly, press the MAIN MENU button on the top left corner of the screen, and this setting will be complete. Experiment with this section by using the various keys to adjust the contrast to a comfortable level. 3.0 OPERATION STANDARD CONTROLS Doc. P/N Rev. 0

30 3.12 Calibration This section will instruct qualified ATLAS SERVICE personnel on how to adjust the offsets for temperature calibration. From the main menu, press the CALIBRATION button located on the right side bottom of the display. The CALIBRATION page will be displayed. There are three temperatures that can be calibrated. The top readings are the signal the controller is receiving from the RTD. The bottom readings are the temperature (in degrees Celsius) that the controller will display on the other pages. To change the displayed reading, use the Add or Sub keys below each temperature input/display. Each tap of the button increment the display by one tenth of a degree in value Follow standard calibration techniques when entering in a calibrated signal, or when comparing current equipment to a calibrated probe. Make the necessary adjustments to each input, and then press the MAIN MENU Key to save the data and leave this page. Doc. P/N Rev. 0

31 3.0 OPERATION STANDARD CONTROLS 3.13 Contact Us This section explains use of the CONTACT US button located on the MAIN MENU. From the main menu, press the CONTACT US button located near the center bottom of the display. The CONTACT US page will be displayed. This page provides the user with the Atlas address, phone number; fax number and web address. Press the MAIN MENU Key to leave this page. Doc. P/N Rev. 0

32 3.0 OPERATION STANDARD CONTROLS 3.14 Power Loss/Resume and Cycle Stop Buttons This section will instruct user concerning the POWER LOSS CYCLE RESUME button, and the CYCLE STOP button on the MAIN MENU. IF power is interrupted to the cabinet during an automatic cycle, and then is restored, the POWER LOSS CYCLE RESUME button is displayed on the MAIN MENU page. This is to notify the user that a power interruption occurred. If the cabinet is in an automatic cycle, it can be stopped by pressing the CYCLE STOP button located near the center bottom of the display. Doc. P/N Rev. 0

33 4.0 OPERATION COMPUTER CONTROLS 4.1 System Overview The controller for all CCX Series Cabinets is fully programmable, utilizing an easy-to-use microprocessor-based programmable controller. In the case of the Computer Controls Package, an IBM compatible computer is used to control the cabinet. This computer is connected to an I/O (input/output) module to actuate the cabinet components. Several standard industry test specifications are built in and pre-programmed, so the user can begin testing immediately after installation and setup procedures are followed. Standard tests can be modified, and custom tests and procedures across multiple parameters can easily be programmed into the controller, providing flexibility, meeting multiple needs, and placing real control into the hands of the user. The computer is normally located on or above the control panel on the right side of the cabinet. Since some customers have specified a desktop model, the computer may be located in an area adjacent to the cabinet rather than on the cabinet. The Computer Controls Package includes a comprehensive data logging feature. The position or status of every control function of the cabinetsuch as cycle time, cycle status, temperature, input status, output status etc., is output to a file for ultimate control, analysis, diagnostics and, most importantly, test documentation. Test reports can be programmed to be almost automatic, in graph and other formats, providing accuracy and documentation that make traditional chart recorders look primitive in comparison. Spreadsheet downloads and graphing provide capabilities that go far beyond the performance of a test, enabling testing and management personnel to integrate information, feedback, and performance into decision-making processes. 4.2 Introduction to Computer Operation The computer is very easy to learn and use. If not familiar with Windows, then it is suggested to take a basic Windows training class prior to the operation of this cabinet. 1. Operating System The operating system used on PC controlled cabinets is Windows by Microsoft. This provides for a more robust and secure control of the computer itself. The cabinet is set up for a direct boot right into the CCX control program. The administrative rights are password protected by Atlas to prevent unauthorized use of the computer such as installation and operation of unrelated programs that may interfere with the CCX control program. None of the computer s setup should be changed unless authorized in writing by Atlas or your local sales representative. Unauthorized changes to the computer s operating system setup will void the warranty and subject the user to all consequences and costs arising from such a change. Doc. P/N Rev. 0

34 4.0 OPERATION COMPUTER CONTROLS 4.2 Introduction to Computer Operation (cont.) 2. Computer The computer will include a color screen and keyboard. Some cabinet functions must be operated by use of the keyboard. Communication to the cabinet I/O block is accomplished by use of a standard serial cable attached to the computer s 9-pin RS232 port. This cable must be connected at all times. 3. Computer Security and Protection If the cabinet includes a notebook computer there is a locking mechanism to keep it secure. The sliding acrylic door on the control top panel has a push lock on the uppermost edge of the door. Turn the key 360 degrees and the lock pin will eject. Now the door can be pushed up. When the cabinet is in operation it is necessary to keep this door closed to protect the computer from possible contaminants in the lab air. 4. Computer Performance Many factors affect the performance of the computer during the control of the machine. It is important to avoid as many factors that will slow down the performance since the main function of the computer is to control the cabinet. Avoid loading other software on the computer as this will slow it down. Be careful of network traffic to the computer if it is connected to a LAN. It is very important to reboot the computer on a regular basis, but not less that every other week. Re booting the machine clears out the RAM memory and any other potential file problems that could cause the machine to Lock-up and stop controlling the cabinet. This is a part of regular maintenance. This is very important where the datalogging frequency of the control software is high, as this creates a very large data file. Doc. P/N Rev. 0

35 4.0 OPERATION COMPUTER CONTROLS 4.2 Introduction to Computer Operation (cont.) 5. Controller Overview There are thirteen basic pages built into this control platform. There are additional pages accessible from one of these main pages that will be explained later, The major areas are as follows: MAIN MENU from this main menu, the following can be selected F1 = SELECT A TEST TO RUN F2 = STATUS OF CURRENT TEST F3 = CURRENT TEST DATE F4 = CURRENT I/O STATUS F5 = HISTORICAL TEST DATA F6 = CALIBRATION OF CABINET F7 = MANUAL CONTROL F8 = REVIEW MAINTENANCE F9 = ADJUST MACHINE PARAMETERS F10 = PROGRAM TEST SPECIFICATIONS F11 = PREVIEW ATLAS PRODUCTS F12 = ON LINE MANUAL- (NOT YET ACTIVE) To move from page (section) to page, follow these steps: 1. Using the mouse, left click on the tab that is labeled with the name of the section or page desired. If on the Main Menu page, use one of the twelve function keys to go to that section. 2. If already on one of the 12 pages, or in a section nested in one of the main 12 pages, use the mouse to left click on the button labeled RETURN. This moves back one level or set of screens. 3. The selected page will appear. Doc. P/N Rev. 0

36 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Main Menu After the boot up of the computer, the CCX control program loads. The control program will automatically index to the MAIN MENU page shown. Along with the Atlas logo, the 12 main program pages are displayed along with the corresponding function key. Additionally, the version of this program is shown in the upper right section of the screen. For example, this screen shows Ver This information tells you what version of software the CCX is running. This information should be available in the event Atlas is called for technical support. Periodic updates will be offered to enhance the cabinet control features. From this screen, all other areas of the program are accessible. To review each page of the controller, review the following. Press F1 or using the mouse, click once using the left mouse key over the section of the screen labeled Select a Test to Run. Doc. P/N Rev. 0

37 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Select a Test This screen is used to start a test profile in the automatic mode. Prior to starting a test, one must be programmed. The programming of a test will be covered later in this manual. Notice the green section on the top right corner of this screen. It states, All devices OK. This must be the case, or a test cannot be started. If any device on this machine is not in a startready mode, then this box will change color and an error message will be displayed in this status box. Until this condition is corrected, the cabinet will not go into an automatic run mode. Sometimes, the controller will offer up a phantom fault when this page is selected due to a communication issue with the I/O module. Prior to tracking down a possible fault, use the mouse and left click once on the reset fault button beneath the fault message box. If this is a phantom fault, this will clear the faults, setting the status box back to green and All devices OK condition. To start a test, use the mouse and select one of the twenty tests in the slide window in the middle of the screen. Using the mouse, left click once on the desired test. This will highlight the test, as shown above with Custom 1. There are additional tests not shown that can be seen by using the slide bar on the right edge of this center window. When the desired test is highlighted, use the mouse and left click once on the green START TEST button If all conditions are OK, the cabinet will start the desired test and proceed to the F2 STATUS OF CURRENT TEST page. If data logging is turned on, one additional step is required before the test will start. Doc. P/N Rev. 0

38 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Data Logging Setup Data Logging can be activated or deactivated in the ADJUST MACHINE PARAMETERS (F9) page. This will be covered later in the manual. If DataLogging is enabled, then a file name must be specified prior to a test being started. When a test name has been selected, and the start test button pressed, a Choose file to log temperature to box will open in the center of the screen. I n t h e F i l e n a m e b o In the filename box, a default file name will be inserted by the computer. This default name will be based on the date and time that is on the computer when this test is started. If this file name is satisfactory then use the mouse and left click once (or press enter on the keyboard) on the save button of this box. If a custom file name is desired, type it in and then use the mouse and left click once on the save button of this box. If the name chosen already exists, the computer will prompt the user to overwrite the file. Answer the question as desired and continue. When this step is completed, the computer will start the desired test and proceed to the F2 STATUS OF CURRENT TEST page. Doc. P/N Rev. 0

39 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) This page can be activated from either the MAIN MENU page, or the SELECT A TEST TO RUN page as described above. This is the main cabinet status page. This page gives a synopsis of what the cabinet is doing. Some of the information shown on this page will not be present on certain cabinets. For example, if the cabinet is not set up for immersion, then all of the items associated with immersion will not appear on this screen. Most of this screen is self-explanatory. For example, this screen shows that the test being run is Custom 1. It is in step number 5 and the next step is number 6 - it is looping to itself in this example. This screen shows that Step 5 is Controlled RH.. In the middle area of the screen many of the test parameters are shown with their ACTUAL, SET POINT and REMAINING condition. Doc. P/N Rev. 0

40 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) Each of these parameters are explained below. Step Time in Minutes Cabinet Temp. in deg. C Bubble Tower Temperature Cabinet % Relative Humidity Immersion Tank Temperature Laboratory Temperature Current Loop Total number of loops This is the amount of time this step in the cycle will run. It can run in Minutes or Seconds. The units are user settable. This is the temperature the cabinet exposure zone is programmed to reach during this step of the program. This is the temperature the bubble tower is programmed to reach during this step of the program. This is the percent RH the cabinet exposure zone is programmed to reach during this step of the program. This is the temperature the immersion tank is programmed to reach during this step of the program. This is a readout of the current laboratory temperature in degrees Celsius. This is the number of loops this step has performed. This is the number of loops this step is programmed to perform. Doc. P/N Rev. 0

41 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) There are several toggle switches (circled below) that actuate mixing and fill cycles if purchased. To activate one of these features, put the mouse pointer over the toggle switch and left click once. If the switch is DOWN, then the feature is OFF. If the switch is UP, then the feature is ON. The list below will describe the function of these features. Mixing Tank Sparger Mixing Tank Fill - This activates an air based agitation sparger in the 60-gallon solution tank on the left side of the cabinet. This sparger stays on until it is manually turned off (the same way it was turned on) or until the user specified timer runs out. This activates a water fill in the 60-gallon solution tank on the left side of the cabinet. The water stays on until the top float switch signals a full condition to the computer. When a full condition is signaled, it turns the water off until it is manually activated aga This feature ensures that the tank will not over-fill. Immersion Tank Sparger - This works in the same way as the Mixing Tank Sparger explained above. The difference is that the air sparger is located in the immersion tank. Immersion Tank Fill - This works in the same way as the Mixing Tank Fill explained above. The difference is that it is the immersion tank that is automatically filled. NOTE: Some of these features are an option and are not on all equipment. They will only appear if the options were purchased with the equipment. Doc. P/N Rev. 0

42 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) Along the lower part of the preceding screen is a purple PAUSE button. Using the mouse to click on the PAUSE button will cause the cycle to PAUSE and the button will change to a green color and change its label to CONTINUE. This button does not show the condition of the test, but instead what it will do to the test if it is pressed. When the test was paused, the condition of the test is shown next to the test that was selected. The screen shows the cabinet in a pause mode. In the pause mode, all cabinet functions that were turned on in the automatic mode are turned off. The pause button is commonly used to check the samples being tested. After the test is put into a PAUSE mode, it is recommended to purge the cabinet s exposure zone prior to opening the cabinet cover. The example above shows the purge blower turned on. This is accomplished by placing the mouse cursor over the PURGE BLOWER switch on the screen and left clicking once. The switch on the screen will move into the up position and turn on the blower. The blower will remain on until the user-defined time elapses, or until the user manually turns off the blower. The blower is turned off the same way it was turned on. Doc. P/N Rev. 0

43 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) When a test has been paused and the exposure zone purged of its environment, the cover can be opened for sample inspection. In the same way that the purge blower was turned on and off, the cover can be opened or closed. Use the mouse to point to the COVER switch and left click on it once. It may take a several (or even up to 60) seconds for the cover to open. This is due to the time it takes for the air cover lifters to fill with the compressed air and overcome the weight of the cover and pull of the dual magnetic seal. If the cover will not open it is most likely do to low air pressure. Call Atlas or your local sales representative for assistance with this condition. When the cover is open, a message is displayed in the Fault condition box located in the upper right corner of the screen. The test cannot be put back into a run mode until the cover is closed. To restart the test, use the mouse and close the cover. When the cover is closed and the All Devices OK message shows in the Fault condition box, the test can be restarted. To restart the test, use the mouse and left click once on the green CONTINUE button. If done properly, the test will continue where it left off. Doc. P/N Rev. 0

44 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) The looping schedule can be shown at a touch of a button. On the status page find the looping button and left click on it once. This will bring up the window shown below. This window will show the programmed loop for each step of the program. With this information, the user can identify exactly where in the nested loop the program currently resides. Without this schedule, the user will only see the looping status of the current step of the running program. To close this looping window, use the mouse and left click once on the return button located inside of this looping window There are a number of green message boxes (number depending on options purchased) located above the stop button. These are present only to tell the operator the position of the motorized valves. These motorized valves are parts of certain options, and therefore are not included on all cabinets. Doc. P/N Rev. 0

45 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) Motorized Valves These motorized valves are for the following purposes: RH Valve in Fresh Air Position The valve position dictates the type of air put into the exposure zone by the blower motor. In the Fresh Air Position the ambient lab air is injected. In the recirculation position, the cabinet s exposure zone air is injected back into the cabinet. Cabinet Drain Open The valve position directs the cabinet drain fluid. In the Open position, the fluid in the exposure zone is routed to the facility floor drain. In the Closed position, fluid is held in the exposure zone and prevented from going down the drain. The closed position is used during an immersion cycle or a wet-bottom RH cycle. Jet Exhaust Valve in Recirculation Position This valve directs the flow of the environment being vented out of the exposure zone. It is either sent to the facility outside vent pipe or to the optional recirculation system. Doc. P/N Rev. 0

46 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) Faults There could be many causes for Faults and warning messages on the CCX. A fault is a condition that causes the cabinet controller to display a message and, in many cases, stop the testing by putting the cabinet into a pause mode. There are two types of fault conditions; latching and nonlatching. A latching fault is one that causes the cabinet to stop its current testing and requires the condition to be corrected before any further testing can proceed. Above is an example of a latching fault. Latching faults are shown in a red colored box. When the condition that created the fault is corrected, the fault must be reset. This is accomplished by using the mouse and pointing to the reset fault box and left clicking once on this box. If the condition is corrected, the status box above will return to a green color and display an All Devices OK message. Non-latching faults may be better described as a warning message. These conditions will also be displayed in the status box. They do not stop the test, or prevent the user from starting a test. When a non-latching fault is displayed, the status box is yellow. If there is more than one fault condition at a time, they will cycle one after another in the status box displaying the message along with the appropriate color. A list of the latching and non-latching faults is in the appendix of this manual. As on all pages, to return to the prior page use the mouse and place the cursor over the return to menu button and click once on the left mouse key. In this case, clicking on the return to menu button from this screen will return the user to the MAIN MENU screen. Doc. P/N Rev. 0

47 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Status of Current Test (F2) (cont.) View Test Profile At the bottom of the F2 status page is a button labeled View Looping Schedule. To view the entire test sequence that the controller is currently running; use the mouse and left click on this button. This will bring up the window shown below. This is a screen shot of the test that was programmed and currently running. This page only displays the test sequence. No changes to the test can be made here. For changes, return to the Main Menu and click on the F10 key. Doc. P/N Rev. 0

48 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Current Test Data (F3) Activate this page from the MAIN MENU page, or the STATUS OF CURRENT TEST page as described above. To activate it from the MAIN MENU page, press the F3 key on the keyboard or, using the mouse, place the cursor over the Current Test Data box on the right side of the screen and left click once. To activate it from the STATUS OF CURRENT TEST page, use the mouse, place the cursor over the View Graph box located at the bottom of the STATUS OF CURRENT TEST page and left click once. The purpose of this screen is to show the user a graphical form of the analog input signals. An analog input signal has a range of values. For example, temperature signals are analog values that typically range from -30 o C to 75 o C. This change in value is plotted on the screen as shown above. Bubble tower pressure and percent RH are other examples of analog signals that are shown on this page. If the user of this cabinet has set the data-logging feature on, all of this information is saved in a.txt file on the computer s hard drive. The name and path of this file is shown at the top of this page. The list of items shown on this screen is dependent on the options and features installed on the user s system. For example, if the user has not purchased the immersion option, then the immersion tank temperature set point and actual temperature will not be shown on this list of analog input signals. The list of available signals for the equipment is shown on the right side of this page. Doc. P/N Rev. 0

49 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Current Test Data (F3) (cont.) CURRENT TEST DATA list of inputs that can be plotted. Abbreviation Chamber Temp. RTD Chamber Temp. RTD SP B.T. Temp RTD B.T. Temp RTD SP Lab Temp RTD Humidity Sensor Humidity Sensor SP B.T. Output P.S.I. Imm. Tank Temp. RTD Imm. Tank Temp. RTD SP Definition The exposure zone s current actual temperature in degrees Celsius. The exposure zone s set point in degrees Celsius for the current step. The bubble tower s current actual temperature in degrees Celsius. The bubble tower s set point in degrees Celsius for the current step. The laboratories current actual temperature in degrees Celsius. The exposure zone s current actual percent relative humidity. The exposure zone s set point for relative humidity in percentage for the current step. The bubble tower s current actual pressure in PSI (pounds per square inch) as it exits the bubble tower (OUT). The immersion tank s current actual temperature in degrees Celsius. The immersion tank s set point in degrees Celsius for the current step. Next to the description of each analog input the actual signal reading is shown. NOTE: Any item listed as a SP (set point) is not actually an analog input. This is a value set by the user on the programming page. These values are listed here to allow the user the ability of comparing set point against actual values in a graphical form. Doc. P/N Rev. 0

50 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Current Test Data (F3) (cont.) Using the mouse, position the cursor over one of the available inputs being plotted. With the click of the left mouse key, a control window will open. In this window, the user can change all of the plot types and colors. The best way to get familiar with these features is to experiment with them. Changing these functions are not permanent. On the lower right section of this page there is a Clear Graph button. Pressing this button will clear all data from the graph. As new data is produced, it will be displayed in the graphing area. Clearing the graph only affects the display, not the physical data stored on the hard drive. The yellow Data Logging Interval in Minutes button shows the user what the interval is at which data is stored onto the hard drive. The number entered represents the number of minutes separating data points. The more frequent the data is logged, the larger the data file will be. Once the data file grows to about 1 megabyte the computer will start another file to record the data. This will continue to happen until the test is stopped. Just above this box, the size of the data file and number of file being written to at that time is displayed. The Print Window button will work only if a printer is connected to the computer. If this feature is activated, and a properly configured printer is attached to the computer, pressing this button will send an image of what is displayed on the screen to the printer. Doc. P/N Rev. 0

51 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Current Test Data (F3) (cont.) The screen below shows further examples of how to change what is displayed on the screen. Using the mouse, position the pointer over one a black box next to the name of the item being graphed. With a mouse left click, the graphing line can be turned on and off for display. This will not affect what is being logged, only what is being displayed. Use the mouse to toggle between data points and date and time display. Using the mouse, experiment with the graph display keys to change the X and Y axes ranges. This will allow for close up examination of the data being displayed. The green recording shows the status of the data logging feature. If it is green, and displays the word Recording, data is being saved to the hard drive. If it indicates Not Recording Click to START data is not being saved to the hard drive. The status of recording feature can be changed as desired. User notes may be typed into the note pad record box. After a note is typed in, use the mouse to press the button just to right of the box. Prior to pressing it, the button will be green and display the words Press to log Note. When it is pressed, it will be yellow and read Note will be logged at next data log interval. The box remains yellow until the next data point is saved, as set by the user. When logged, the box will revert to its original green color. The best way to become familiar with all of the features of this page is to experiment. Nothing can be damaged with this experimentation. The user is encouraged to adjust all of the available features until comfortable with how to use them. Doc. P/N Rev. 0

52 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Current I/O Status (F4) This page can be activated from either the MAIN MENU page, or the STATUS OF CURRENT TEST page. To activate it from the MAIN MENU page, press the F4 key on the keyboard, or using the mouse, place the cursor over the Current I/O Status box on the left side of the screen and left click once. To activate it from the STATUS OF CURRENT TEST page, use the mouse, place the cursor over the View I/O Status box located at the bottom of the STATUS OF CURRENT TEST page and left click once. The purpose of this screen is to show the user a visual representation of all of the important inputs and outputs, both digital and analog. The top left section of the screen shows the status of the digital outputs. A blank box indicates the output is OFF. A green box indicates the output is ON. This allows the user to easily see what is ON and OFF when a test is running. The top right section displays the position of all of the digital outputs such as float and limit switches. A green box indicates that the switch is closed or made; a red box indicates that the switch is open or not made. The left lower section shows all analog inputs, such as temperatures and pressures. Doc. P/N Rev. 0

53 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Historical Test Data (F5) This page is activated from the MAIN MENU page. To activate it go to the MAIN MENU page, press the F5 key on the key board, or using the mouse, place the cursor over the HISTORICAL TEST DATA box on the right side of the screen and left click once. The purpose of this screen is to allow the user to open an existing data file and display the graph on the computer screen. When the user activates this screen, a Choose Data Logged file to display box will appear. Use the mouse to select the data file to open, and click on the OPEN key on the lower right side of this box. When a data file is chosen, the computer will display the data in the same format as explained in the F3 Current Test Data section of this manual. Refer back to that section for instruction on using this page. There are additional features on this section of the controller that are not on the F3 section, as explained on the following pages of this manual. Doc. P/N Rev. 0

54 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Historical Test Data (F5) (cont.) Once the file opens, it will show the data that was recorded during the test being run. The data file will display the data in the same format as explained in the F3 Current Test Data section of this manual. Refer back to that section for instruction on using this page. One special feature on this page is the Chart vs. Spreadsheet toggle switch as shown below. Once this switch is changed to spreadsheet, the data will be displayed in a spread sheet format as shown to the right. You can switch back and forth between these two formats to examine the data as desired. The time and date vs. minutes toggle switch can also be activated to display the data based on data points (minutes) or the time and date that the data was written to the hard drive. Doc. P/N Rev. 0

55 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Calibration (F6) This page is activated from the MAIN MENU page. To activate it go to the MAIN MENU page, press the F6 key on the key board or, using the mouse, place the cursor over the CALIBRATION OF CABINET box on the right side of the screen and left click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The passwords for each password-protected page are different. From the factory, the passwords are as follows; F6 CALIBRATION OF CABINET: not published, contact Atlas Tech Service F7 MANUAL CONTROL: 2 F9 ADJUST MACHINE PARAMETERS: 3 F10 PROGRAM TEST SPECIFICATIONS: 1 The password for the calibration page is not published since only trained calibration personnel should be making adjustments to these parameters. When a calibration is needed, contact Atlas or your local sales/service representative. If you perform calibration services in-house, contact Atlas for assistance. Doc. P/N Rev. 0

56 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Calibration (F6) (cont.) This screen allows a trained calibration technician to calibrate the cabinet s analog inputs. Using the mouse, position the pointer over the orange box and left click once. A window will open up allowing the user the ability to choose which input to calibrate. After choosing, follow the instructions in the calibration instruction box. At the end of the calibration procedure, the computer will supply a set of offset numbers. The user must take the offsets supplied and enter them into the offset boxes. For further detail, contact Atlas or your local sales representative. 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

57 4.3 Controller Pages Manual Control (F7) This page is activated from the MAIN MENU page. To activate it go to the MAIN MENU page, press the F7 key on the key board or, using the mouse, place the cursor over the MANUAL CONTROL box in the middle of the screen and left click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The password for this page is 2. Enter a 2 in the password box and, using the mouse, click on the OK button at upper right. The purpose of this screen is to allow the user to manually turn ON and OFF the cabinet devices. This screen CANNOT be activated while a test is being conducted. If a test is running, the user will have to wait until the test is complete or stop the test to activate this page. This page is particularly useful when troubleshooting. The user can turn on (activate) a device and verify the output. For example, if the cabinet heaters are activated, the user can verify heat. If the D.I. to Trap is turned on, water will enter the air trap assembly, and the input representing the Trap level switch will light as the water level fills. If the Trap Drain Solenoid is activated the water will drain, and the Trap level switch input will turn gray showing an empty position. 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

58 4.3 Controller Pages Manual Control (F7) (cont.) This page is much like the Current I/O Status page discussed earlier. The main difference is that on the Current I/O Status page the user could not turn devices ON or OFF, but only view the status of these devices. With this page, the user can actually turn the cabinet devices ON and OFF. Use the mouse to point it to one of the red switches and left click once on the switch. The switch will turn green. Move to the right and turn on the device chosen. Digital input status is shown at the right of the page, and analog input values are shown in the bottom section. 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

59 4.3 Controller Pages Review Maintenance (F8) This page is activated from the MAIN MENU page. To activate it go to the MAIN MENU page, press the F8 key on the key board or, using the mouse, place the cursor over the REVIEW MAINTENANCE box in the middle of the screen and left click once. The purpose of this page is to reset the reminders that will pop up on the Status box of the F2 ( Status of Current Test ) page of the controller. If one of the timers set in this section runs out of time, the message will be displayed on the F2 page. There are seven sections to this page. 1. Message number - this shows how many messages are programmed. 2. Maintenance Message this is the message that will be displayed. 3. Set Hours The number of hours that must elapse prior to the message being displayed. If the timer is reset, it will be reset to this number. 4. Hours remaining The number of hours that remain until the message will be displayed. 5. Active The status of this message; If the active button is green in color, it means the message will be displayed after the timer expires. If the active button is red, this message will be ignored. 6. Reset Click on this button to reset the timer. 7. Timed out If this section is green in color, then the timer has not expired. If it is orange, then the timer has expired. 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Doc. P/N Rev. 0

60 Review Maintenance (F8) (cont.) As an example, the timer for the Check/Change (if needed) the Salt Solution Filter has expired. To reset this timer, click on the yellow reset button next to this message. Once the timer is reset, the message will no longer be displayed on the F2 page and the counter will restart the count. Doc. P/N Rev. 0

61 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) This page is activated from the MAIN MENU page. To activate it go to the MAIN MENU page, press the F9 key on the key board or, using the mouse, place the cursor over the ADJUST MACHINE PARAMETERS box on the screen and left click once. This is a password-protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The password for this page is 3. Enter a 3 in the password box and, using the mouse, click on the OK button. The purpose of this screen is to allow the user to set certain parameters specific to the user s needs. These parameters will be set globally for all areas of the controller. See the next page for an overview of this page Doc. P/N Rev. 0

62 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Below is an overview of this entire page. There are many different sections on this page. Most of them will not require adjustments, but some will. 1. Alarm, Warning and message setup. 2. Timers and cycle feature setup. 3. account setup. 4. Edit tolerance setup 5. Edit test names 6. Edit PID parameters 7. Shut down Application. Each features is discussed on the following pages. Alarm, Warning and message setup. This is a list of the alarms, warning and messages that can appear on the F2 status screen message box. These messages will be data logged as directed. Each message can be set up to initiate any one of four different actions. 1. Full Alarm Actions taken include a. Pause the current test b. Activate alarm relay c. Display the message d. Datalog the message 2. Warning Alarm Actions taken include a. Activate alarm relay b. Display the message c. Datalog the message 3. Notification message 4. Disable Alarm Actions taken include Actions taken include; a. Display the message NONE b. Datalog the message Doc. P/N Rev. 0

63 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) To change the action, click on the arrow next to the message, and a drop down box will appear. Using the mouse, click on the desired action and the box will disappear, leaving the choice showing in the box next to the message. The definitions of these alarms are listed elsewhere in this manual. NOTE: The user may change any one of theses messages to any one of these actions. Careful attention must be given to these choices as very important safety alarms can be disabled. If an internet connection is available, there is also a section that allows the user to activate a particular message for notification. Click next to any message to be included in notification. Once an item is activated, a bright green button illuminates next to it. Any item that does not have a green button illuminated next to it will not be included in the notification. The notification system will be described in a following section. Doc. P/N Rev. 0

64 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Timers and cycle feature setup The right side top section of the page has a box as shown below. This is a list of various cabinet functions that can be set on a global basis for the equipment. These features are as follows; Blower Purge Time This is the time in seconds that the purge blower will remain on when the purge blower button is activated on page F2 (Status of Current Test). When the timer has elapsed, the blower will automatically turn off. This purge blower is used to evacuate fog from the cabinet prior to opening the cabinet cover. Mix Tank Sparger Time (optional feature) The is the time in seconds that the 60-gallon (227 liter) solution tank air sparger will remain on when the Mixer button is activated on page F2 (Status of Current Test). When time has elapsed, the mixer will turn off. There is also a similar timer for the optional immersion tank. Immersion Tank Sparger Time (optional feature) The is the time in seconds that the immersion solution tank air sparger will remain on when the Mixer button is activated on page F2 (Status of Current Test). When time has elapsed, the mixer will turn off. There is also a similar timer for the optional immersion tank. Passwords These four lines allow the user to reset the passwords for the pages that are password protected. The passwords listed above are the default passwords set at the factory. NOTE: If a user changes these passwords, it becomes the user s responsibility to remember them. Otherwise Atlas will have to reprogram the unit at the user s expense. Doc. P/N Rev. 0

65 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Power Loss Code - This Power Loss Code sets the activity of the controller if the electrical power is lost to the cabinet and then returns. The four choices are: 1. Continue cycle restart cycle when power returns. 2. Pause cycle pause the cycle when power returns. 3. Stop cycle stop the cycle when power returns. 4. Continues cycle for set time with this choice, the cycle will continue only if the power is off for less than the assigned timer. If the power is off longer than the assigned timer, then the cycle will stop. These features only stay active as long as the computer does not lose power. If the computer shuts off due to a power outage, then the test will be turned off. Salt to Tower Over Fill - This is the time in seconds that the internal fog reservoir will overfill with salt solution after the float switch has indicated a full condition. This allows for a slight overfill of solution so that the float switch and solenoid will not activate too often. If the pressure to the fog tower is low it may be beneficial to set this timer at one to three seconds. If the pressure to the fog tower is not low that is best to leave this time are set at zero. The factory preset for this number is normally zero. D.I. to Tower Over Fill - This is the time in seconds that the internal fog reservoir will overfill with D.I. water solution after the float switch has indicated a full condition. This allows for a slight overfill of solution so that the float switch and solenoid will not activate too often. If the pressure to the fog tower is low it may be beneficial to set this timer at one to three seconds. If the pressure to the fog tower is not low that is best to leave this time are set at zero. The factory preset for this number is normally zero. Solution No. 2 to Tower Over fill This feature is the same as the two described above. This is for solution coming from a remote reservoir and is an optional tank. Doc. P/N Rev. 0

66 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Controlled RH Dry Out Temperature This feature is used only during the controlled RH cycle. When controlled RH is running, and the actual relative humidity is higher than the set point, the controller will temporarily reassign the cabinet temperature set point to this number. This helps dry out the cabinet interior and lower the relative humidity. Once the relative humidity is at set point, the cabinet temperature will be reassigned to the original set point. The factory preset for this option is 60 C. Data Logging Interval in Minutes This setting is the number in minutes that defines how often data is written to the hard drive during the data logging feature. It is suggested that during diagnostic test runs this number be set low, for example to 1. However, to save hard drive space, and only collect data for test runs this number can be set higher. Cycle time or to pause when cycle is paused - When activated, this feature will pause the test cycle timer when the test is paused. When deactivated the cycle timer will continue to run while the cabinet is in a pause condition When Enabled the circle next to the label will be green in color. If Disabled, the circle will be dark in color. To Enable or Disable, simply use the mouse, position the cursor over the circle and left click once. This feature as well as the next five to be described all operate the same way. Enable Data Logging - When enabled, the Data Logging button will record all of the cabinet s parameters and conditions to the computer s hard drive while conducting a test. If Disabled then no data logging will take place. Manual Step Mode When enabled, the Manual Step Mode will allow the user to manually advance the automatic cycle from one step to the next, or advance the test condition by minutes. This feature allows the user to override the cycle timer and proceed to the next minute, or cycle step. This ability is particularly useful when troubleshooting a newly written test cycle. The F2 page will have two buttons for use with this feature. Doc. P/N Rev. 0

67 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Fixed dry out temperature during controlled humidity This setting will turn on and off the Controlled RH Dry Out temperature feature described above. When enabled, the RH cabinet temperature set point will be reset to dry out the cabinet. When disabled, the cycle programmed temperature set point will not be temporarily change. Elapsed cycle time vs. time and date cycles The computer controls has two methods of cycle programming and execution. A. First is a time elapsed method. Each cycle is set for a certain number of minutes, and once the time for a step has expired, the next step is executed. B. Second is a time of day and day of week method. Under this control, the cycle run will be determined by the date and time on the computer. This feature button allows the user to decide which method will be used. When enabled, the controller will use the time elapsed method (most commonly used). Temperature to be displayed in Fahrenheit The standard unit of temperature measurement used by the computer control system is degrees Celsius. With the enabling of this feature, the computer will use and display temperatures in degrees Fahrenheit. NOTE: The controller will not automatically convert the numbers for temperature set point in the programmed test. If this feature is enabled, the user should reprogram the test set points in Fahrenheit. Doc. P/N Rev. 0

68 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) account setup If the computer for the controls is connected and logged into a company ethernet system with capabilities, than this feature can be used. Click on the Click to Edit Account button on the bottom of the F9 page. This action will open another window that allows for account setup. In this window, the user must set up: 1. server address 2. To: address 3. From: address 4. Subject Line 5. Message Additionally, the interval at which repeat s are to be sent can be set up. Your company IT department should have all of this information. If one of the fault conditions listed on the F9 page (that has activation enabled) were to trip, then an will be sent with the information typed above, and the text for that fault or message. Doc. P/N Rev. 0

69 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Edit tolerance setup This control system allows for the use of time and tolerance based analog input signal monitoring. Click on the Click to Edit tolerances button on the bottom if the F9 page to open this feature. This action will open another window that allows for tolerance editing. Each analog sensor can have a setting for maximum variation from set point. If the input varies for more than the time allotted, an action will be performed. That action is set up on the Alarm, Warning and Message setup screen of the F9 page already covered in this manual. In addition, there are low and high limit settings for certain analog signals. If the input varies for more than the time allotted, then an action will be taken. That action is set up on the Alarm, Warning and message setup screen of the F9 page already covered in this manual. If the optional RTD # 5, 6, 7 and 8 are purchased, a maximum variation between these temperature settings can be monitored. The factory settings for all of these items are set up so that none of them activate. If operation of this feature is desired, the user must set lower tolerance values. Doc. P/N Rev. 0

70 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Edit test names This feature allows users to change any of the names assigned to test programs. Click on the Click to Edit Test Names button on the bottom if the F9 page to open this feature. This action will open another window that allows for test name editing. This page that will display all of the current names assigned to the test profiles. There are a total of 40 tests available for computer controls, 20 for timer based programming, and 20 for date based. There are several tests preprogrammed at the factory. Any of these names can be changed. To change the name of Custom 1, use the mouse and place the cursor in the box that displays Custom 1. Use the backspace key to erase the Custom 1 name. Using the keyboard, type in the new name desired. Additionally, the names of optional user outputs 1-4 and RTDs 5-8 can be labeled on this page. The label assigned will be used throughout this controller making it easy for the user to identify items specific to their industry. To return back to the Adjust Machine Parameters page, use the mouse and click on the blue RETURN button. If changes were made to any of the labels on this page, a dialog box will open prompting the user to either save the change or cancel it. Use the mouse to click on the desired choice. Doc. P/N Rev. 0

71 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Edit PID parameters This control system allows for the user to change the PID settings for the temperature and humidity control loops. Click on the Click to Edit PID Parameters button on the bottom if the F9 page to open this feature. There are four possible choices for temperature and humidity control loops. This action will open another window that allows for test name editing. This screen is used to adjust the temperature or humidity control for the different control loops. Careful attention must be used when changing this page as wrong numbers can cause the equipment to never achieve set point, always overshoot set point and everything in between. CAUTION: PID is a very complicated formula that controls the way a device reaches a set point. If the user is not familiar with PID and would like a further explanation, it is suggested that a PID controls manual be purchased and studied. All of the PID settings are adjusted at the factory prior to shipping. If the cabinet is unable to reach or maintain temperature or humidity set points, these PID settings may have been changed. Cabinet loading and lab conditions can effect how a cabinet reaches set point. Doc. P/N Rev. 0

72 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Adjust Machine Parameters (F9) (cont.) Computer Controls Shutdown Procedure 1. From the main menu, click on the F9 button, or press F9 on the keyboard 2. Once prompted for a password, enter 3 and click on OK. 3. The control code should now be on the F9 page and the display should appear shown.. 4. To shut down the computer controls software, click on the round button labeled Shut Down Application. 5. Wait for the computer control code to shut down. The code will then appear in a box such as the following. Click on the FILE label on the top left corner of the screen. Next, click on EXIT. This will shut down the software completely. Doc. P/N Rev. 0

73 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Program Test Specifications (F10) This page is activated from the MAIN MENU page. To activate it go to the MAIN MENU page, press the F10 key on the key board or, using the mouse, place the cursor over the PROGRAM TEST SPECIFICATIONS box on the left side of the screen and left click once. This is a password protected page of the controller. Prior to opening the page, the user must use the keyboard to enter in the correct password, and press OK on the password window. The password for this page is 1. Enter a 1 in the password box and, using the mouse, click on the OK button. The purpose of this screen is to allow the user to review, change or create a test profile used during automatic mode. There are a total of 20 test profiles displayed here, each being up to 100 steps long. See the next page for an overview of this page Doc. P/N Rev. 0

74 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Program Test Specifications (F10) (cont.) This is the Program Test Specifications page. There are several sections to this page. First, select the test to view, change or create. Position the cursor over the desired test name and left click once. This will select a test. The blue-green strip represents the step number for the chosen test. The first 27 steps are shown in this main screen. To view steps use the mouse and scroll bar to move the test parameters into view. When programming a test, there are several conditions the cabinet can achieve if the cabinet was set up for them. For the purpose of this manual, it will be assumed that all conditions are available, as shown at right. Doc. P/N Rev. 0

75 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Program Test Specifications (F10) (cont.) Some conditions are exclusive of one another, and some can be combined. This first section is exclusive, meaning that only one condition from this list can be activated per step. In this graphic, step one has salt fog chosen as the desired test condition for this step. Below is a description of each test condition. SALT FOG Atomization of the solution in the 60-gallon (227 liter) solution tank using the fogging tower(s). DRY CYCLE Activates the cabinet s purge blower and heater to dry the exposure zone. HIGH HUMIDITY Atomization of D.I. water using the fogging tower(s), creating a % condensing humidity. WET BOTTOM RH Fills the bottom of the exposure zone of the cabinet with D.I. water and heats it using the cabinet heater. This creates a % nonfogging condensing humidity. CONTROLLED RH Uses the cabinets heaters, blower, and fogging tower(s) to control the RH between 30 95%, +/- 5%. IMMERSION FILL Moves solution from the immersion holding tank into the cabinet exposure zone. IMMERSION DRAIN Moves the immersion solution from the cabinet exposure zone back to the immersion holding tank. COLD Activates the optional remote conditioner for sub zero temperatures. AMBIENT Opens the cabinet cover (if automated cover lifters were installed) to expose the parts being tested to ambient lab conditions. CUSTOM CYCLE No action is taken with this condition, however, since a condition must be selected in this section in order to activate the other sections, this can be selected to activate the other sections. FOG #2 HUMIDITY Atomization of the solution in an optional second 60-gallon (227 liter) solution tank using the fogging tower(s). 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

76 4.3 Controller Pages Program Test Specifications (F10) (cont.) The conditions in orange and rose can be selected in conjunction with others after one condition is selected in the first set. SPRAY PUMP Uses a magnetic drive (or similar) pump to pull solution from the 60-gallon (227 liter) reservoir and push it into the spray bar header for direct spray impingement onto the test specimens. TIME IN SEC. This changes the timer for a specific step from minutes to seconds. IMM (immersion) HOLD SOAK USER OUTPUT 1-4 CHAM HOLD SOAK CHAM RAMP SOAK RH RAMP SOAK Holds the cabinet at a specific step in the cycle even if the step time has elapsed until the programmed immersion tank temperature setpoint has been attained. Activates an output on the control I/O during that step. The user can connect a device to that output and have the device activated during any specified step. User output #1 is installed as standard equipment. User outputs 2, 3 and 4 are optional and will not be installed unless purchased. Holds the cabinet at a specific step in the cycle even if the step time has elapsed until the programmed cabinet exposure zone temperature set-point has been attained. Meters the power to the cabinet heaters so that the exposure zone temperature set-point is achieved at the end of the step time. Meters the humidification and dehumidification system so that the exposure zone RH set-point is achieved at the end of the step time. 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

77 4.3 Controller Pages Program Test Specifications (F10) (cont.) After the test conditions are chosen for each step, values for temperatures, relative humidity and looping must be set. To the right is an example of set points for these conditions. If certain cells are left blank, the controller may ignore that parameter. STEP TIME CABINET TEMP. SET PT BUBBLE TOWER SET PT RH SET PT IMM TANK SET PT LOOP TO STEP NUMBER OF LOOPS This is the time that this step will be run, in minutes. If it is left blank, the controller will run the next step. All 100 steps will be run by the controller. The temperature in degrees C that the cabinet s exposure zone will attain during a given step. The temperature in degrees C that the cabinet s bubble tower will attain during a given step. It is recommended to use 41 o C for any step that does not call for salt fog or high humidity. This will keep the bubble tower warm. The percent RH that the cabinet s exposure zone will attain during a given step. The controller will only run this condition if CONTROLLED RH is chosen in the first set of conditions. The temperature in degrees C that the cabinet s immersion solution holding tank zone will attain during a given step. The next step the controller will go to after completing the current step. If this is left blank, or has a 0 in it, the controller will go to the next step. The number of times the controller will repeat the programmed loop for a given step. 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

78 4.3 Controller Pages Program Test Specifications (F10) (cont.) The best way to learn this cabinet programming page is to experiment. Below is an example of a programmed test cycle using the timer based programming option. Notice that as a condition is chosen, the button will light up indicating that it is activated for that step. When all of the desired changes have been made to a test, save it by clicking on the Save Changes button. The computer will ask if the file should be replaced. The file MUST be replaced to save the changes. PRACTICE ONLY! MAKE SURE TO CHANGE THE SETTING BACK TO ITS ORIGINAL VALUE. Doc. P/N Rev. 0

79 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Program Test Specifications (F10) (cont.) Below is an example of a programmed test cycle using the time of day and day of week based programming option. Note the following. 1. There is no looping on this type of programming, the controller simply looks to see what day it is and what time it is, and then executes that test condition. 2. The timers are set in military time. 3. A test condition will stay in a particular step until a new step is identifies. For example, if you start a salt fog step at 12:00.01 on Sunday morning, and set up a dry step on Monday at 2:45 PM, then salt fog will run that entire time until the new step starts. If you start this test up on Monday morning at 8:00 AM, it will perform a salt fog until 2:45 PM when it moves to dry. Use the Return button to go back to the MAIN MENU page when programming is complete. Doc. P/N Rev. 0

80 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Data Logging File PURPOSE: The purpose of this file is to document how the cabinet performed during a test. LOCATION: If the Data Logging feature of the computer controls is activated (see F9 screen) then the controller will create a data-file for every new test started in the automatic mode. By default, these files are saved in a sub-directory of the C hard drive of the computer: C:\Test Directory\Data Log. These files can be saved in other areas of the hard drive, or across a network if the user chooses a new location when prompted. It is not recommended to save the datafile to the computer s diskette drive (A: drive) because constant use will shorten the life of its mechanical components. The name of the file can be assigned by the user. If the user does not assign a file name the computer will assign one based on the computer s time and date. The file extension ends with.txt. Although the file is a simple text file, it is formatted in such a way to make the data easy to use in a standard spreadsheet program such as Microsoft Excel. This file can also be opened in a word processor program such as Microsoft Notepad, Wordpad or Word. The difficulty with opening the file in a word processor is that all the data in the file will not align correctly like it will in a spreadsheet program. Additionally, in a spreadsheet program, the data is easily graphed and manipulated. If the datalogged file must be moved to another computer, there are two methods to do so. The best way, in terms of file size that can be transferred, is via a Local Area Network, or LAN, which allows direct copying of files between directories/folders from one computer to another. If the laptop is not connected to a LAN, the datalogged file must be copied to a 3.5 diskette. Therefore, consideration must be given to the interval at which data is saved, which can be as often as every minute. When saving data to a file every minute, it will reach one megabyte in size after 3-4 days. If data is saved less frequently (such as every three or four minutes) it will take longer to reach maximum diskette transfer size. (see Function on next page) 4.0 OPERATION COMPUTER CONTROLS Doc. P/N Rev. 0

81 4.3 Controller Pages Data Logging File (cont.) FUNCTION: The easiest way make use of these data files is with Microsoft Excel. Open Excel, select FILE, and OPEN. Choose the directory in which the file is located. Additionally, on the lower left side of this window, select ALL FILES. Next, select the name of the file that is to be opened. Then, click on the OPEN button. When the OPEN button is activated a TEXT IMPORT WIZARD window will open. There is no need to complete all three steps of the process. Click on the FINISH button to complete the import of this data file. Doc. P/N Rev. 0

82 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Data Logging File (cont.) Imported data will be displayed like any other spread sheet. There are five sections in this data file. 1. File information reports the software version, file name, test number and name. 2. Calibration Array documents the calibration settings for the cabinet at the time this test was started. 3. PID parameters the PID parameters determine how the controller ramps temperature and humidity. 4. Test Profile documents the profile settings that were used for the test. These settings are the test condition, the time of each step, the setpoints for tempera-ture/humidity, and any looping functions. The user can review the test profile that was running at the time this datafile was generated. The first three columns are dedicated to the actual events that are running in the test profile. The numbers in these columns correspond to an actual test condition. For example, a number 1 in the Exclusive Event column means that a SALT FOG condition was running during this step in the cycle. These numbers can be added together in the Non-exclusive section to combine test functions. For example, to run a spray cycle in seconds, add and the result of 3 will signify this combination. The table below lists the event code numbers associated with each test condition. When looking at a data file, use this key to determine how a test profile was programmed. Exclusive Hold/Ramp soak Event Code # Description Event Code # Description 1 Salt Fog 1 Cabinet Hold Soak 2 Dry Cycle 2 Cabinet Ramp Soak 4 Fog Humidity 8 Wet Bottom RH 16 Controlled RH Non-exclusive 32 Immersion Fill Event Code # Description 64 Drain to Tank 1 Spray Pump 128 Drain to Waste 2 Time in Seconds 256 Ambient 4 Immersion Hold Soak 512 Custom Cycle 8 User Output Doc. P/N Rev. 0

83 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Data Logging File (cont.) 5. Test Data actual test parameter outputs. In this section, each row is one data point, and each column is a parameter, such as Cabinet set point, Cabinet actual temperature, and so on. Since the interval for recording data is set by the user, each row will reflect that interval. In this example, data is recorded every minute. 1. DATE - date this data point was written 2. TIME - time that this data point was written 3. CHAM TEMP - actual cabinet temperature 4. CHAM S P - cabinet temperature set point. 5. BT TEMP - bubble tower actual temperature 6. BT S P - Bubble tower set point 7. LAB TEMP - laboratory temperature. 8. RH - relative humidity reading (optional) 9. RH S P - relative humidity set point (optional) 10. BT OUT PRES - bubble tower output pressure 11. IMM TEMP - immersion reservoir temperature (optional) 12. IMM S P - immersion reservoir set point (optional) 13. WET BULB TEMP - wet bulb temperature, actual (optional) 14. JACKET TEMP - air jacket temperature, actual (optional) 15. RTD #7 - actual temperature for RTD #7 (optional) 16. RTD #8 - actual temperature for RTD #8 (optional) 17. BT IN PRES - bubble tower temperature input pressure (optional) 18. BT FLOW - air flow for compressed air into the bubble tower (optional) 19. TEST NAME & STATUS - name of the test being run, and the status of this test 20. CURRENT STEP - the current step number of the test that is being run 21. NEXT STEP - the number of the next step to be run in the test profile 22. STEP TIME - length of time for which this step is set to be run 23. TIME REMAIN - the length of time that is left to run for this step 24. FAULT STATUS - message showing any fault at the time of the data point 25. NOTE PAD - any note that the user typed into the graphing page 26. EVENT - the condition (i.e. salt fog, dry, etc.) that was running during this data point 27. GOTO STEP - the next step that is to be performed after the current one. 0 means that it will advance to the next step. 28. TOTAL LOOPS - the number of loops this step is to be repeated INPUTS - the position (1=ON, 0=OFF) of inputs number INPUTS - the position (1=ON, 0=OFF) of inputs number INPUTS - the position (1=ON, 0=OFF) of inputs number OUTPUTS - the position (1=ON, 0=OFF) of outputs number OUTPUTS - the position (1=ON, 0=OFF) of outputs number OUTPUTS - the position (1=ON, 0=OFF) of outputs number OUTPUTS - the position (1=ON, 0=OFF) of outputs number Doc. P/N Rev. 0

84 4.0 OPERATION COMPUTER CONTROLS 4.3 Controller Pages Data Logging File (cont.) NOTE: not all cabinets have all of the inputs or all of the outputs. This is dependent on the options purchased with the cabinet. Using input and output positions listed in items can be quite useful in determining what the cabinet was doing at the time of the data point. However, since Excel sees this data as a whole number, it will not display leading zeros when it imports the data. To correct this, these eight columns must be reformatted. To reformat these columns, perform the following steps: a. Select columns AC, AD, (directions for AE below), AF, AG, AH and AI by holding down the CTRL key and clicking on the top of these columns. b. Next click on FORMAT, then CELLS, and a window will open. c. Click on CUSTOM and GENERAL will be displayed in the Type window. d. Overwrite the GENERAL setting with 8 zeros; and then click OK. Repeat steps a-d replacing the columns selected with AE, and replace the GENERAL settings with only 4 zeros After all changes are made click on Save and change the file type to EXCEL WORKBOOK. The following two pages show the I/O key to use for deciphering the positions of the inputs and outputs on the data file. Doc. P/N Rev. 0

85 5.0 PREPROGRAMMED TESTS 5.1 Preprogrammed Tests (Standard Controls) CCX - ASTM B117 Interval Description Time Temp. Code 1 Salt Fog 1440 minutes 35 o C 1 Repeat this step for the desired number of cycles (default is 42). Bubble Tower Temperature set point #1 = 48 o C Bubble Tower Temperature set point #2 = 63 o C Bubble Tower Temperature set point #3 = 41 o C (for all Salt Fog cycles) (for all High Humidity cycles) (for all other cycles) Description Event Code Salt Fog 1 High Humidity (fogging) 2 Dry Cycle / purge 4 Solution Spray 8 Set Current Step In Seconds 16 Salt Fog + Timer In Seconds 17 High Humidity + timer in seconds 18 Dry cycle + timer in seconds 20 Solution Spray + timer in seconds 24 Guaranteed Soak 32 Dry cycle + Guaranteed Soak 36 Cover Open - Ambient 64 Cover Open + timer in seconds 80 User output ON 128 Salt Fog + user output ON 129 High Humidity + user output ON 130 Dry Cycle + user output ON 132 Solution Spray + user output ON 134 User output ON + timer in seconds 144 Dry Cycle + user output ON + timer in seconds 148 Solution Spray + user output ON + timer in seconds 150 Cover Open + user output ON 192 Cover Open + user output ON + timer in seconds 208 Doc. P/N Rev. 0

86 5.0 PREPROGRAMMED TESTS 5.1 Preprogrammed Tests (Standard Controls) (cont.) CCX - CCT-I Interval Description Time Temp. Code 1 Salt Fog 240 minutes 35 o C 1 2 Dry 120 minutes 60 o C 4 3 Humidity 120 minutes 50 o C 2 Repeat these 3 steps for the desired number of cycles (default is 10). Bubble Tower Temperature set point #1 = 48 o C Bubble Tower Temperature set point #2 = 63 o C Bubble Tower Temperature set point #3 = 41 o C (for all Salt Fog cycles) (for all High Humidity cycles) (for all other cycles) Description Event Code Salt Fog 1 High Humidity (fogging) 2 Dry Cycle / purge 4 Solution Spray 8 Set Current Step In Seconds 16 Salt Fog + Timer In Seconds 17 High Humidity + timer in seconds 18 Dry cycle + timer in seconds 20 Solution Spray + timer in seconds 24 Guaranteed Soak 32 Dry cycle + Guaranteed Soak 36 Cover Open - Ambient 64 Cover Open + timer in seconds 80 User output ON 128 Salt Fog + user output ON 129 High Humidity + user output ON 130 Dry Cycle + user output ON 132 Solution Spray + user output ON 134 User output ON + timer in seconds 144 Dry Cycle + user output ON + timer in seconds 148 Solution Spray + user output ON + timer in seconds 150 Cover Open + user output ON 192 Cover Open + user output ON + timer in seconds 208 Doc. P/N Rev. 0

87 5.0 PREPROGRAMMED TESTS 5.1 Preprogrammed Tests (Standard Controls) (cont.) CCX CCT-IV Interval Description Time Temp. Code 1 Salt Fog 10 minutes 35 o C 1 2 Dry 155 minutes 60 o C 4 3 Humidity 75 minutes 50 o C 2 4 Dry 160 minutes 60 o C 4 5 Humidity 80 minutes 50 o C 2 LOOP # 1 Repeat steps 5 to 4 five times LOOP #2 Repeat steps 4 to 1 ten times Bubble Tower Temperature set point #1 = 48 o C Bubble Tower Temperature set point #2 = 63 o C Bubble Tower Temperature set point #3 = 41 o C (for all Salt Fog cycles) (for all High Humidity cycles) (for all other cycles) Description Event Code Salt Fog 1 High Humidity (fogging) 2 Dry Cycle / purge 4 Solution Spray 8 Set Current Step In Seconds 16 Salt Fog + Timer In Seconds 17 High Humidity + timer in seconds 18 Dry cycle + timer in seconds 20 Solution Spray + timer in seconds 24 Guaranteed Soak 32 Dry cycle + Guaranteed Soak 36 Cover Open - Ambient 64 Cover Open + timer in seconds 80 User output ON 128 Salt Fog + user output ON 129 High Humidity + user output ON 130 Dry Cycle + user output ON 132 Solution Spray + user output ON 134 User output ON + timer in seconds 144 Dry Cycle + user output ON + timer in seconds 148 Solution Spray + user output ON + timer in seconds 150 Cover Open + user output ON 192 Cover Open + user output ON + timer in seconds 208 Doc. P/N Rev. 0

88 5.0 PREPROGRAMMED TESTS 5.1 Preprogrammed Tests (Standard Controls) (cont.) CCX - ASTM G85 Annex 5 Interval Description Time Temp. Code 1 Salt Fog 60 minutes 25 o C 1 2 Dry 60 minutes 35 o C 4 Repeat these 2 steps for the desired number of cycles (default is 84). Bubble Tower Temperature set point #1 = 48 o C Bubble Tower Temperature set point #2 = 63 o C Bubble Tower Temperature set point #3 = 41 o C (for all Salt Fog cycles) (for all High Humidity cycles) (for all other cycles) Description Event Code Salt Fog 1 High Humidity (fogging) 2 Dry Cycle / purge 4 Solution Spray 8 Set Current Step In Seconds 16 Salt Fog + Timer In Seconds 17 High Humidity + timer in seconds 18 Dry cycle + timer in seconds 20 Solution Spray + timer in seconds 24 Guaranteed Soak 32 Dry cycle + Guaranteed Soak 36 Cover Open - Ambient 64 Cover Open + timer in seconds 80 User output ON 128 Salt Fog + user output ON 129 High Humidity + user output ON 130 Dry Cycle + user output ON 132 Solution Spray + user output ON 134 User output ON + timer in seconds 144 Dry Cycle + user output ON + timer in seconds 148 Solution Spray + user output ON + timer in seconds 150 Cover Open + user output ON 192 Cover Open + user output ON + timer in seconds 208 Doc. P/N Rev. 0

89 5.0 PREPROGRAMMED TESTS 5.1 Preprogrammed Tests (Standard Controls) (cont.) CCX - GM9540P Interval Description Time Temp. Code 1 Salt Mist Cycle 1 min. 23 o C +/ Ambient Soak 89 min. 23 o C +/ Salt Mist Cycle 1 min. 23 o C +/ Ambient Soak 89 min. 23 o C +/ Salt Mist Cycle 1 min. 23 o C +/ Ambient Soak 89 min. 23 o C +/ Salt Mist Cycle 1 min. 23 o C +/ Ambient Soak 209 min. 23 o C +/ Humidity Cycle 480 min. 49 o C +/ Ramp to Dry 90 min. 60 o C +/ Dry Cycle 390 min. 60 o C +/-3 4 Repeat these 11 steps for the desired number of cycles (default is 10). Bubble Tower Temperature set point #1 = 48 o C Bubble Tower Temperature set point #2 = 63 o C Bubble Tower Temperature set point #3 = 41 o C (for all Salt Fog cycles) (for all High Humidity cycles) (for all other cycles) Description Event Code Salt Fog Cycle 1 High Humidity Cycle (100%) 2 Dry Cycle (low RH) or Purge 4 Solution Spray 8 Set current Step to Seconds (not minutes) 16 Guaranteed Soak ON 32 Cover Open / Close 64 User Output NOTE: In order to meet this test properly, General Motors requires that the Automated Air cover lifters be used to open the cover during the ambient states to allow the lab ambient conditions dry out the parts being tested. Doc. P/N Rev. 0

90 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) CCX - ASTM B117 Doc. P/N Rev. 0

91 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX - ASTM G85 A5 Doc. P/N Rev. 0

92 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX CCT-I Doc. P/N Rev. 0

93 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX CCT-IV Doc. P/N Rev. 0

94 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX GM9540P NOTE: In order to meet this test properly, General Motors requires that the Automated Air cover lifters be used to open the cover during the ambient states to allow the lab ambient conditions dry out the parts being tested. Doc. P/N Rev. 0

95 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX SAE J2334 Doc. P/N Rev. 0

96 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX ASTM D1735 Doc. P/N Rev. 0

97 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX MCT-1M Doc. P/N Rev. 0

98 5.0 PREPROGRAMMED TESTS 5.2 Preprogrammed Tests (Computer Controls) (cont.) CCX MCT-2M Doc. P/N Rev. 0