Atlas BCX Series User manual

BCX Series Operating Manual Page 1
Table of Contents Rev. 4.70 AMTT Oct04
I. INTRODUCTORY NOTES..............................................................................................................5
A. Preface_________________________________________________________________________________ 5
B. Manual Conventions, Notes________________________________________________________________ 5
II. BCX SERIES OVERVIEW.............................................................................................................6
A. BCX Characteristics ______________________________________________________________________ 6
B. BCX Construction & Specifications _________________________________________________________ 6
III. SAFETY INSTRUCTIONS............................................................................................................7
A. Please follow safety instructions and precautions_____________________________________________ 7
IV. GENERAL CABINET & CYCLING OVERVIEW .......................................................................... 8
A. Salt Fog Step____________________________________________________________________________ 8
B. Dwell Step ______________________________________________________________________________ 8
V. LOCATION & SITE PREPARATION ............................................................................................9
A. Unloading the BCX: Material handling Caution________________________________________________ 9
B. Site selection & Preparation _______________________________________________________________ 9
VI. INSTALLATION & REQUIREMENTS........................................................................................ 10
A. Drain Connection (Customer supplied & installed) ___________________________________________ 10
B. Vent Connection________________________________________________________________________ 11
C. Compressed Air Connection______________________________________________________________ 11
D. Water Supply Requirements and Connection ________________________________________________ 12
E. Solution Reservoir overflow ______________________________________________________________ 12
F. Electrical Connection ____________________________________________________________________ 12
G. Level Floor ____________________________________________________________________________ 13
H. Location_______________________________________________________________________________ 13
I. Utility Services Testing___________________________________________________________________ 13
J. Lab Temperature and Humidity ____________________________________________________________ 13
K. Component Valves ______________________________________________________________________ 14
L. Solenoid Valve Assignments______________________________________________________________ 15
VII. BCX SERIES COMPONENTS .................................................................................................. 16
A. Controller: OMRON _____________________________________________________________________ 16
B. Purge _________________________________________________________________________________ 16
C. cabinet Heater/s ________________________________________________________________________ 16
D. Bubble Tower __________________________________________________________________________ 16
E. Internal Salt Solution Reservoir ___________________________________________________________ 17
F. Fog Nozzle _____________________________________________________________________________ 17
G. Dispersion Tower/s _____________________________________________________________________ 17
H. Diffuser _______________________________________________________________________________ 18
I. Solution Transfer Pump __________________________________________________________________ 18
VIII. RUNNING THE CABINET........................................................................................................ 19
Bubble Tower _____________________________________________________________________________ 20
Air Relief Valve (on the Bubble Tower) ________________________________________________________ 20
Standard Omron Controls - Temperature Setting________________________________________________ 21
Cycling Control Package____________________________________________________________________ 22
A. Introduction to Operating the PLC through the VCU __________________________________________ 23
B. Controller Overview _____________________________________________________________________ 25
C. Auto __________________________________________________________________________________ 27
D. Display Cycle Status ____________________________________________________________________ 28

Page 2 BCX Series Operating Manual
E. Profile Set-Up __________________________________________________________________________ 35
F. Manual ________________________________________________________________________________ 42
F. Machine Set-Up_________________________________________________________________________ 44
G. Password______________________________________________________________________________ 48
H. Display Setup __________________________________________________________________________ 52
I. Calibration _____________________________________________________________________________ 54
J. Control Buttons_________________________________________________________________________ 56
IX. ADVANCED OPERATION – COMPUTER CONTROLS.......................................................... 59
Introduction to operating the computer________________________________________________________ 59
Main Menu________________________________________________________________________________ 62
F1: select a test to run _____________________________________________________________________ 63
F2: status of current test ___________________________________________________________________ 65
F3: current test data _______________________________________________________________________ 73
F4: current I/O status ______________________________________________________________________ 77
F5: historical test data _____________________________________________________________________ 78
F6: calibration of cabinet ___________________________________________________________________ 79
F7: manual control ________________________________________________________________________ 81
F9: adjust machine parameters ______________________________________________________________ 83
F10: Program Test Specifications ____________________________________________________________ 89
X. OPERATING INSTRUCTIONS.................................................................................................. 101
A Salt Spray _____________________________________________________________________________ 101
B End-Of-Test Procedure __________________________________________________________________ 102
XI. SAMPLE RECOMMENDATIONS, USE OF RACKS, MOUNTS.............................................. 103
XII. FOG COLLECTION PROCESS & PROCEDURES ................................................................ 104
A. Fog Dispersion Control and Controls _____________________________________________________ 104
B. Determining & Measuring Collection Rates_________________________________________________ 105
XIII. TEST METHODOLOGY & SPECIFICATIONS....................................................................... 105
XIV. MAINTENANCE..................................................................................................................... 106
A. Check Before Each and Every Test: The Rule of Three_______________________________________ 106
B. Routine mounthly Maintenance __________________________________________________________ 106
C. Annual Service ________________________________________________________________________ 108
D. Calibration____________________________________________________________________________ 109
XV. TROUBLESHOOTING, NOTES.............................................................................................. 110
A. General_______________________________________________________________________________ 110
B. Special Note on Solution Purity: filter, fog nozzle ___________________________________________ 110
C. Troubleshooting Contents_______________________________________________________________ 110
D. No Fog _______________________________________________________________________________ 111
E. Low Collection Rates ___________________________________________________________________ 111
F. High Collection Rates___________________________________________________________________ 111
G. Uneven Collection Rates ________________________________________________________________ 112
H. Low Relative Humidity __________________________________________________________________ 112
I. No Heat in Bubble Tower ________________________________________________________________ 112
J. Cover Bounces ________________________________________________________________________ 113
K. Cloudy Bubble Tower___________________________________________________________________ 113
L. Incorrect pH level ______________________________________________________________________ 113
M. Inconsistent Air Pressure in Bubble Tower_________________________________________________ 113
N. Bubble Tower Fills with Water over the Float Switch_________________________________________ 114
O. Salt Settles in Bottom of Salt Solution Reservoir____________________________________________ 114
XVI. WARRANTY INFORMATION & SERVICE............................................................................ 115

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

Page 4 BCX Series Operating Manual
Other Lab Testing Cabinets available from Atlas Material Testing Technology LLC and its authorized
global representatives:
SF – Traditional Salt Fog (Spray) Cabinets SF-Walk-in/Drive-in – for oversized samples
CCX - Advanced Cyclic Cabinet Modified CCX – with pass-through
mechanical/electrical ports
SRC100 – variable pressure Spray/Rain Chamber

BCX Series Operating Manual Page 5
I. INTRODUCTORY NOTES
A. PREFACE
Thank you for selecting an ATLAS lab corrosion test cabinet. Our success is measured,
first, by your selection of a cabinet that is manufactured to our Total Quality standards
and, second, by your continued satisfaction. Our commitment to total quality extends
beyond manufacturing, and continues well into your future. If you have comments or
suggestions regarding any aspect of the design, operation, or maintenance of our
equipment, or this operation manual, please contact Atlas Material Testing Technology [
[email protected] ] or your authorized Atlas representative. Please mention the
Revision #, found at the upper right of Page 1.
Please read the following installation and operating instructions in their entirety before
beginning. This manual covers installation, operation, maintenance, calibration and
trouble-shooting of the BCX cabinet. When questions arise that are not answered by the
manual, please contact Atlas or your authorized Atlas representative. Electrical,
plumbing and layout drawings are shipped with each cabinet.
During shipping, storage, and installation the BCX may collect dust, dirt, or other debris.
If this occurs, clean the inside of the BCX thoroughly with a mild, non-abrasive cleanser
and thoroughly rinse with distilled or deionized water prior to use.
Since this unit can be used to perform many different tests, always refer to the particular
test specification for temperature settings and other guidelines. Familiarity with the test
specification(s), as well as cabinet operation, will make installation and operation of the
unit easier. In the event of conflict, the test specification supersedes this manual. Also,
we recommend operating the cabinet for 24 hours to adjust and monitor collection rates
before running an actual test.
If the BCX has not yet been delivered, please note the material handling caution noted
in Section V, which also applies at any time the cabinet is moved.
Please keep in touch with ATLAS regarding upgrades, desired options, or other testing
needs. We will also maintain regular contact, and we wish many years of accurate,
dependable testing.
B. MANUAL CONVENTIONS, NOTES
The end of a section is noted by this symbol: [ ]
This manual is written and published by Atlas Material Testing Technology LLC under
license. All rights reserved by the copyright owner. Nothing herein can be reproduced
in any form by anyone other than direct ATLAS customers for internal use in
operating or maintaining this equipment. Trademarks or trade names used in the
manual remain the property of their respective owners. 

Page 6 BCX Series Operating Manual
II. BCX SERIES OVERVIEW
A. BCX CABINET CHARACTERISTICS
• Durable, all plastic construction • Automated fill on Bubble Tower
• Built-in Solution Reservoir • Front access to all cabinet components
• Temperature with Wet Bulb & Dry
Bulb display
• Translucent cover (excluding BCX9000
and BCX11000
B. BCX CABINET CONSTRUCTION & SPECIFICATIONS
ATLAS manufactures the BCX cabinet using advanced fiberglass, providing high corro-
sion resistance. State of the art techniques ensure longevity and strength. This cabinet
will not rust from corrosive solutions that are used in many testing processes. ATLAS’
all plastic design provides a “natural” insulation that helps make testing conditions
consistent, repeatable, and controlled. The dual magnetic cover seal (BCX9000 has a
water seal) and proper ventilation keeps fog inside the cabinet.
BCX2000 BCX3000 BCX4000 BCX9000 BCX11000
Internal *
Capacity 565 litres 20 ft3850 litres
30 ft31130 litres 40 ft32548 litres 90 ft33115 litres 110 ft3
Test Space *
Testing Plane 0.91 m2 9.81 ft21.37 m2 14.71 ft21.77 m2 19.01 ft22.21 m2 22.06 ft24.21 m2 45.4 ft2
Internal *
Dimension
1270 mm L (50”)
717 mm W (28.25”)
641 mm H (25.25”)
1905 mm L (75”)
717 mm W (28.25”)
641 mm H (25.25”)
1905 mm L (75”)
927 mm W (36.5”)
641 mm H (25.25”)
1930 mm L (76”)
1143 mm W (45”)
1155 mm H (45.5”)
2267 mm L (89.25”)
1860 mm W 73.25”)
762 mm H (30”)
Total cabinet
Volume** 982.5 litres 34.7 ft31,472.5 litres
52.0 ft31,925.5 litres 68.1 ft33,822 litres 135 ft34870 litres 172 ft3
External
Dimensions.
1930 mm L (76”)
889 mm W (35”)
1422 mm H (56”)
2565 mm L (101”)
889 mm W (35”)
1422 mm H (56”)
2565 mm L (101”)
1118 mm W (44”)
1422 mm H (56”)
2692 mm L (106”)
1321 mm W (52”)
2159 mm H (85”)
2820 mm L (111”)
2286 mm W (90”)
1829 mm H (72”)
Floor Space,
incl. Operator
Access
2032 mm L (80”)
2057 mm W (81”) 2667 mm L (105”) 2057 mm W (81”) 2667 mm L (105”) 2286 mm W (90”) 2794 mm L (110”) 2540 mm W (100”) 3099 mm L (122”) 3912 mm W (154”)
Solution
Reservoir 132 litres / 35 gallons 132 litres / 35 gallons 132 litres / 35 gallons 132 litres / 35 gallons 132 litres / 35 gallons
* The inside dimensions given are “usable testing space.” They do not include unusable testing space: below the
Air Diffuser where heaters are located, or space within the cover where fog moves laterally.
** Total Cabinet Volume provide as a means to compare against cabinets from other manufacturers that report
volume within the cover. 

BCX Series Operating Manual Page 7
III. SAFETY INSTRUCTIONS
A. PLEASE FOLLOW SAFETY INSTRUCTIONS AND PRECAUTIONS
1. Read this Manual in its entirety before operating the equipment.
2. Never install any device for the purpose of overriding any safety interlock.
3. Never alter the electrical wiring for the purpose of overriding any safety interlock.
4. All solutions and chemicals that may be used in the equipment must be handled and
disposed of in accordance with established safety procedures.
5. Never operate the equipment with any solutions or concentrations of solutions that are
not compatible with the materials of construction.
6. Never operate the equipment at temperatures that are not compatible with the
materials of construction.
7. Never operate the equipment when under the influence of drugs or alcohol.
8. Consult your own policies, procedures, or manuals that govern equipment installation,
utilities, safety, and regulatory compliance. 

Page 8 BCX Series Operating Manual
IV. GENERAL CABINET & CYCLING OVERVIEW
The ATLAS BCX is a lab corrosion test cabinet. Its purpose is to create a corrosive salt fog
or high humidity environment within its exposure zone.
A. SALT FOG STEP
During the Salt Fog Step, salt solution is atomized into a fog. This is the same setup that
normally would be used when operating according to ASTM B117. Hot, humid air is
created by bubbling compressed air (usually at 1.03bar / 15 psi) through a vertical tube
(Saturation Tower, Bubble Tower) that is about 3/4 full of heated 48°C (118°F) deionized
water.
Salt Solution is fed into the internal reservoir by a float switch and solenoid. When the
pressurized air is routed to the Atomizer Nozzle, Salt Solution is drawn upward and
atomized into a corrosive fog. The BCX is usually heated during this cycle at 35°C
(95°F) by the cabinet heater/s. The temperature can be varied; the temperature is set at
the controller.
The Salt Solution can be replaced with other electrolytes to create a corrosive fog with
different properties.
B. DWELL STEP
During the Dwell Step, no action is taken by any of the BCX components. If desired, the
cabinet can be heated by the cabinet heaters. 

BCX Series Operating Manual Page 9
V. CABINET LOCATION & SITE PREPARATION
A. UNLOADING THE BCX: MATERIAL HANDLING CAUTION
Be very careful when unloading or moving the ATLAS BCX . It is made of Fiberglas™ and
can be damaged by forklifts. It is recommended that the BCX only be lifted from under the
steel frame with a forklift, and with great care. After the BCX is unloaded, it can be rolled
to the installation site.
B. CABINET SITE SELECTION & PREPARATION
It is very important to select an appropriate location for the ATLAS BCX unit. A poor or
improper location may cause inaccurate results. Below is a list of considerations:
• A climate controlled room with a clean, level floor (see NOTE 2).
• Access to a floor drain.
• Access to a roof vent or outside wall.
• Near the proper electrical service.
• Near a compressed air line.
• Near a supply of pressurized DI (deionized) or distilled water (meeting ASTM D1193
Grade IV, ISO 3696, or JIS K8150).
• Choose a location that will allow proper entry to the cabinet access panels for
maintaining and servicing.
• Plan for access for 360°viewing of test items through the cabinet cover as desired.
NOTE 1: If any of these utility requirements are not available, they need to be brought to
the location. See the drawing for locations of connections to the cabinet.
NOTE 2: The cabinet location needs to be maintained at a consistent temperature and
humidity range. The recommended temperature range is 20-25°C (68-77°F). As indicated
above, warmer temperatures may cause the cabinet to operate out of specification for certain
test cycles. Never allow the temperature around the cabinet to approach O°C (32°F). 

Page 10 BCX Series Operating Manual
VI. CABINET INSTALLATION & REQUIREMENTS
All connections and tests of service should be made prior to applying electrical power to the
cabinet.
There are several valves that must be in the proper positions before the BCX is started and
used for testing. Failure to set these valves properly can result in flooded tanks, and/or
empty Solution Reservoirs. Below is a listing of the proper valve setup procedures.
A. DRAIN CONNECTION (CUSTOMER SUPPLIED & INSTALLED)
There are two different drain connections to be made.
1. cabinet Exposure Zone (main cabinet), 1.9 cm (3/4”), drain line
2. Solution Reservoir, 9.525 cm (3/8”) OD tube, drain line.
3. Bubble Tower Drain.
The BCX utilizes a dual vent/drain port on the back side of the cabinet. This port is 10.2
cm (4”) in diameter. A “T” (customer supplied) should be placed on this port and on one
side of the “T” the size should be reduced to 1.9 cm (3/4”) drain line. This drain line
MUST gravity feed to the supplied Wet Bottom Drain Assembly, and then to the
customer’s floor drain. This cabinet is not designed to drain to a location above floor
level. Do not directly connect into the floor drain. Allow the cabinet drain line to "lay"
over the floor drain.
Connected to this drain is a “Wet Bottom Drain” assembly.
This assembly is designed to keep the heater in
the BCX’ exposure zone covered with water.
This creates a more even heat as well as raises the
humidity in the Exposure Zone. This assembly
must be installed on the BCX in order for it to run
correctly. If this device was not purchase from
ATLAS, then it will have to be created during the
installation process. The height of this device is
critical. In addition, this assembly must be
secured (usually to the floor) by the customer to
take the stress of the weight of the drain/vent system off of the cabinet’s drain/vent
nipple.
Notice also that, during operation, the ball valve on this Wet Bottom Assembly must be
CLOSED to make the wet bottom work.
From the back side of the Wet Bottom Drain assembly, connect a drain line to the
customer’s floor drain.

BCX Series Operating Manual Page 11
When the valves are installed into these drains, set them as follows;
cabinet Drain - CLOSED
Solution Tank Drain - CLOSED - Ball valve #3
Bubble Tower Drain - CLOSED – Ball valve # 2
The above Drain valves that are normally closed can be opened for draining and
cleaning.
B. VENT CONNECTION
The cabinet utilizes a dual vent/drain port on
the back side of the cabinet centered along the
cabinet length and about 17.8 cm (7 inches)
above the lab floor. This port is 10.2 cm (4”)
in diameter. A “T” should be placed on this
port and on one side of the “T” a vent should
be run outside of the laboratory and building.
If this vent length exceeds 4.5 meters, (15’)
then the customer should consult an expert
concerning proper “power” venting methods to
ensure against any possible back pressure into the cabinet.
In addition, there is a 2” vent port located on the center back part of the cabinet just
above the 4” vent/drain connection. The customer must connect a 2” vent line to the
same vent pipe leaving the laboratory.
See the drawing in that accompany the BCX to see how to configure the vent and drain.
In addition, it may be required to connect a customer-supplied 47 lps (100 cfm) exhaust
fan to this vent tube to draw the air out of the cabinet. Contact a building engineer or
other ventilation expert for possible sizing.
C. COMPRESSED AIR CONNECTION
Compressed air must be free of oil, water and other
contaminants. If the compressed air is not clean, the
customer must install an oil/water extractor in the air
line prior to connection to the cabinet. In addition,
this air must be regulated to 2.8 bar (40 psi). The
BCX uses about 1.8 lps (3.5 cfm) during operation of
the fogging cycles. The BCX cabinet has a “Quick-
connect” fitting for the incoming air supply that will
accept a 9.525 mm (3/8”) OD polyurethane tubing.
If the cabinet is equipped with Air cover lifters, there
will be a second air connection to the combination air regulator / filter which will be
located about here.

Page 12 BCX Series Operating Manual
D. WATER SUPPLY REQUIREMENTS AND CONNECTION
DI/Distilled water is used in the Bubble Tower and for mixing of the particular
electrolyte (example 5% salt solution, CASS solution etc.) for the fogging system. The
type of water used is usually described by the test specification as found in ASTM D1193
Grade IV, ISO 3696, and JIK K8150. Pay close attention to the type of water used.
The only type of water to be used in this
instrument is deionized or distilled water in
compliance with the above specifications. The
use of other water can damage the pH meter as
well as certain components of the cyclic test
cabinet. It is suggested that the user of a BCX
cabinet get a copy of the above specifications
and read the description for the different types
of water. The BCX cabinet has a “quick-
connect” fitting for the incoming water supply
that will accept a 9.525 mm (3/8”) OD poly-
urethane tube. This water supply pressure
must be regulated to between 1-2 bar (15-30
psi).
E. SOLUTION TANK OVERFLOW
The cabinets 35 gallon solution tank has an overflow port. During installation, the
customer should install a ¾” line to this port and run it to an open facility drain.
F. ELECTRICAL CONNECTION
This cabinet is wired for use with the electrical supply stated on the confirmed Purchase
Order. The amperage draw for this set-up is listed on the electrical drawings.
It is required that only a qualified electrician connect power wires the cabinet. The
electrician will need to drill a hole into the fiberglass electrical enclosure, and bring the
wires into the cabinet from a customer-supplied, lockable, fused disconnect. This
connection is to be made to the electrical panel and attached to the proper terminal strip.

BCX Series Operating Manual Page 13
G. LEVEL FLOOR
The BCX must be installed on a level floor. If the floor is slightly uneven, the adjustable
feet can be used to level the cabinet. Improper leveling of the cabinet can result in poor
testing results.
H. LOCATION
When the BCX is installed, the only access required for loading and maintenance is in the
front of the cabinet. Choose a location that will allow proper entry to this area with at
least 0.9 meters ( 3 feet) of open area in front.
I. UTILITY SERVICES TESTING
After all utility services have been connected, they should be tested. All connections and
lines should be inspected, as applicable:
1. Leaks at connections or on lines.
Inspect connections, and test all air, water, and drain lines for leaks. Refer to
the relevant drawings that accompanied the BCX to locate the correct
illustration.
2. Voltage
Inspect connection, and check the electrical service for proper voltage. Refer
to the relevant drawings that accompanied the BCX to locate the correct
illustration.
J. LAB TEMPERATURE AND HUMIDITY
For the BCX to function properly it needs to be installed into a climate-controlled room
at a consistent temperature and humidity range. The recommended temperature range is
20-25 °C (68-77°F). Never allow the temperature around the cabinet to approach O°C
(32°F). The recommended humidity is not to exceed 60%. If the temperature or
humidity is out of these ranges it may cause the cabinet to operate out of specification for
certain test cycles.

Page 14 BCX Series Operating Manual
K. COMPONENT VALVES
The cabinet is equipped with several “Ball Valves” for ease of operation and
maintenance. They are listed as follows.....
Ball Valve # Description Valve Position
1 Salt Solution Filter Valve - OPEN
Used to change the Salt Solution Filter
2 Bubble Tower Water Drain - CLOSED
Used to drain the Bubble Tower for cleaning
3 Salt Solution from Solution Reservoir - OPEN
Used to allow Salt Solution to leave the Solution
Reservoir
4 Air to the Solution Transfer Pump - CLOSED
Used to turn the transfer pump on and off.
Normally this is in a closed position and will be
opened as needed to turn the pump on
5 Air to Diaphragm Pump - OPEN
Used to “throttle” the air into the Dispersion Tower
Fill Pump.
9 External. Condensate Valve #1 - CLOSED
Used to allow condensation to collect in the black tubing.
Open when taking collection rates, then close.
10 External. Condensate Valve #2 - CLOSED
11 External. Condensate Valve #3 - CLOSED
12 External. Condensate Valve #4 - CLOSED
13 Air to the Electronics Enclosure (BV #9) - ADJUST
Used to “meter” air into the electronics enclosure;
pressurizes area to keep salt out and cool electronics
27 Salt Solution Tank Drain (customer supplied) - CLOSED
Used to drain the salt solution tank for cleaning
& solution changeover
The OPEN and CLOSED status listed above are preset at the factory (with the exception
of #27), and this one should remain in CLOSED position during testing. These valve
positions can be altered for cabinet cleaning and maintenance.
The illustration in the back of this manual will show the approximate location of these
valves.
NOTE: The numbering of these ball valves are not in sequence for a reason. This cabinet
can be updated at a later date to a full cyclic corrosion (CCX) test cabinet. If that update
occurs, then the numbers will stay consistent and remain the same for the CCC cabinet.

BCX Series Operating Manual Page 15
L. SOLENOID VALVE ASSIGNMENTS
The cabinet is equipped with three “Solenoid Valves” for automatic operation and
delivery of air, DI water, and salt solution to cabinet components. They are listed as
follows:
Solenoid # Description
1 DI Water to Bubble Tower
When opened, it will allow DI water into the Bubble Tower.
This solenoid is controlled by the Bubble Tower Level Switch.
2 Air to Bubble Tower (Moist Air )
When opened, it will allow compressed air into the Bubble
Tower. This solenoid is controlled by the items selected by
the operator for a specific test interval.
3 Salt Solution to Fog Nozzle Feed Reservoir
When opened, it will allow Salt Solution to fill the fog nozzle
feed reservoir. This solenoid is controlled by the Fog Nozzle
feed reservoir float switch.
Note: On a BCX 3000 or 4000,
Solenoid #3 is located under the second
solution transfer pump. This solenoid
will be located here.

Page 16 BCX Series Operating Manual
VII. BCX SERIES COMPONENTS
The following sections provide brief notes on major components of the BCX Series.
A. CONTROLLER: OMRON
The controller for all standard BCX Series cabinets
is the OMRON controller. It is set to function in
degrees Celsius. See the enclosed literature for
specifics on this controller. Option cycling
controller available.
B. PURGE
The purge Toggle valve is located on the front of the control panel and allows the user to
PURGE the fog out of the cabinet prior to opening the cover. This will prevent corrosive
fog from entering the lab. Simply toggle the valve when you desire to purge the cabinet,
and close when done. In a vertical position the air is directed to the bubble tower. In an
offset position (in any direction) the air is directed to the inside of the cabinet for
purging.
C. CABINET HEATER(S)
cabinet Heater(s) maintain the cabinet temperature during testing. They are controlled by
the OMRON controller. These heaters are located at the floor of the cabinet, beneath the
Diffuser Plate. The size and wattage of heaters depends upon the size of the cabinet.
D. BUBBLE TOWER
1. The function of the Bubble Tower (also called Saturation Tower or
Humidifier) is to saturate the air with moisture and heat the air
before it reaches the atomizer nozzle, where it mixes with solution
to produce fog. Air must be saturated at temperatures higher than
temperatures within the Exposure Zone.
2. Tower refill operations require a pause in operation. The Bubble
Tower Water Float Sensor will detect “low water,” the Tower
Heater will be turned off; and the fog solenoid valve will close.
The Water Fill solenoid will open, filling the Bubble Tower until
the Water Float Sensor detects “high water,” and shuts the Water
Fill solenoid valve. The test resumes at the place where it paused,
and the test continues.
3. The Tower has two over-temperature protections.
a) Setpoint at the Controller.
b) Thermocouple with a reset built into the Heater(s).

BCX Series Operating Manual Page 17
E. INTERNAL SALT SOLUTION RESERVOIR
The BCX reservoir holds 132 liters/ 35 gallons of salt solution, sufficient to perform 3-5
days of continuous salt spray testing depending on the cabinet size and settings.
1. Water: Use Dl or distilled water to make solution (according to the test specification).
2. In-line Filter: Large particulates and contaminants are prevented from entering the
system by the in-line salt solution reservoir filter, which needs to be replaced
periodically (see Maintenance for details).
F. FOG NOZZLE
The fog nozzle appears to be a simple plastic nozzle, but it is a critical part in the proper
functioning of the cabinet, and in obtaining accurate test results. Constructed of a clear,
non-corroding, acrylic resin, it is carefully crafted to specification. Hole diameter of the
nozzle are very small and precision-fabricated, and it must be kept clear and free of salt,
crystalline buildup or obstruction (do not scrape or use rough tools). To keep the nozzle
free of blockage, the whole system should be flushed with warm, clean water for an hour
at the end of each test period to remove all residual salt, preventing crystallization.
G. DISPERSION TOWER
The dispersion tower is where the salt solution and the
humidified air meet at the atomizer nozzle to create the
fog. It consists of:
a. vertical or horizontal baffle system
b. pickup tube/baffle
c. atomizer nozzle
d. internal feed reservoir

Page 18 BCX Series Operating Manual
H. DIFFUSER
What seems to be a “false floor” of the cabinet is actually an Air Diffuser; its function
being to distribute air flow within the Exposure Zone. Samples or undue weight
shouldn’t be placed upon it.
I. SOLUTION TRANSFER PUMP
This cabinet is equipped with a 35-gallon Solution Reservoir. This is not a mixing tank.
The salt solution should be mixed in another container and transferred into this reservoir.
Due to the location, it is not practical to “pour” the mixed salt water into this reservoir.
To get the pre-mixed salt solution into the reservoir, a couple of simple steps must be
taken.
1. Mix the salt solution in a
separate container.
2. Get this pre-mixed solution
close 1-1.5 m / 3-5’ to the
BCX’s 35-gallon reservoir.
3. Put the tubing from the transfer
pump’s inlet into the container
holding the pre-mixed solution.
4. Change ball valve #3 (Salt
Solution from solution
reservoir) from its normally
OPEN position to a CLOSED
position
5. Change ball valve #4 (air to the
Solution transfer pump) from its
normally CLOSED position to
an OPEN or partially OPEN
position. The more you OPEN
it, the faster the pump will move
solution into this 35-gallon
reservoir.
6. When all of the solution is
moved, put these two valves
into their original positions, coil
up the tubing and the transfer is
complete.

TRANSFER PUMP

BCX Series Operating Manual Page 19
VIII. RUNNING THE CABINET
Refer to drawing number 850001
1. Ensure that the Omni-Fog™ Dispersion Tower(s) is
inside the cabinet and that tubing is connected as
shown in the appropriate drawing. The red tubing
(connection #4) is for air to the atomizer nozzle, and
the yellow tubing (connection #5) is for salt solution
to the internal reservoir.
2. Connect the customer-supplied pressurized DI (or
distilled) water supply to the fitting marked #2 as
shown on the drawing. Use 9.525mm / 3/8” OD
poly tubing to make this connection, and make sure
the tubing is completely inserted into the plastic
fitting before tightening. The recommended water pressure for this line is between
1.03-1.72bar / 15-25psi.
3. Make certain that the…
• Manual valve (ball valve # 2) for the Bubble Tower Drain is CLOSED.
• Manual toggle valve (located on the control panel) for Air to Purge Line or Air to
Bubble Tower is in the Bubble Tower position (centered and upright).
4. Make certain the cabinet cover is closed.
5. Set cabinet temperature control to desired temperature. (The cabinet temperature is
preset at 35ºC.) Refer to Section IX, TEMPERATURE SETTING for temperature
setting instructions.
6. Press the ON button located on the control panel’s ON/OFF switch.
7. Turn the cabinet heater switch to the ON position and check the electrical circuit to
be certain the cabinet heaters are operating. The pilot light marked "cabinet Heaters"
should be lit.
NOTE: Allow 15-30 minutes (depending on cabinet size, heater voltage, and room
temperature) for the cabinet to heat to setpoint temperature.
When the cabinet has reached the desired setpoint, the cabinet heaters will turn off and
the pilot light will go out. (The pilot light will go on and off with the heaters to indicate
the heaters are maintaining the desired temperature.)

Page 20 BCX Series Operating Manual
BUBBLE TOWER
1. Now that pressurized DI water ( use only ASTM D1193 type IV water) is connected
to the Bubble Tower the cabinet controls will keep it full of water.
• When the float switch inside the Tower
detects a low water condition, the Air
Solenoid (#5) closes to depressurize the
Tower, and the DI Water Solenoid (#1) opens
to allow the Tower to Fill. When the float
switch detects a full water condition, these
solenoids reverse and normal operation
resumes.
2. Turn Bubble Tower heater switch to an ON
position and check the electrical circuit to be
certain that the heater is heating properly. The
Bubble Tower temperature control is factory
preset at 48ºC.
3. Turn on the customer-supplied compressed air
(connected to fitting # 1) to the Bubble Tower
air, and adjust the pressure (using the pressure
regulator located on the control panel) until 15
psi (1.03 bar) is indicated on the pressure gauge
located on the control panel.
The Bubble Tower is now in operation and ready for
use.
AIR RELIEF VALVE (ON THE BUBBLE TOWER)
All valves are factory set at 1.4bar / 20 psi when supplied with the cabinet.
To adjust the valve:
• Turn up the pressure on the Bubble Tower until it reaches 20 psi (1.4bar). This
will cause the valve to release pressure when it reaches this point.
• Pull up on the top portion of the valve and turn the valve until the desired setpoint
is reached.
• Reduce Bubble Tower pressure to previous setting. (20-23 psi / 1.4-1.6bar).