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.