How to Choose an Air-Cooled Xenon Lamp Aging Chamber

1. Working Principle and Structural Composition

1. Working Principle

The QINSUN air-cooled xenon arc weathering test chamber adopts long-arc xenon lamps to simulate full-spectrum sunlight (including ultraviolet UV, visible light and infrared IR). It cools the lamps through forced air convection without a water cooling unit. Combined with temperature-humidity adjustment, spraying and rainfall circulation systems, it simulates outdoor conditions such as sunlight exposure, high temperature and high humidity, and rain erosion to conduct accelerated weathering aging tests on materials. The material failure that takes years under natural aging can be completed within 200–1000 hours.

The equipment is equipped with closed-loop irradiance control. UV sensors monitor irradiance at 340nm/420nm in real time and automatically adjust lamp current to maintain stable light intensity. Circulating air ducts ensure uniform temperature, irradiance and humidity inside the chamber, meeting the requirements of GB/T 16422.2 and ASTM G155.

2. Overall Structure

Light Source System: Air-cooled xenon arc lamps (rated power: 1.8kW/3kW), air cooling ducts, optical filters (CIRA daylight filter / window glass filter), lamp housing assembly

Irradiance Control System: UV irradiance sensors (340nm/420nm), PID controller, automatic irradiance compensation module

Temperature & Humidity System: Heating tubes, centrifugal fan, humidifier, platinum resistance thermometers, humidity sensor

Spray & Rainfall System: High-pressure spray pump, stainless steel nozzles, spray solenoid valve, rainwater recovery loop

Specimen Movement System: Rotating frame (360° rotation at 1r/min), specimen clamps, sample mounting plates

Safety Protection System: Over-temperature protection, lamp overload protection, water shortage protection, door interlock switch, fan failure alarm

Chamber Body: SUS304 stainless steel inner tank, internal dimensions 500×500×600mm, double-layer tempered observation window, insulation layer thickness ≥50mm

2. Technical Parameters and Performance Indicators

(Compliant with GB/T 16422.2, ASTM G155 and ISO 4892-2)

Lamp Type: Air-cooled long-arc xenon lamp, rated power 1.8kW/3kW

Irradiance Range: 0.30～1.20W/m² at 340nm; 0.50～2.00W/m² at 420nm; control accuracy ±2%

Black Panel Temperature (BPT): 35～85℃, temperature fluctuation ±1℃

Chamber Temperature: 25～70℃, temperature uniformity ±2℃

Relative Humidity: 30%～95% RH, humidity control accuracy ±3% RH

Sample Rotating Frame: Diameter Φ450～Φ500mm, rotation speed 1r/min for uniform irradiance

Spray Function: Spray pressure 0.1～0.15MPa, adjustable spray cycle (1min～999h)

Optional Filters: CIRA daylight filter or Window glass filter (single selection)

Nominal Lamp Service Life: 500h; replacement after 400h is recommended to stabilize irradiance

Power Supply: AC220V±10%/50Hz, rated power 4.5～6kW

Uniformity Standard: Irradiance deviation ≤5% and temperature deviation ≤2℃ at any three points of the sample area

3. Installation, Commissioning and Operating Procedures

(I) Installation Specifications

Ambient Requirements: Ambient temperature 23±2℃, relative humidity 20%–80% RH; avoid direct sunlight, dust and corrosive gas

Ventilation Requirements: Reserve heat dissipation space ≥300mm on the top and rear of the equipment with smooth exhaust; operation in fully enclosed spaces is forbidden

Water Supply Requirements: Deionized water or pure water with resistivity ≥1MΩ·cm, water pressure 0.1～0.3MPa; tap water is prohibited

Electrical Requirements: Independent circuit with grounding resistance <4Ω; equipped with air switch and leakage protection (trip current ≤30mA)

(II) Commissioning Steps

No-load trial run: Turn on temperature control, fan and rotating frame for 2 hours; check stable temperature and abnormal noise

Irradiance calibration: Ignite the xenon lamp and preheat for 30 minutes, set standard irradiance (e.g. 0.51W/m² at 340nm) and stabilize for 1 hour; it is qualified if the deviation ≤±2%

Spray system commissioning: Activate spraying function and check uniform atomization, unobstructed nozzles and zero water leakage

Safety interlock test: The light source cuts off automatically when the door is opened; the equipment shuts down automatically after simulating over-temperature alarm

(III) Standard Operating Procedures (Cycle example per GB/T 16422.2)

Specimen preconditioning: Condition specimens at 23℃/50% RH for 24 hours with clean surfaces free of scratches and oil stains

Specimen mounting: Fix specimens on the rotating frame with spacing ≥5mm to prevent shielding and contact between samples

Close the door and set parameters: Irradiance, black panel temperature, humidity, light/spray/condensation cycle

Lamp startup and operation: Preheat for 30 minutes first; formal test begins after irradiance and temperature stabilize

Periodic inspection during test: Record irradiance, temperature and humidity every 24 hours; check the spray system, rotating frame and water level

Test completion: The lamp turns off automatically; maintain ventilation for 30 minutes for cooling, and open the door for sampling only when the temperature drops below 40℃

Specimen storage: Take photos, grade samples and conduct mechanical, appearance, color difference and gloss tests

4. Daily Maintenance Specifications

1. Daily Inspection

Check the water tank level and replenish deionized water

Observe lamp operation for flicker and tube blackening

Confirm normal operation of the rotating frame, fan and spray system

2. Weekly Maintenance

Clean and unclog spray nozzles

Gently wipe the glass window of the UV sensor with anhydrous ethanol

Clear accumulated water and debris at the chamber bottom and ensure smooth drainage

3. Monthly Maintenance

Clean air duct filters and lamp housing heat dissipation vents to guarantee air cooling efficiency

Inspect bearings of the rotating frame and add high-temperature resistant grease

Calibrate black panel temperature and zero point of irradiance

4. Lamp Replacement (Critical Item)

Replace the lamp after 400 cumulative working hours; the maximum service life shall not exceed 500 hours

Wear gloves during replacement; direct hand contact with the lamp tube is forbidden

Irradiance recalibration is mandatory after lamp replacement before resuming tests

5. Annual Maintenance

Thoroughly clean the chamber, pipelines, heating and humidifying components

Calibrate irradiance, temperature and humidity and file internal/external calibration records

Inspect electrical circuits, wiring terminals and all safety protection devices

5. Test Standards and Test Methods

1. Applicable Standards

GB/T 16422.2 Plastics — Methods of Exposure to Laboratory Light Sources — Part 2: Xenon Arc Lamps

ISO 4892-2 Plastics — Methods of Exposure to Laboratory Light Sources — Part 2: Xenon Arc Lamps

ASTM G155 Standard Practice for Operating Xenon Arc Light Apparatus for Exposure of Nonmetallic Materials

ASTM D4459 / ASTM D6695 / SAE J2527 / PV1303

2. Common Industry Test Cycles

Dry Aging Cycle (No Spraying)

Light exposure: Continuous irradiation at 60℃/50% RH

Light & Spray Combined Humid Aging Cycle

102 minutes of light exposure + 18 minutes of spraying

Comprehensive Outdoor Simulation Cycle (Light + Spray + Condensation)

Light exposure stage + spray stage + dark high-humidity condensation stage

3. Common Irradiance Settings

340nm: 0.51W/m² (general standard), 0.65W/m² (accelerated test), 1.0W/m² (high-intensity accelerated test)

420nm: 1.10W/m², 1.5W/m² (widely used for coatings and automotive exterior parts)

6. Fault Diagnosis and Troubleshooting

Fault: Xenon lamp fails to ignite or extinguishes frequently

Causes: Aged lamp, faulty trigger board, incompletely closed door switch, unstable power supply, poor heat dissipation

Solutions: Replace the lamp; inspect the door control switch; stabilize power supply; clean air ducts for sufficient cooling

Fault: Low or continuously declining irradiance

Causes: Lamp attenuation, contaminated sensor, aged optical filter, incorrect parameter settings

Solutions: Clean the sensor; replace the optical filter; replace the lamp; complete recalibration

Fault: Excessively high temperature or failed temperature control

Causes: Clogged air ducts, faulty fan, adhered heating contactor, drifted sensor

Solutions: Clean filter screens; replace the fan; calibrate the temperature probe

Fault: No spray output or insufficient water flow

Causes: Blocked nozzles, faulty water pump, damaged water solenoid valve, water shortage

Solutions: Dredge nozzles; inspect the water pump; replace the solenoid valve; replenish deionized water

Fault: Rotating frame stalls or generates abnormal noise

Causes: Faulty drive motor, loose chain, seized bearing, triggered overload protection

Solutions: Inspect the motor; tighten the chain; lubricate bearings; rearrange specimens to eliminate jamming

7. Safe Operation and Protection Requirements

Xenon lamps generate intense ultraviolet radiation. Door opening and direct eye contact with the light source are prohibited during operation; protective goggles must be worn for inspection

Tap water is forbidden to avoid scaling blockage of the spray system and corrosion of the chamber and lamps

The equipment operates at high temperatures; do not touch the chamber, lamp housing and heating components to prevent scalds

Press emergency stop and cut off power supply immediately upon abnormal noise, peculiar smell or smoke; operation with faults is prohibited

Cut off power supply and cool the lamp for more than 30 minutes before replacement to avoid high-temperature scalds and electric shock

8. Irradiance Control and Calibration Methods

Control Logic: Real-time signal collection by UV sensor → PID adjustment → automatic irradiance stabilization

Calibration Cycle: Internal calibration once a month, third-party metrological calibration once a year

Calibration Procedure: Use a standard radiometer to conduct multi-point testing in the sample area and adjust equipment coefficients until the deviation ≤±2%

Key Requirement: Recalibration is required after optical filter aging or lamp replacement; otherwise, test data is invalid

9. Specimen Preparation and Test Result Analysis

Specimen Requirements: Flat, undeformed and scratch-free with dimensions complying with standards; at least 3 parallel specimens per test group

Post-test Evaluation Items: Surface discoloration, gloss loss, cracking, chalking, blistering, peeling and mildew growth

Performance Testing Items: Color difference ΔE, gloss, tensile strength, impact strength, adhesion and light transmittance

Judgment Criteria: Grade specimens in accordance with product standards; qualified products feature color difference ≤ΔE 3.0 without cracking or chalking

10. Application Fields and Model Selection Guide

1. Main Test Materials

Conduct weathering aging tests on plastics, coatings, paints, inks, rubber, textiles, leather, automotive exterior trims, photovoltaic materials, outdoor electronic products and more.

2. Key Model Selection Points

Air-cooled model: Simple structure, low maintenance cost and small footprint, ideal for R&D and routine quality inspection (most widely used)

Capacity Options: 150L (standard), 300L, 500L (for mass specimen testing)

Optical Filter Selection: CIRA filter (simulate direct outdoor sunlight); Window filter (simulate light transmitted through glass for indoor articles)

Mandatory Configurations: Automatic irradiance control, rotating sample frame and spray system

Viewpoints

The stability of air-cooled xenon arc weathering test chambers mainly relies on lamp service life and irradiance calibration. Continuous use over 400 hours causes irradiance attenuation and distorted test cycles. 80% of data deviations are caused by overdue lamp replacement and uncalibrated sensors.

Deionized water is an essential matching medium. Tap water leads to nozzle blockage, lamp scaling and chamber corrosion within 3 months, which will completely damage the water circuit system.

Comparison between air-cooled and water-cooled models: Air-cooled units require no cooling water tower, feature simple installation and lower failure rates, suitable for weathering tests of most materials. Water-cooled models are only recommended for ultra-high power and high-precision continuous operation scenarios.

Xenon lamp aging test results cannot be directly converted into actual service years and are only used for formula comparison, quality control and certification testing. Data correction combining local total irradiance, temperature and humidity is required for service life prediction.

2026-07-08 11:20