In recent years the proliferation of portable devices and the «start&stop» system introduction in the automotive field led to increase R&D activity on this product range, enlarging the batteries offer to introduce in the market best performing products.
Tests based upon charge and discharge cycles are a key activity in laboratories involved in battery testing. The instruments used for such tests often subject batteries to demanding and lengthy test protocols and can normally be interfaced with various devices.
ACS climatic chambers play a primary role offering the possibility to conduct tests in controlled temperature and humidity conditions similar to those a battery may encounter over the course of its operating lifetime.
The Battery Test range has been optimized in accordance with the hazard levels defined by the EUCAR, with each hazard level associated with a series of accessories.
The end user should be familiar with the type of test to be performed and is responsible for selecting the appropriate hazard level.
Once the hazard level is established based on the EUCAR table, the equipment should be fitted with all the devices envisaged for the specific level and those below it to ensure full protection.
Moreover, in the case of the maximum hazard level (Level 7 – Explosion), it is necessary to make a specific estimation, since the proposed devices might not be sufficient for guaranteeing the safety level required.
EUCAR Hazard Levels and related accessories:
| Hazard Level | Description | Criteria for Severity Classification & Effects |
|---|---|---|
| 0 | No Effect | No effect. No loss of functionality |
| 1 | Reversible Loss of Function | No defect; no leakage; no venting, fire, or flame; no rupture; no explosion; no exothermic reaction or thermal runaway. Temporary loss of battery functionally. Resetting of protective device needed. |
| 2 | Irreversible defect/damage | No leakage; no venting, fire, or flame; no rupture; no explosion; no exothermic reaction or thermal runaway. RESS irreversibly damage. Repair needed. |
| 3 | Leakage Δ mass < 50% | No venting, fire, or flame; no rupture; no explosion. Weight loss < 50% of eleetrolyte weight. Light smoke (electrolyte=solvent+salt). |
| 4 | Leakage Δ mass ≥ 50% | No fire or flame; no rupture; no explosion. Weight loss ≥ 50% of electrolyte weight. Heavy smoke (electrolyte=solvent+salt). |
| 5 | Fire or Flame | No rupture; no explosion (i.e. no flying parts) |
| 6 | Rupture | No explosion. RESS could disintegrate but slowly without flying parts of high thermal or kinetic energy. |
| 7 | Explosion | Explosion (i.e. disintegration of the RESS with externalyy damaging thermal & kinetic forces). Exposure to toxic substances in excess of OSHA limits. |
Table 1: Severity Levels (Adopted and modified by EUCAR)
The models indicated in the below table can be provided as Battery Test Chamber.
| BASIC VERSION | E VERSION | ES VERSION | flower® VERSION | ESS VERSION |
|---|---|---|---|---|
| CLIMATIC AND THERMOSTATIC MODEL | CLIMATIC MODEL | CLIMATIC AND THERMOSTATIC MODEL | CLIMATIC MODEL | CLIMATIC AND THERMOSTATIC MODEL |
| Field T -40/+180°C | Field T -20/+180°C | Field T -40/+180°C | Field T -40/+180°C | Field T -70/+180°C |
| DM340 (T) DM600 (T) DM1200 (T) DM1600 (T) |
DM340 E DM600 E DM1200 E DM1600 E |
DM340 (T) ES DM600 (T) ES DM1200 (T) ES |
FM340 FM600 FM1200 |
DM 250 C (T) ESS DM 500 C (T) ESS DM 1000 C (T) ESS DM 1400 C (T) ESS |
| Field T -70/+180°C | Field T -70/+180°C | Field T -70/+180°C | ||
| DM340 C (T) DM600 C (T) DM1200 C (T) DM1600 C (T) |
DM340 C (T) ES DM600 C (T) ES DM1200 C (T) ES |
FM340 C FM600 C FM1200 C |
Control and management system and interfaces
Controlled by PLC and Advanced HMI
Remote access
There is a wide range of possibilities thanks to the built-in MyKratos™ and MyAngel24™; multichamber control also available upon request
Electromagnetic closing system
Ensures the security of environmental tests
Air treatment system
Ensures a precise control of the climatic parameters inside the chamber with minimal thermal inertia; an axial fan allows rapid temperature variations of both air and specimen.
Humidification system (only climatic version)
The humidifier with a self-contained heater and dedicated controlling S/W offers two great advantages:
- it does not require distilled or demineralised water to operate properly
- it uses ‘dry’ vapour in order to avoid condensation on the specimens and to reproduce real environmental conditions
ACCESSORIES FOR BATTERY TEST:
Optical/acoustic tower light alarm and 4 supplementary PT100 sensors:
The tower light has 3 signal levels (white, green, and red) to quickly alert the operator of any abnormal conditions. The 4 supplementary sensors may be used to monitor the temperature of the specimen in the chamber and generate an alarm if dangerous overheating occurs.
GN2 or compressed air purge system:
The function of the device is to guarantee a washing and a constant change of gas in the useful test area.
If it is connected to a gaseous nitrogen line, the oxygen level inside the test chamber is lowered as a further effect; in this case, the system can be combined with the oxygen presence sensor to optimize the consumption (the fluxing stops when the oxygen level drops below a defined threshold).
Sampling system for monitoring:
Cooling unit, on the top of the chamber, to dehumidify the air flow extracted from the internal chamber volume before the inlet to the sensors.
Oxygen sensor, H2 sensor, CO sensor:
Monitors the gases in the chamber in all operating conditions envisaged in the technical specifications.
Overpressure valve:
This valve is positioned on the top of the chamber and is designed to protect the chamber from any gradual release of gas from the specimen. The system is not designed to compensate for internal overpressures of an explosive nature. This accessory comes with 2 additional mechanical fasteners to keep the door closed.
The device must be properly connected to the outside in order to avoid contamination of the test area. Flange connection DN500 according to EN 1092-1.
CO2 protection system:
The system is equipped with a control unit, an alarm panel, an emergency button, a thermostat with dedicated temperature probe and a system with a CO2 cylinder.
The CO2 discharge is activated by exceeding a temperature threshold (settable by the user) measured by a dedicated PT100 or by exceeding the CO2 threshold inside the chamber.
The detection system, provided with its own power supply, activates the CO2 in the chamber.
The CO2 bottle is empty.
HAZARD Level and Related Accessories
The range of accessories has been optimized in accordance with the hazard levels defined by the EUCAR, with each hazard level associated with a series of accessories.
The end user should be familiar with the type of test to be performed and is responsible for selecting the appropriate hazard level.
Once the hazard level is established based on the EUCAR table, the equipment should be fitted with all the devices envisaged for the specific level and those below it to ensure full protection.
Moreover, in the case of the maximum hazard level (Level 7 – Explosion), it is necessary to make a specific estimation, since the proposed devices might not be sufficient for guaranteeing the safety level required.
| Hazard Level | ACCESSORY Description |
|---|---|
| 0...2 | OPTICAL/ACOUSTIC ALARM + 4 SUPPLEMENTARY PT100 SENSORS -- Chamber Height +350mm |
|
3...4 |
SAMPLING SYSTEM FOR MONITORING COMPRESSED AIR OR GN2 WASHING WITH FLOW METER OXYGEN MONITORING SYSTEM -- Dewpoint reduction up to +75°C; +5°C increase of Min. Temp.; chamber H +300mm H2 MONITORING SYSTEM -- Dewpoint reduction up to +75°C; +5°C increase of Min. Temp.; chamber H +300mm CO MONITORING SYSTEM -- Dewpoint reduction up to +75°C; +5°C increase of Min. Temp., chamber H +300mm OVERPRESSURE VALVE -- Chamber height +250 mm, Dewpoint reduction up to +90° C, Minimum Temp. increased +5° C |
| 5...6 |
CO2 PROTECTION SYSTEM ≤340 L (Hazard Level 5...6) Dewpoint reduction up to +75°C; +5°C increase of Min. Temp., chamber W +200mm (empty CO2 bottle) |
System includes the following components:
Mechanical cooling based on single stage system (-40°C) or cascade systems (–70°C). The cooling system is realized with semi-hermetic alternative type compressors including an automatic injection-type protection system. This protects the compressors when they are cooling down from high temperatures.
The chamber is heated by means of electrical heaters, protected by safe thermostats that disconnect overall chamber main power components (such as compressors, fans and heaters) in case of accidental over-temperature.
Direct humidification occurs through an electrical vapour humidifier.
The chamber is equipped with a water storage tank (about 18 l capacity) and a water connection on the back of the chamber for automatic refilling.
There are three ways to ensure the water supply needed for any kind of climatic tests:
In order to reduce water consumption, water recycling can be activated through a button on the control panel (only possible when the specimen does not contaminate the water during the test).
Dehumidification is performed by the condensation cooler (dew point cooler) directly connected to the refrigeration circuit. This principle permits high stability of parameters in conjunction with energy-efficient dehumidification.
Temperature Measurement with Pt100 thermal probe Class A, max precision 0,3K.
Relative humidity measurement with Assmann psychrometric system complete with Pt100 thermal probes.
Relative Humidity range from 10% to 98% within the temperature range [+10°C; +95°C].
Dew Point range:
The values refer to the basic version at ambient temperature of +22°C, with temperature and humidity measurement made in the air inlet.
The chamber is equipped with a PLC (Programmable Logic Controller) for managing all the chamber’s functions and safety interlocks. The HMI system consists of an on-board panel (Keykratos Evo) and a remote control (MyKratos™ including MyAngel24™) connected to the chamber.
On-Board Panel (Keykratos Evo) consists of 3.5 inch Analog Touch Panel 65,536 colours with a touch menu with related pop up screens, allowing the following activities: main chamber's parameter setup, manual control, possbility to start the last stored profile, visualization of eventual alarm notifications.
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