Operating Instructions.

Additional Operating instructions and function

description for Espec Temperature Chambers
including safety features for testing lithium-ion
batteries.

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 Content page

1. Important information for operators and users ............................................................. 3

2. General Warnings and Cautions................................................................................... 3
3. System description ....................................................................................................... 4
4. Overview of Parts. ........................................................................................................ 5
4.1. Front Panel. .................................................................................................................. 5
4.2. Right side control Panel. .............................................................................................. 6
4.3. Top Panel. .................................................................................................................... 7
4.4. Left side panel. ............................................................................................................. 7
5. Additional features and safety items. ........................................................................... 8
5.1. Safety control display and controller. .......................................................................... 8
5.2. Safety contact for Charge/discharge system. ............................................................... 8
5.3. Explosion vent. ............................................................................................................. 8
5.4. CO2 Fire extinguishing System. .................................................................................. 9
5.5. CO and H2 Gas detection. ............................................................................................ 9
5.6. Product temperature sensors. ..................................................................................... 10
5.7. Emergency stop Switch. ............................................................................................. 10
5.8. Forced Cooling. .......................................................................................................... 10
5.9. Nitrogen Purge. .......................................................................................................... 11
5.10. Door lock. ................................................................................................................... 11
6. Installation. ................................................................................................................. 12
7. Operations .................................................................................................................. 13
7.1. Start the test chamber ................................................................................................. 13
7.2. Stop the test chamber ................................................................................................. 14
8. Chamber status normal operation............................................................................... 15
9. Chamber status Alarm operation ................................................................................ 16
10. Description of safety control display ......................................................................... 20
11. Parameter Menus ........................................................................................................ 22
12. Manual operation flushing and door lock .................................................................. 23
13. Connection with the Charger/Discharger ................................................................... 24
13.1. RS-232 communication. ............................................................................................. 24
13.2. Wired safety contacts. ................................................................................................ 24
14. Maintenance and Calibration. .................................................................................... 25
14.1. Espec Temperature chamber. ..................................................................................... 25
14.2. CO and H2 Gas detection. .......................................................................................... 25

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 1. Important information for operators and users
Read the operating instructions of the temperature chamber and the operating instructions
of all safety equipment carefully and familiarize yourself with the operation and functioning
of these systems before used.
The test chamber, including all safety devices should only be used by persons that are
familiar with the operation and potential hazard involved.

Also safety devices may have errors. Therefore, open the temperature chamber only when
no hazardous conditions are to be expected.

2. General Warnings and Cautions

• The Temperature chamber with safety features is approved for testing of lithium-ion
batteries.

• Operation and service must be performed by knowledgeable and specially trained

personnel who have been informed of the potential hazards.

•The Temperature chamber may only be used for the purpose as described above.
Other use of the chamber can result in dangerous situations and/or damage to property.

• No liability for damages due to improper use or inappropriate use.

• The manufacturer can not anticipate every danger.

In the operator's manual and safety instructions contained warnings and instructions may
not include all hazards

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 3. System description
The system basically consists of:

Espec Temperature Chamber

• Temperature chamber for the simulation of
ambient temperatures from -75 °C to +150 °C.

For more information: See the operating manual of the test chamber

Additional safety devices

• Emergency stop button on the front of the Temperature Chamber.
• Viewing window in chamber door with Safety film.
• Electro mechanical door locking system.
• Explosion vent with activation sensor and stainless steel frame.
• Safety control system with PLC and display.
• Two temperature sensors for monitoring of the test specimen and/or test chamber
temperature with fast temperature raise safety function.
• N2 flush system.
• Compressed air flush system.
• CO Gas detection system.
• H2 Gas detection system.
• CO2 Fire Extinguisher system.
• Preparation for future installation of smoke detection.
• Relay outputs (floating) for controlling external flushing.
• Relay output (floating) to release external charging stations.

Additional functions of the safety control display

• Monitoring of all safety equipment.
• Safety control display for information and alarm messages.
• Control of the electro mechanical door lock.
• Control of the acoustic and visual indicators.
• Maximum temperature raise limits of the monitoring sensors in °C/min.

System
Active

Safety control display

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 4. Overview of Parts.
4.1. Front Panel.

1. Instrumentation.
Interface unit for setting temperature, starting and
stopping tests, etc. Contains functions for
controlling temperature.
2. Operating Panel. 1.
Power, Start/stop, Help and display buttons.
3. Overheat protector. 2.
Stops the chamber to prevent damage to specimens.
4. Forced Cooling.
The function will switch off the electrical heater so the 3.
Chamber will cool down.
5. Emergency Reset. 4.
In the event of an emergency, fire detection, gas 5.
detection or explosion a emergency relay will shut down 6.
the chamber.
After this the relay must be reset with the key switch on the 7.
front of the chamber.
6. Nitrogen Purge.
Manual flush of the test area with Nitrogen for 30-3600 sec.
7. Emergency Stop Switch. 8.
In case of an emergency the chamber can be stopped immediately
by manually push the emergency Stop Switch.
After activation the switch must be pulled back before the emergency
can reset.
8. Fire Extinguisher manual activation.
Manual activation of the CO2 fire Extinguisher.

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 4.2. Right side control Panel.
4 6 8 9

5 7 10 11
1. Specimen temperature control sensor.
Connection for a temperature sensor to monitor and control the temperature of the
specimen. See also the Espec User manual.
2. Communication port RS-232.
For monitoring and controlling the chamber with a PC.
3. Specimen power control.
Supplies power to specimens. If chamber operations are stopped by trouble,
a contact opens to shut OFF power supply to specimens.
Time signals.
Outputs signals via a contact relay to a remote location during operation.
4. Pressure Gauge for compressed air.
Indicated the pressure of the connected compressed air supply.
5. Pressure regulator for compressed air.
6. Pressure Gauge for Nitrogen.
Indicated the pressure of the connected Nitrogen supply.
7. Pressure regulator for Nitrogen.
8. Flow meter Nitrogen.
Indication of the Nitrogen flow when the Nitrogen flush is activated.
9. Safety control display.
Monitoring of all safety equipment.
10. Acknowledge/Reset button.
Short push: Switch of the alarm buzzer when there is an alarm.
Long push (> 2 Sec.): Acknowledge the active alarms and reset the PLC to clear the
alarms.
11. Main Power Switch.
Turns primary power supply to the chamber ON/OFF.

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 4.3. Top Panel.

1 2 3 4
1. Acoustic/optical warning device.
Signals when the CO2 fire extinguisher is activated.
2. Exhaust box.
Including Explosion vent.+ Break detector, Gas exhaust pipe.
3. Electro mechanical door lock.
Locks the door when the chamber is active or switched off.
4. Signal Tower.
Signals the status of the chamber with color light and sound.

4.4. Left side panel.

1 2 3

1. Gas detection controler for CO.

For monitoring en detection of CO Gas.
Alarm1: 25 % of 200 ppm
Alarm2: 50% of 200 ppm
2. Gas detection controler for N2.
For monitoring and detection of N2 Gas.
Alarm1: 25% of 4 vol%(LEL)
Alarm2: 50% of 4 vol%(LEL)
3. Extinguisher CO2.
Extinguisher CO2 - 6 kg, RAL 3000, with solenoid valve
4. Fire controle unit.
For monitoring and controlling of the CO2 fire extinguisher.

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 5. Additional features and safety items.
Several extra features are installed on the standard Espec temperature chamber.
These extra safety features are necessary when batteries are tested inside the chamber.
The safety features are connected to a Safety controller and the status is showed on the
safety control display and the signal tower.
See Chapter 11 of this manual for the active messages and signals on normal operations and
in case of an alarm.

5.1. Safety control display and controller.

All safety device are connected to a safety controller with the following functions:
• Monitoring of all safety equipment.
• Safety control display for information and alarm messages.
• Control of the electric mechanical door lock.
• Control of the acoustic and visual indicators.
• Maximum temperature raise limits of the monitoring sensors in °C/min.
• Setup of flush times with Air or Nitrogen.
• Controlling safety contact for Charge/discharge system.

5.2. Safety contact for Charge/discharge system.

The chamber is equipped with a contact to activate/deactivate the charge/discharge system.

This contact will be switched on when there is no alarm and the temperature chamber is
running.
In case of an alarm this contact is switching off the charge/discharge system.
This contact must always be connected when a charge/discharge system is used.
The contact is located on Terminal X5-17 and X5-18 of the electric panel.

5.3. Explosion vent.

If an explosion occurs inside the chamber, the blast force is released from this vent to
weaken the impact.
A brake plate is installed and will brake if the pressure is getting to high.
A sensor will detect a broken plate and will switch of the chamber.
The safety control display give’s the message:
-Espec & Charger stopped
-Alarm Expl.vent
-Emergency OFF

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 5.4. CO2 Fire extinguishing System.

The CO 2 Fire extinguishing system consist of the following items:

- Fire control unit UE02.
- CO2 Bottle with solenoid valve.
- Spray nozzle.
- Manual tripping device.
- Acoustic/optical warning device.
- Thermal switch 162°C.

The spray nozzle and the thermal switch are installed inside the test area of the temperature
chamber.
When the temperature inside the chamber will be higher than 162°C the extinguisher will be
activated and CO2 is sprayed inside the test area via the nozzle.
The extinguisher can also be activated by pushing the glass on the manual tripping device in
front of the chamber.

The status of the Fire extinguisher is displayed also on the Fire control unit UE02.
When the fire extinguisher is activated by the thermal switch or the manual tripping device,
Linie 1 is active.
In case of an activation the alarm must be reset on this controller with the reset button.
Via the operation off switch the fire extinguisher system can be switched off.
In this case the temperature chamber cannot be used for a test.

5.5. CO and H2 Gas detection.

The SH-WAD gas detection units are located behind the glass door on the left side of the
temperature chamber.
The SH-WAD unit is a wall mount model, suction type, gas detection unit equipped with
integrated membrane pump to draw in the air/gas mixture, and designed for the continuous
monitoring of these mixtures.
These units have a 2 fixed alarm levels and are connected to the safety controller.
When the alarm levels are reached a alarm will sound and the safety controller displays the
active alarm.
The gas sensors need to be calibrated every 6 months.
For more information about the gas detections see also the Operation Guide of the SH-
1003WAD.

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 5.6. Product temperature sensors.

2 product temperature sensors are installed in the test area of the temperature chamber.
These sensors can be placed on the product and will measure the temperature of the
product.
With the safety control display a max. allowed temperature increase can be set so when the
temperature is rising to fast the chamber will have an alarm and forced cooling is activated.
See 5.8. for the explanation of forced cooling.
The temperature increase can be set between 0,5 to 10°C/min.

5.7. Emergency stop Switch.

The emergency stop switch is located on the front of the chamber.

Use this switch to stop chamber operation during an emergency.

Press the emergency stop switch on the instrumentation panel.

The main power of the temperature chamber will be switched off and the safety contact of
the charge/discharge system will open.

To reset the alarm:

- Pull Emergency switch
- Use Key switch
- Push acknowledge/reset button >2sec.

5.8. Forced Cooling.

On normal operation of the temperature chamber the temperature is controlled with the
temperature controller. This temperature controller will activate the cooling system or the
electrical heaters when needed.
When the set point of the chamber is <62°Cthe cooling system is always running.
In this case the electrical heater are used to control the chamber.
The forced cooling option will deactivate the electrical heaters so the chamber will cool
down automatically without changing this set point.
This option can be switched on with a button on the front of the chamber.
Forced Cooling can also be activated by the product temperature sensors.
When the temperature of the product will rise faster than the set point the forced cooling is
activated.

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 5.9. Nitrogen Purge.

It is possible to flush the test area with Nitrogen Gas.

This is possible with the button in front of the chamber.
The length of the flush time can be set with the safety control display.
See chapter 12 of this manual.

5.10. Door lock.

The temperature chamber is equipped with an electric mechanical door lock and 2 manual
door locks.
The electric mechanical door lock will lock the door when the chamber is switched off, while
running and in case of an alarm.
The door can only be opened after a test when there is no alarm.

The mechanical door locks must always be locked before starting the chamber.

Mechanical door lock Electric door lock

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 6. Installation.
See the “Environmental Stress Chamber AR Series basic manual” chapter 4 for the
installation of the Espec temperature chamber.

The chamber is equipped with a Air connection and Nitrogen connection for
flushing the test area and are located on the back of the chamber.
8mm Push-in connection.
These connection must be made before a test can be started.
Both connections have a pressure sensor that will give an alarm if the
pressure is too low.
Setting of pressure sensor: 1 Bar.

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 7. Operations
The temperature chamber can be controlled with the touch screen controller on the
chamber. A test can be started when there are no active alarms or notes on the safety
controller display.

The test chamber can be controlled if:

• The emergency stop switch is not activated, and the emergency stop relay is released using
the key switch.
• No alarms are active.
• The door of the test chamber is closed and locked.
• The pressure of the external flush medium is ok.
• The alarm input connection of the charging station is connected.
If this contact is not used, a 24V jumper must be made.
• The safety control display status is: System Active

Note: To open the test chamber, the test must be completed.

When the test is completed, air or N2 will be purged for the amount of time that is set on
the safety control display.
After this time the door lock is deactivated and the door can be opened!

7.1. Start the test chamber

• Set the desired temperature at the control display of the temperature chamber or select a
program.

• Position the temperature sensors in the test room or on the test product and set the
required alarm parameters on the additional safety control display.

• Make sure the flushing media is connected and ready to use.

• Connect the release contact from the external charging station to the test chamber or
create a bridge across the appropriate terminals.

• Connect the potential-free alarm contact of the charging station to the test chamber or
create a bridge across the appropriate terminals.

• Close the test chamber door.

• The test chamber can only be put into operation when the door handle is fully pushed.

• Start the selected program on control display of the temperature and humidity chamber.

• Check if the system is functioning properly after a short period of time.

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 7.2. Stop the test chamber

• Stop the chamber on the controller of the temperature chamber.

• The chamber stops and the test area will be flushed with N2 for the amount of time that is
set on the safety control display.

• After flushing the door lock is released and the door can be opened.

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 8. Chamber status normal operation

Description Status Message safety control display

- Temperature chamber not - No light. CHAMBER DOOR UNLOCKED
active. - No tone. CHARGER STOP.
- Chamber door closed but
unlocked.

- Temperature chamber not - Orange light flashing. CHAMBER DOOR UNLOCKED

active. - No tone. CHARGER STOP.
- Chamber door open.

- Temperature chamber active. - Green light constant. SYSTEM ACTIVE

- No tone.
- Door locked.
- Temperature chamber - Air purge for 30-3600 sec. SYSTEM ACTIVE
stopped with chamber - Green Flashing.
controller.
After flushing AFTER FLUSHING
- No light. CHAMBER DOOR UNLOCKED.
- Door unlocked. CHARGER STOP
- Temperature chamber active. - N2 purge for 30-3600 sec. MANUAL ACTIVATION
- N2 purge manual switch. - Green constant. NITROGEN PURGE
**ACTIVE**
- Temperature chamber active. - Heater is switched off. SYSTEM ACTIVE
- Forced cooling manual switch. - Only cooling.

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 9. Chamber status Alarm operation
Description
- Emergency switch activation.
- Explosion vent activated.
- Alarm product sensor 1.
- Alarm product sensor 2.
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Status Message safety control display
- Chamber controller switching ALARM EMERG.STOP.
off. ESPEC & CHARGER
- Red light flashing. **EMERGENCY OFF*
Reset Procedure:
- Push/Pull Emergency switch.
- Use Key switch.
- Push acknowledge/reset
button >2sec.
- Chamber controller switching ALARM EMERG.STOP/
off. ALARM EXPL.VENT.
- Red light flashing. ESPEC & CHARGER
- Pulse tone. **EMERGENCY OFF **
Reset Procedure:
- Push/Pull Emergency switch.
- Use Key switch.
- Push acknowledge/reset
button >2sec.
- Red light flashing. S1 FORCED COOLING.
- Pulse tone. **CHARGER STOP**
- Heater is switched off.
Reset Procedure:
- Cool down the chamber.
- Push acknowledge/reset
button >2sec.
- Red light flashing. S2 FORCED COOLING.
- Pulse tone. **CHARGER STOP**
- Heater is switched off.
Reset Procedure:
- Cool down the chamber
- Push acknowledge/reset
button >2sec.
Operation Manual Battery test chamber 16
 Description
- CO Error.
- CO Alarm 1.
Sensor range: 0-200ppm.
Alarm 1 at: 25%.
- CO Alarm 2.
Sensor range: 0-200ppm.
Alarm 2 at: 50%.
- H2 Error.
- H2 Alarm 1.
Sensor range: 0-4 vol%(LEL)
Alarm 1 at: 25%.
- H2 Alarm 2.
Sensor range: 0-4 vol%(LEL)
Alarm 2 at: 50%.
01-2-2013 V1.0
Status Message safety control display
- Chamber stays in operation. ERROR GAS DETECTION
- Orange light flashing. **CHARGER STOP**
- Constant tone.
Reset Procedure:
- Push acknowledge/reset
button >2sec.
- Chamber stays in operation. WARNING CO ALARM 1
- Orange light flashing. **CHARGER STOP**
- Constant tone.
Reset Procedure:
- Push acknowledge/reset
button >2sec.
- Orange light flashing. CO GAS ALARM 2
- Constant tone. **CHARGER STOP**
Reset Procedure:
- Push acknowledge/reset
button >2sec.
- Chamber stays in operation. ERROR GAS DETECTION
- Orange light flashing. **CHARGER STOP**
- Constant tone.
Reset Procedure:
- Push acknowledge/reset
button >2sec.
- Chamber stays in operation. SYSTEM ACTIVE
- Compressed air will flush for
120 sec.
If H2 level >25% after 120 sec.:
H2 GAS ALARM 1
- Orange light flashing.
**CHARGER OFF**
- Constant tone.
Reset Procedure:
- Use Key switch.
- Push acknowledge/reset
button >2sec.
- Chamber stays in operation. H2 GAS ALARM 2
- Orange light flashing. **CHARGER OFF**
- Constant tone.
Reset Procedure:
- Use Key switch.
- Push acknowledge/reset
button >2sec.
Operation Manual Battery test chamber 17
 Description Status Message safety control display

- Batec Alarm. - Chamber stops operation.

Activated by:
- Manual tripping device.
- Thermal switch 162°C.
- Red light flashing. ALARM EMERG.STOP
- orange light flashing. ALARM FIRE EXTING.
- Pulse tone. ESPEC & CHARGER
- Acoustic warning device
*EMERGENCY OFF**
active.

Reset Procedure:
- Push/Pull Emergency switch.
- Use Key switch.
Push acknowledge/reset button
>2sec.
- Batec Fault. - Chamber stays in operation. FAILURE FIRE EXT.
- Orange light flashing. **CHARGER STOP**
- Constant tone.

- Batec OFF.
- Pressure Nitrogen.
Alarm setting: 1 Bar
Reset Procedure:
-Push acknowledge/reset
button >2sec.
- Chamber stops operation ALARM EMERG.STOP
- Red light flashing. ALARM FIRE EXTING.
- Pulse tone. ESPEC & CHARGER
*EMERGENCY OFF**
Reset Procedure:
- Push/Pull Emergency switch.
- Use Key switch.
- Push acknowledge/reset
button >2sec.
- Orange light flashing. FAILURE NITROGEN
- Constant tone. **CHARGER STOP**

- Pressure Air.
Alarm setting: 1 Bar
Reset Procedure:
- Push acknowledge/reset
button >2sec.
- Orange light flashing. FAILURE AIR SUPPLY
- Constant tone. **CHARGER STOP**

Reset Procedure:
- Push acknowledge/reset
button >2sec.

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 All alarms are connected to an alarm relay that will be activated if an alarm occurs.
For an additional alarm, the alarm relay is activated when a new alarm signal is active for
more than 5 sec.
By briefly pressing the confirmation key, the alarm bell switch off and The flashing light
comes on permanently.
Active faults are still displayed in the control display.

The alarm sound is automatically switched off after 10 minutes. The alarm light stays on.
With a long press (> 2 sec.) on the acknowledgment button all active alarms are cleared (to
confirm it sounds once), active messages are still displayed.

When the emergency stop switch is used or the explosion vent has activated the emergency
relay. This must be reset with the key switch located on the front of the chamber.

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 10. Description of safety control display

The status display is only informative, operating conditions are displayed together with
indicator lights.
The exact assignment of the control inputs and outputs can be found in the attached circuit
diagram.

• In operating mode, the display shows the time and the switching states of the digital inputs
and outputs.

• Warnings and error messages in text, displayed alternating with the messages on the
display. Several active faults are displayed in sequence.

All control parameters can be viewed and changed in two menus.

The parameter menu can be entered by pressing the A button.

With the B button the parameters can be selected.

Changeable parameters can be selected in the display mode using the arrow keys.
The release for changing a parameter is done with the OK button to flash the value starts to
change.
The flashing value can be changed using the arrow keys within the specified limits.
The confirmation of the settings is done by pressing the OK button.

When there is no key input for 5 minutes or by pressing the ESC key, the controller will
return to the status page.

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 Menu tree of the controller

123456789ABCDEFG
Status display
123456789A
15:30

A-Button pressed 1 time >>>Menu 1 Measured

Operation and Button B Temperature
Limits Sensor 1: ***,**
>>Press button B (Deg Celsius)

Other parameters of
the chamber data

>>>Menu 2 Manual
A-button pressed 2 times
Offset and Flush Time
Delays Button B Nitrogen: 60 sec
>>Press Button B (30-3600 Seconds)

Other parameters of
the chamber data

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 11. Parameter Menus
Menu 1 / operating and limits
parameter Description parameter Codes Setting limits

Value of temperature sensor only display

1 inside test room.
A comparison with the actual
value of the temperature
control sensors of the test
chamber is recommended
before using.
See Menu 2 / offset and
delay times.
Limit setting maximum Maximum temperature raise 00.00 to +10.00 °C/min
temperature sensor 1. sensor 1
Test room: 00.00
(Deg/Minute)
Value of temperature sensor only display
2 inside test room.
A comparison with the actual
value of the temperature
control sensors of the test
chamber is recommended
before using.
See Menu 2 / offset and
delay times.
Limit setting maximum Maximum temperature raise 00.00 to +10.00 ° C/min
temperature sensor 2. sensor 2
Test room: 00.00
(Deg/Minute)

Menu 2 / Offset and delay times

parameter Description parameter Codes Setting limits

Offset temperature sensor 1. Actual value correction -10.00 To +10.00 K

control sensor 1

Offset temperature sensor 2. Actual value correction -10.00 To +10.00 K

control sensor 2

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 12. Manual operation flushing and door lock

123456789ABCDEFG

123456789A
15:30

To trigger the flushing, the next keys must be pressed simultaneously: and

To stop flushing, the next keys must be pressed simultaneously: and

When using this combination the electric door lock will be deactivated.

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 13. Connection with the Charger/Discharger
The Espec temperature and humidity chamber can be connected with the charger via:
- RS-232 communication.
- Wired safety contacts.

13.1. RS-232 communication.

The chamber can be controlled with the software of the charger system.
For more info see the manual of the charge system.

13.2. Wired safety contacts.

The temperature and humidity chamber has several options to connect the charger.
In cause of an emergency the charger and chamber can be stopped.
The charger will be stopped in the following situation:
- Emergency stop button is pressed.
- Explosion vent is activated.
- CO or H2 Gas detection.
- The Espec chamber has an alarm.

The contact is located on Terminal X5-17 and X5-18 of the electric panel.
For other possible connections see the wiring diagram.

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 14. Maintenance and Calibration.
14.1. Espec Temperature chamber.

Yearly maintenance and Calibration is recommended.

The Temperature chamber will be checked on several points and all safety features will be
checked.

14.2. CO and H2 Gas detection.

Regular preventive maintenance of the detection equipment ensures optimum safety.

All maintenance, calibration and testing should be carried out by qualified personnel.
Training courses for your maintenance staff are available upon request.
We recommend carrying out maintenance/calibration at least every six months (unless
particular circumstances request for a shorter interval, please ask Bionics Instrument to
advise).

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