DOT Walk-In Chamber and Two DRACARYS for Power4Future

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Il Disgelo developed for Power4Future a battery-testing platform consisting of one 8.5 m³ DOT Walk-In climatic chamber and two identical DOT DRACARYS-1500D climatic chambers.

The equipment was configured to support thermal-climatic testing of batteries and related components, integrating control, monitoring and dedicated safety systems for battery-testing applications according to configurations associated with EUCAR 6 hazard levels.

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Developed Solution

The platform includes an 8.5 m³ Walk-In climatic chamber, intended for larger DUTs and heavier loads, together with two identical DRACARYS-1500D chambers, which can be used as independent test stations for climatic testing of batteries and smaller components.

The Walk-In chamber is built with a modular structure, AISI 304 stainless-steel interior, reinforced floor and large access door. The two DRACARYS units are approximately 1500-litre monoblock chambers, featuring a wider temperature range and higher dynamic performance.

The overall system was developed to ensure:

• three climatic test stations dedicated to battery testing;
• one 8.5 m³ Walk-In chamber;
• two identical DOT DRACARYS-1500D chambers;
• thermal and climatic testing of batteries and related components;
• management of DUTs with different dimensions and masses;
• programmable temperature control;
• humidity control according to configuration;
• dedicated gas-monitoring systems;
• CO, H₂ and O₂ detection according to configuration;
• door-locking systems and safety interlocks;
• DUT temperature monitoring;
• air-exchange and purging systems;
• overpressure protection devices;
• Roxtec cable feedthrough provisions;
• water mist fire-suppression systems;
• programming, data logging and supervision through CliMaLogic®;
• connection to external systems via Ethernet and Modbus TCP/IP.

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Main Technical Data

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DOT Walk-In – 8.5 m³

• quantity: 1;
• usable volume: approx. 8.5 m³;
• internal dimensions: 2300 × 2400 × 2000 mm;
• approximate external dimensions: approx. 2500 × 2600 × 2200 mm;
• temperature range: −10 °C to +70 °C;
• temperature accuracy: ±0.5 °C over time;
• heating rate: approx. 1 °C/min;
• cooling rate: approx. 1 °C/min;
• allowable heat dissipation at −10 °C: approx. 3 kW;
• reference internal load: up to approx. 800 kg for temperature-rate evaluation;
• floor load capacity: up to approx. 4000 kg;
• clear door opening: approx. 2300 × 2000 mm;
• insulation: 100 mm;
• interior: AISI 304 stainless steel;
• compressor: Dorin H1500CS, approx. 15 HP;
• condensation: water-cooled;
• installed power: approx. 30 kW;
• approximate weight: approx. 1800 kg.

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DOT DRACARYS-1500D

• quantity: 2 identical units;
• usable volume per chamber: approx. 1500 litres;
• internal dimensions: 1500 × 1000 × 1000 mm;
• external dimensions: approx. 1700 × 2100 × 2030 mm;
• temperature range: −40 °C to +180 °C;
• heating rate: approx. 3 °C/min;
• cooling rate: approx. 2 °C/min;
• humidity range: 20% to 98% RH;
• temperature uniformity: ≤ 2 °C;
• humidity uniformity: up to approx. ±2–3% RH under the specified conditions;
• internal shelf: stainless steel, load capacity up to approx. 360 kg;
• door: with heated 450 × 450 mm viewing window;
• side feedthroughs: 2 × Ø100 mm;
• refrigeration system: single-stage unit, approx. 7.5 HP;
• refrigerant: R452A;
• installed power: approx. 22 kW per chamber;
• approximate weight: approx. 1600 kg per chamber;
• control: DOT PLC with CliMaLogic®;
• programming: up to 50 programs with 20 steps each;
• data logging: CSV export via USB;
• communication: Ethernet, VNC Viewer and Modbus TCP/IP.

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Battery Testing Safety

The equipment was configured with specific protection systems dedicated to battery testing, including:

• emergency stop;
• optical and acoustic alarm;
• electromechanical door locking;
• DUT thermal protection;
• CO, H₂ and O₂ gas monitoring;
• air-exchange and purging systems;
• overpressure relief devices;
• Roxtec cable feedthroughs;
• temperature and smoke sensors;
• water mist fire-suppression system;
• safety logics integrated with the control system.

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Result

The project enabled Power4Future to implement a platform consisting of three complementary climatic systems, capable of covering different battery-testing requirements: one Walk-In chamber for larger DUTs and two identical DRACARYS chambers for independent testing of more compact components and systems.

The combination of different test volumes, wide temperature ranges, climatic control and dedicated battery safety systems provides high flexibility for validation programs while maintaining the possibility of running multiple tests in parallel.