Binder MK 240 Operational manual

Issue 03/2021 Art. no. 7001-0409
Operating Manual
Translation of the original operating manual
LIT MK (E5)
Battery test chambers
Model
Model version
Art. No.
LIT MK 240 LITMK240-400V 9020-0402, 9120-0402
LITMK240-400V-C 9020-0404 (with voltage and frequency changer)
LIT MK 720 LITMK720-400V 9020-0403, 9120-0403
LITMK720-400V-C 9020-0405 (with voltage and frequency changer)
BINDER GmbH
Address: Post office box 102, 78502 Tuttlingen, Germany Phone: [phone]
Fax: [phone] Internet: http://www.binder-world.com
E-mail: [e-mail] Service Hotline: [phone]
Service Fax: [phone] Service E-Mail: [e-mail]
Service Hotline USA: [phone] or [phone] x3
Service Hotline Asia Pacific: [phone] or [phone]
Service Hotline Russia and CIS: [phone]

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Contents
1. SAFETY.................................................................................................................. 7
1.1 Personnel Qualification .......................................................................................................................7
1.2 Operating manual................................................................................................................................7
1.3 Legal considerations ...........................................................................................................................7
1.4 Structure of the safety instructions......................................................................................................8
1.4.1 Signal word panel .....................................................................................................................8
1.4.2 Safety alert symbol ...................................................................................................................8
1.4.3 Pictograms ................................................................................................................................9
1.4.4 Word message panel structure.................................................................................................9
1.5 Localization / position of safety labels on the chamber ....................................................................10
1.6 Type plate..........................................................................................................................................10
1.7 General safety instructions................................................................................................................11
1.7.1 Notes on the installation site...................................................................................................12
1.7.2 Notes on loading and operation..............................................................................................13
1.7.3 Notes on handling CO2...........................................................................................................14
1.7.4 Notes on handling nitrogen when using it as inert gas ...........................................................15
1.7.5 Precautions when handling gas cylinders ..............................................................................15
2. INTENDED USE ................................................................................................... 16
2.1 Use ....................................................................................................................................................16
2.1.1 EUCAR Hazard levels – Overview .........................................................................................17
2.2 General requirements for the chamber load .....................................................................................18
2.3 Tests with EUCAR hazard level up to max. 3...................................................................................18
2.3.1 Requirements for the chamber load .......................................................................................18
2.3.2 Operation with the max. Expectation of an EUCAR event with hazard level 3 ......................19
2.4 Tests with EUCAR hazard level 4 to 6..............................................................................................19
2.4.1 Requirements for the chamber load .......................................................................................19
2.4.2 Detection and secure inclusion of an event within the battery test chamber by immanent
safety with a defined load (max. one single 18650 cell with LIT MK 240, max. three 18650
cells with LIT MK 720).............................................................................................................21
2.4.3 Detection and safe inclusion of an event within the battery test chamber by additional opera-
tor-provided measures with a defined load.............................................................................21
2.5 Medical devices.................................................................................................................................22
2.6 Personnel Requirements...................................................................................................................22
2.7 Installation site requirements and ambient conditions ......................................................................22
3. FORESEEABLE MISUSE .................................................................................... 23
4. RESIDUAL RISKS................................................................................................ 24
5. OPERATOR RESPONSIBILITY, DOCUMENTATION, AND MEASURES .......... 27
5.1 Risk assessment ...............................................................................................................................27
5.2 Employee training and protocols.......................................................................................................27
5.3 Operating instructions .......................................................................................................................28
5.4 Protective equipment ........................................................................................................................28
5.5 Standard Operating Procedures (SOPs) ..........................................................................................28
5.6 Testing and maintenance..................................................................................................................28
5.7 System logbook.................................................................................................................................29
5.8 Operation log.....................................................................................................................................29
6. TESTING .............................................................................................................. 30
6.1 Objective of testing............................................................................................................................30
6.2 Scope of the tests .............................................................................................................................30
6.2.1 Testing before initial commissioning.......................................................................................30

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6.2.2 Tests of technical ventilation systems, extinguishing systems, gas warning devices, inerting
devices, devices, protective systems or safety, control or regulating devices, and other tech-
nical devices for explosion protection .....................................................................................31
6.2.3 Inspection after changes requiring review ..............................................................................32
6.2.4 Recurring tests........................................................................................................................32
6.3 Proof of tests .....................................................................................................................................32
7. CHAMBER DESCRIPTION .................................................................................. 33
7.1 Manufacturer's safety plan: Protective measures and equipment ....................................................33
7.2 Chamber overview ............................................................................................................................35
7.3 Safety module on the right side of the chamber ...............................................................................37
7.4 Lateral control panel..........................................................................................................................38
7.5 Rear power switch.............................................................................................................................39
7.6 Instrument panel ...............................................................................................................................39
7.7 Rear chamber view ...........................................................................................................................40
7.8 Gas detection ....................................................................................................................................41
7.9 CO2fire suppression device (can be triggered automatically and manually) ...................................43
7.9.1 Automatic triggering of the CO2fire suppression device ........................................................44
7.9.2 After triggering of the CO2fire suppression device.................................................................44
7.10 Mechanical door lock ........................................................................................................................44
7.11 Exhaust port with reversible pressure relief flap ...............................................................................45
8. COMPLETENESS OF DELIVERY, TRANSPORTATION, STORAGE, AND
INSTALLATION.................................................................................................... 46
8.1 Unpacking, and checking equipment and completeness of delivery ................................................46
8.2 Guidelines for safe lifting and transportation.....................................................................................47
8.3 Storage..............................................................................................................................................47
8.4 Location of installation and ambient conditions ................................................................................47
9. INSTALLATION AND CONNECTIONS ............................................................... 49
9.1 Connecting the CO2pressurized gas cylinder ..................................................................................49
9.2 Inertization connections for customer systems.................................................................................49
9.3 Installation of the voltage and frequency changer (chambers with voltage and frequency changer)
..........................................................................................................................................................51
9.4 Electrical connection .........................................................................................................................52
9.4.1Information on connecting the battery test chamber ..............................................................52
9.4.2 Connecting the voltage and frequency changer (for chambers equipped with a voltage and
frequency changer) .................................................................................................................53
10. FUNCTIONAL OVERVIEW OF THE MB2 CHAMBER CONTROLLER............... 55
10.1 Operating functions in normal display...............................................................................................56
10.2 Display views: Normal display, program display, chart-recorder display..........................................57
10.3 Controller icons overview ..................................................................................................................58
10.4 Operating modes...............................................................................................................................60
10.5 Controller menu structure..................................................................................................................61
10.5.1 Main menu ..............................................................................................................................62
10.5.2 “Settings” submenu.................................................................................................................63
10.5.3 “Service” submenu..................................................................................................................63
10.6 Principle of controller entries.............................................................................................................64
10.7 Performance during and after power failures....................................................................................64
10.8 Performance when opening the door................................................................................................65
11. COMMISSIONING................................................................................................ 65
11.1 Preparing and activating the general safety devices ........................................................................65
11.1.1 Inserting the CO2pressurized gas cylinder ............................................................................65
11.1.2 Activating the gas detection system .......................................................................................66
11.1.3 Connection of the coil connector on the CO2pressurized gas cylinder .................................67
11.1.4 Function test of the valve ........................................................................................................67
11.1.5 Connecting the CO2flushing line (high-pressure hose) .........................................................68

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11.2 Commissioning an operator-provided inertization ............................................................................69
11.3 Handling the safety devices during operation ...................................................................................70
11.4 Turning on the chamber....................................................................................................................70
11.5 Controller settings upon start up .......................................................................................................71
12. SET-POINT ENTRY IN “FIXED VALUE” OPERATING MODE........................... 72
12.1 Set-point entry through the “Setpoints” menu...................................................................................72
12.2 Direct setpoint entry via Normal display............................................................................................73
12.3 Special controller functions via operation lines .................................................................................73
13. NOTIFICATION AND ALARM FUNCTIONS........................................................ 75
13.1 Alarms via indicator light with integrated buzzer...............................................................................75
13.1.1 Connections and forwarding of notifications and alarms to customer systems......................76
13.2 Notification and alarm messages overview on the MB2 chamber controller ....................................77
13.2.1 Notifications ............................................................................................................................77
13.2.2 Alarm messages .....................................................................................................................78
13.2.3 State of alarm..........................................................................................................................78
13.2.4 Resetting an alarm, list of active alarms.................................................................................79
13.2.5 Activating / deactivating the audible alarm (alarm buzzer) of the MB2 controller ..................79
14. BEHAVIOR WHEN/AFTER TRIGGERING OF THE CO2FIRE SUPPRESSION
DEVICE ................................................................................................................ 80
15. TEMPERATURE SAFETY DEVICES................................................................... 80
15.1 Over temperature protective device (class 1) ...................................................................................80
15.2 Temperature limiter class 2...............................................................................................................81
15.3 Overtemperature safety controller (adjustable temperature limiter class 2 ......................................81
15.3.1 Safety controller modes ..........................................................................................................81
15.3.2 Setting the safety controller ....................................................................................................82
15.3.3 Message and measures in the state of alarm.........................................................................83
15.3.4 Function check........................................................................................................................83
15.4 Over/under temperature safety device class 2 (option) ....................................................................84
16. TIMER PROGRAM: STOPWATCH FUNCTION .................................................. 85
16.1 Starting a timer program ...................................................................................................................85
16.1.1 Performance during program delay time ................................................................................85
16.2 Stopping a running timer program ....................................................................................................86
16.2.1 Pausing a running timer program ...........................................................................................86
16.2.2 Cancelling a running timer program........................................................................................86
16.3 Performance after the end of the program........................................................................................86
17. TIME PROGRAMS ............................................................................................... 87
17.1 Starting an existing time program .....................................................................................................87
17.1.1 Performance during program delay time ................................................................................88
17.2 Stopping a running time program......................................................................................................88
17.2.1 Pausing a running time program.............................................................................................88
17.2.2 Cancelling a running time program.........................................................................................88
17.3 Performance after the end of the program........................................................................................88
17.4 Creating a new time program............................................................................................................89
17.5 Program editor: program management.............................................................................................89
17.5.1 Deleting a time program..........................................................................................................90
17.6 Section editor: section management.................................................................................................91
17.6.1 Add a new program section ....................................................................................................92
17.6.2 Copy and insert or replace a program section........................................................................92
17.6.3 Deleting a program section.....................................................................................................93
17.7 Value entry for a program section.....................................................................................................94
17.7.1 Section duration ......................................................................................................................94
17.7.2 Set-point ramp and set-point step...........................................................................................95
17.7.3 Special controller functions via operation lines.......................................................................96

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17.7.4 Setpoint entry..........................................................................................................................97
17.7.5 Tolerance range......................................................................................................................98
17.7.6 Repeating one or several sections within a time program......................................................99
17.7.7 Saving the time program.........................................................................................................99
18. WEEK PROGRAMS ........................................................................................... 100
18.1 Starting an existing week program..................................................................................................100
18.2 Cancelling a running week program ...............................................................................................100
18.3 Creating a new week program ........................................................................................................101
18.4 Program editor: program management...........................................................................................102
18.4.1 Deleting a week program......................................................................................................103
18.5 Section editor: section management...............................................................................................104
18.5.1 Add a new program section ..................................................................................................105
18.5.2 Copy and insert or replace a program section......................................................................105
18.5.3 Deleting a program section...................................................................................................106
18.6 Value entry for a program section...................................................................................................106
18.6.1 Set-point ramp and set-point step modes.............................................................................106
18.6.2 Weekday ...............................................................................................................................107
18.6.3 Start time...............................................................................................................................107
18.6.4 Setpoint entry........................................................................................................................108
18.6.5 Special controller functions via operation lines.....................................................................108
19. USER MANAGEMENT....................................................................................... 109
19.1 Authorization levels and password protection.................................................................................109
19.2 Log in...............................................................................................................................................112
19.3 Log out ............................................................................................................................................113
19.4 User change....................................................................................................................................113
19.5 Password assignment and password change.................................................................................114
19.5.1 Password change .................................................................................................................114
19.5.2 Deleting the password for an individual authorization level..................................................116
19.5.3 New password assignment for “Service” or “Admin” authorization level when the password
function was deactivated ......................................................................................................117
19.6 Activation code................................................................................................................................118
20. GENERAL CONTROLLER SETTINGS.............................................................. 119
20.1 Selecting the controller’s menu language .......................................................................................119
20.2 Setting date and time ......................................................................................................................119
20.3 Selecting the temperature unit ........................................................................................................121
20.4 Display configuration.......................................................................................................................121
20.4.1 Adapting the display parameters ..........................................................................................121
20.4.2 Touchscreen calibration........................................................................................................122
20.5 Network and communication...........................................................................................................123
20.5.1 Serial interfaces ....................................................................................................................123
20.5.2 Ethernet ................................................................................................................................124
20.5.2.1 Configuration .................................................................................................................124
20.5.2.2 Display of MAC address ................................................................................................125
20.5.3 Web server............................................................................................................................125
20.5.4 E-Mail....................................................................................................................................126
20.6 USB menu: Data transfer via USB interface ...................................................................................127
20.7 Turning off the interior lighting automatically ..................................................................................128
21. GENERAL INFORMATION ................................................................................ 128
21.1 Service contact page.......................................................................................................................128
21.2 Current operating parameters.........................................................................................................129
21.3 Event list..........................................................................................................................................130
21.4 Technical chamber information.......................................................................................................130
22. CHART RECORDER DISPLAY ......................................................................... 131
22.1 Views...............................................................................................................................................131
22.1.1 Show and hide legend ..........................................................................................................131

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22.1.2 Switch between legend pages ..............................................................................................131
22.1.3 Show and hide specific indications .......................................................................................132
22.1.4 History display.......................................................................................................................132
22.2 Setting the parameters....................................................................................................................135
23. NOTES ON REFRIGERATING OPERATION .................................................... 136
24. ANTI-CONDENSATION PROTECTION VIA OPERATION LINE....................... 137
25. ZERO-VOLTAGE SWITCHING OUTPUTS VIA OPERATION LINES ............... 138
26. OPTIONS............................................................................................................ 139
26.1 APT-COM™ 4 Multi Management Software (option)......................................................................139
26.1.1 APT-COM™ 4 Basic Edition.................................................................................................139
26.2 RS485 interface (option) .................................................................................................................139
26.3 Data logger kit (option)....................................................................................................................139
26.4 Analog outputs for temperature (option) .........................................................................................140
26.5 Object temperature display with flexible Pt 100 temperature sensor (option) ................................140
26.6 Compressed air connection (option) ...............................................................................................141
27. CLEANING AND DECONTAMINATION ............................................................ 141
27.1 Cleaning the battery test chamber following normal operation.......................................................142
27.2 Cleaning the battery test chamber after triggering of the CO2fire suppression device..................143
27.3 Decontamination / chemical disinfection.........................................................................................144
28. MAINTENANCE: INSPECTION, MAINTENANCE, TROUBLESHOOTING,
REPAIR, TESTING............................................................................................. 145
28.1 General information, personnel qualification...................................................................................145
28.2 Maintenance intervals, service........................................................................................................146
28.3 Inspections ......................................................................................................................................147
28.4 Simple troubleshooting....................................................................................................................147
28.5 Sending the chamber back to BINDER GmbH ...............................................................................150
29. DISPOSAL.......................................................................................................... 150
29.1 Disposal of the transport packing....................................................................................................150
29.2 Decommissioning............................................................................................................................151
29.3 Disposal of the chamber in the Federal Republic of Germany .......................................................151
29.4 Disposal of the chamber in the member states of the EU except for the Federal Republic of Ger-
many................................................................................................................................................152
29.5 Disposal of the chamber in non-member states of the EU .............................................................154
30. TECHNICAL DESCRIPTION.............................................................................. 154
30.1 Factory calibration and adjustment .................................................................................................154
30.2 Over-current protection ...................................................................................................................154
30.3 Definition of usable volume.............................................................................................................154
30.4 Technical data.................................................................................................................................155
30.5 Equipment and options (extract) .....................................................................................................157
30.6 Accessories and spare parts (extract) ............................................................................................158
30.7 Dimensions......................................................................................................................................159
31. CERTIFICATES AND DECLARATIONS OF CONFORMITY............................. 161
31.1 EU Declaration of Conformity..........................................................................................................161
31.2 Certificate for the GS mark of conformity of the “Deutsche Gesetzliche Unfallversicherung e.V.“
(German Social Accident Insurance) DGUV...................................................................................164
31.3 Safety concept certificate from TÜV Süd ........................................................................................166
32. CONTAMINATION CLEARANCE CERTIFICATE ............................................. 167
32.1 For chambers located outside the USA and Canada .....................................................................167
32.2 For chambers located in the USA and Canada ..............................................................................170

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Dear customer,
For the correct operation of the chambers, it is important that you read this operating manual completely
and carefully and observe all instructions as indicated. Failure to read, understand and follow the instruc-
tions may result in personal injury. It can also lead to damage to the chamber and/or poor equipment per-
formance.
1. Safety
1.1 Personnel Qualification
The chamber must only be installed, tested, and started up by personnel qualified for assembly, startup,
and operation of the chamber. Qualified personnel are persons whose professional education, knowledge,
experience and knowledge of relevant standards allow them to assess, carry out, and identify any potential
hazards in the work assigned to them. They must have been trained and instructed, and be authorized, to
work on the chamber.
Only trained personnel with knowledge of the handling of hazardous substances and lithium-ion accumu-
lators as well as knowledge of the operating instructions may set up and install, commission, operate, clean
and decommission the chamber. Further technical requirements (e.g. electrical knowledge) and knowledge
of the service manual are required for maintenance and repairs. The requirements specified by the operator
for PPE (personal protective equipment) must be observed. Training on handling compressed gas cylinders
is required to replace the CO2compressed gas cylinder.
1.2 Operating manual
This operating manual is part of the components of delivery. Always keep it handy for reference in the
vicinity of the chamber. If selling the unit, hand over the operating manual to the purchaser.
To avoid injuries and damage observe the safety instructions of the operating manual. Failure to follow
instructions and safety precautions can lead to significant risks.
DANGER
Dangers due to failure to observe the instructions and safety precautions.
Serious injuries and chamber damage. Risk of death.
Observe the safety instructions in this Operating Manual.
Follow the operating procedures in this Operating Manual.
Carefully read the complete operating instructions of the chamber prior to installing
and using the chamber.
Keep the operating manual for future reference
Make sure that all persons who use the chamber and its associated work equipment have
read and understood the Operating Manual.
This Operating Manual is supplemented and updated as needed. Always use the most recent version of
the Operating Manual. When in doubt, call the BINDER Service Hotline for information on the up-to-date-
ness and validity of this Operating Manual.
1.3 Legal considerations
This operating manual is for informational purposes only. It contains information for correct and safe in-
stalling, start-up, operation, decommissioning, cleaning and maintenance of the product. Note: the contents
and the product described are subject to change without notice.

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Understanding and observing the instructions in this operating manual are prerequisites for hazard-free use
and safety during operation and maintenance. Images are to provide basic understanding. They may devi-
ate from the actual version of the chamber. The actual scope of delivery can, due to optional or special
design, or due to recent technical changes, deviate from the information and illustrations in these instruc-
tions this operating manual. In no event shall BINDER be held liable for any damages, direct or incidental
arising out of or related to the use of this manual.
This operating manual cannot cover all conceivable applications. If you would like additional information,
or if special problems arise that are not sufficiently addressed in this manual, please ask your dealer or
contact us directly, e.g. by phone at the number located on page one of this manual
Furthermore, we emphasize that the contents of this operating manual are not part of an earlier or existing
agreement, description, or legal relationship, nor do they modify such a relationship. All obligations on the
part of BINDER derive from the respective purchase contract, which also contains the entire and exclusively
valid statement of warranty administration and the general terms and conditions, as well as the legal regu-
lations valid at the time the contract is concluded. The statements in this manual neither augment nor
restrict the contractual warranty provisions.
1.4 Structure of the safety instructions
In this operating manual, the following safety definitions and symbols indicate dangerous situations follow-
ing the harmonization of ISO 3864-2 and ANSI Z535.6.
1.4.1 Signal word panel
Depending on the probability of serious consequences, potential dangers are identified with a signal word,
the corresponding safety color, and if appropriate, the safety alert symbol.
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious
(irreversible) injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
(irreversible) injury
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor
(reversible) injury
NOTICE
Indicates a potentially hazardous situation which, if not avoided, may result in damage to the product
and/or its functions or of a property in its proximity.
1.4.2 Safety alert symbol
Use of the safety alert symbol indicates a risk of injury.
Observe all measures that are marked with the safety alert symbol in order to avoid death or
injury.

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1.4.3 Pictograms
Warning signs
Electrical hazard
Hot surface
Explosive atmosphere
Stability hazard
Lifting hazard Pollution Hazard Harmful substances
Risk of corrosion and /
or chemical burns
Biohazard
Danger of frost
Mandatory action signs
Mandatory regulation
Read operating
instructions
Disconnect the power
plug
Lift with mechanical
assistance
Environment protection
Wear protective gloves
Wear safety goggles
Prohibition signs
Do NOT touch
Do NOT spray with
water
Do NOT climb
Information to be observed in order to ensure optimum function of the product.
1.4.4 Word message panel structure
Type / cause of hazard.
Possible consequences.
∅Instruction how to avoid the hazard: prohibition.
Instruction how to avoid the hazard: mandatory action.
Observe all other notes and information not necessarily emphasized in the same way, in order to avoid
disruptions that could result in direct or indirect injury or property damage.

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1.5 Localization / position of safety labels on the chamber
The following labels are located on the chamber:
Pictograms (Warning signs)
Hot surface (on chamber door)
Cold surface (on chamber door)
Electrical hazard
(chamber with voltage and frequency
changer: on the voltage and fre-
quency changer)
Service label
Figure 1: Position of labels on the chamber
Keep safety labels complete and legible.
Replace safety labels that are no longer legible. Contact BINDER service for these replacements.
1.6 Type plate
The type plate sticks to the left side of the chamber, bottom right-hand, above the refrigerating module.
Figure 2: Type plate (example of LIT MK 240 regular chamber)
Nominal temp.
110 °C
5,60 kW / 12,0 A
Max. operating pressure 29 bar
230 °F
400 V / 50 Hz
Stage 1: R 452 A – 1,40 kg
IP protection
20
Safety device
DIN 12880
3 N ~
Contains fluorinated greenhouse gases
Class
2.0
covered by the Kyoto Protocol
Art. No.
9020-0402
Project No.
Built
2021
Battery test chamber
BINDER GmbH
Im Mittleren Ösch 5
78532 Tuttlingen / Germany
www.binder-world.com
LIT MK 240
E5
Serial No. 00000000000000
Made in Germany