Inficon FTC3000 Quick guide

Translation of the original operating instructions
FTC3000
Flexible test chamber for ELT3000
mima95en1-04-(2208)
Catalog No.
600-102
From software version
--

INFICON GmbH
Bonner Strasse 498
50968 Cologne, Germany

INFICON Table of contents
FTC3000-Operating-instructions-mima95en1-04-(2208) iii
Table of contents
1 About this manual .......................................................................................................................................... 5
1.1 Target groups........................................................................................................................................... 5
1.2 Warnings .................................................................................................................................................. 5
1.3 Definition of terms .................................................................................................................................... 6
2 Safety............................................................................................................................................................... 7
2.1 Intended use ............................................................................................................................................ 7
2.2 Duties of the operator............................................................................................................................... 8
2.3 Owner requirements................................................................................................................................. 8
2.4 Dangers.................................................................................................................................................... 9
3 Scope of delivery, transport........................................................................................................................ 12
4 Description.................................................................................................................................................... 13
4.1 Function ................................................................................................................................................. 13
4.2 Markings on the device .......................................................................................................................... 14
4.3 Technical data........................................................................................................................................ 15
5 Installation .................................................................................................................................................... 16
5.1 Setup ...................................................................................................................................................... 16
5.2 Mount the device.................................................................................................................................... 16
5.3 Connect device ...................................................................................................................................... 18
6 Operation ...................................................................................................................................................... 19
6.1 Perform leak test .................................................................................................................................... 21
7 Cleaning and maintenance.......................................................................................................................... 22
7.1 Sending for repair or maintenance......................................................................................................... 22
7.2 Cleaning the housing ............................................................................................................................. 22
7.3 Clean membranes and lip gaskets......................................................................................................... 23
7.4 Change membrane support ................................................................................................................... 24
7.5 Check liquid separator ........................................................................................................................... 28
7.6 Change liquid separator ......................................................................................................................... 29
7.7 Cleaning hoses ...................................................................................................................................... 30
7.8 Checking inline filter ............................................................................................................................... 31
7.9 Change inline filter ................................................................................................................................. 31
7.10 Change the hinges of the test chamber .................................................................................................32
7.11 Change the coil spring of the measuring chamber................................................................................. 33

Table of contents INFICON
iv FTC3000-Operating-instructions-mima95en1-04-(2208)
7.12 Service by the manufacturer ..................................................................................................................35
7.13 Maintenance plan FTC3000................................................................................................................... 35
8 Accessories and spare parts ...................................................................................................................... 36
9 Decommissioning ........................................................................................................................................ 37
9.1 Disposing of the device .......................................................................................................................... 37
9.2 Sending in the device............................................................................................................................. 37
10 CE Declaration of Conformity ..................................................................................................................... 39
11 UK Declaration of conformity...................................................................................................................... 40

INFICON About this manual | 1
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1 About this manual
Product names may occur in the document, which are added for identification
purposes only and belong to the respective owner of the rights.
1.1 Target groups
This instruction manual is intended for operators and technically qualified personnel
with experience in leak detection technology and the integration of leak detectors in
leak detection systems. In addition, the installation and use of the device require
knowledge of electronic interfaces.
1.2 Warnings
DANGER
Imminent hazard resulting in death or serious injuries
WARNING
Hazardous situation resulting in potential death or serious injuries
CAUTION
Hazardous situation resulting in minor injuries
NOTICE
Hazardous situation resulting in damage to property or the environment

1 | About this manual INFICON
6 / 42 FTC3000-Operating-instructions-mima95en1-04-(2208)
1.3 Definition of terms
Minimum detectable leak rate
The minimum detectable leak rate that can be detected by the leak detector under
ideal conditions (< 1 x 10-6 mbar l/s*).
* Helium equivalent leak rate for DMC with a pressure difference of 1000 mbar versus
0 mbar.
GCU
Gas Control Unit (basic unit, operating unit)
GDU
Gas Detection Unit
DMC
Dimethyl carbonate, typical solvent in battery electrolyte. CAS No. 616-38-6
MSDS
Material Safety Data Sheet

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2 Safety
2.1 Intended use
The flexible test chamber is designed for leak testing of Li-ion cells and Li-ion
batteries. Uncharged cells / batteries can be tested safely. For testing charged cells /
batteries, further safety measures must be taken to avoid personal injury and damage
to property.
• For validation of the test, cells prepared as leaky are placed in the chamber. The
preparation of the cells, which creates further hazards, is performed by the
operator and is not an integral part of the test or the device. Testing of leaking
cells will result in soiling of the flexible test chamber and possibly "contamination".
Cells to be tested with the flexible test chamber must be pre-qualified. For this
purpose, uncharged cells are examined, for example, to determine whether they
can withstand the stresses of the leak testing. Suitable measures for the safety of
man and machine must be taken by the operator.
• The test objects must be filled with an electrolyte in which one solvent component
ideally consists of dimethyl carbonate (DMC, CAS No. 616-38-6).
• Depending on the internal structure of the test objects and the external
geometries, local mechanical stresses can occur on the test objects. This can
damage the test objects themselves, but also other components located in the test
chamber.
• Make sure that the test chamber and the outer wall of the test objects are clean.
Leak testing with charged test objects represents an additional safety risk and
should only be carried out by appropriately trained personnel and with the
installation of further safety measures.
• Make sure that the test objects are supported by the flexible membrane from all
sides. The distance between the test objects in the test chamber must be at least
four times the thickness of the test objects as a circumferential distance from other
test objects. Furthermore, a distance of at least 5cm to the edge of the test
chamber must be maintained.
Also, no other materials, except for specially designed protective frames or
protective edges, should be placed in the test chamber (e.g. holders for several
test objects), as this does not allow reliable stabilization by the test chamber
membrane on the test objects.
Incorrect usage Avoid the following unintended uses:
• Testing of partially or fully charged cells and batteries without further safety
measures
• Use outside the technical specifications, see "Technical Data".
• Use in locations with very low humidity.
• Use in radioactive areas.

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• Use in potentially explosive atmospheres.
• Use in areas with risk of electromagnetic interference.
• Closing the test chamber while your fingers are in the swivel range of the test
chamber.
• Use of accessories or spare parts, which are not listed in this manual.
• Testing of test objects whose current collectors can be short-circuited via the test
chamber ring.
• Test of test objects that touch the sealing lips of the foil chamber.
• Test of sharp objects
• Testing of wet or damp test objects.
• Test of test objects with significant differences in temperature to the environment.
• Testing of cells and batteries that are visibly damaged.
• Use of tools that may damage the sealing surfaces or elastomers of the test
chamber during mechanical cleaning.
Note: This device is not intended to be used in residential areas and cannot ensure
adequate protection of radio reception in such environments. The battery leak detector
does not perform a safety function. In the event of strong electromagnetic interference,
measured values could be falsified. It is recommended to check the function of the test
chamber regularly (e.g. with a calibration leak).
2.2 Duties of the operator
• Read, observe, and follow the information in this manual and in the work
instructions provided by the owner. This concerns in particular the safety and
warning instructions.
• Always follow the complete operating instructions for all work.
• If you have any questions about operation or maintenance that are not answered
in this manual, contact customer service.
2.3 Owner requirements
The following notes are for companies or any person who is responsible for the safety
and effective use of the product by the user, employees or third parties.
Safety-conscious operation
• Only operate the flexible test chamber and the battery leak detector if it is in
technically perfect condition and shows no signs of damage.
• Only operate the flexible test chamber and the battery leak detector as intended,
in a safety-conscious and hazard-conscious manner and in compliance with these
operating instructions.

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• Provide ambient conditions that are suitable for operating staff, the test chamber
and the test specimen.
• Adhere to the following regulations and observe their compliance:
– Intended use
– General applicable safety and accident prevention regulations
– International, national and local standards and guidelines
– Additional device-related provisions and regulations
• Only use original parts or parts approved by the manufacturer.
• Keep this instruction manual available on site.
Personnel qualifications
• Only allow instructed personnel to work with the flexible test chamber and the
battery leak detector. The instructed personnel must have received appropriate
training. This includes knowledge of the dangers posed by leaking electrolyte/
solvent.
• Make sure that authorized personnel have read and understood the instruction
manual and all other applicable documents.
2.4 Dangers
The measuring instrument was built according to the state-of-the-art and the
recognized safety regulations. Nevertheless, improper use may result in risk to life and
limb on the part of the user or third parties, or damage to the unit or other property
may occur.

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WARNING
Danger to health due to hazardous materials and substances
Test specimens are usually filled with substances that are hazardous to health. If
these substances leak during the test, they are freely accessible to the operator after
the test.
► Wear appropriate protective clothing, especially gloves, gowns, and face shields.
► Ensure sufficient ventilation at the installation location.
► Avoid contact with skin, eyes, or clothing.
► Avoid inhaling these substances.
► Only test specimens for leak tightness that do not show any damage or smell of
electrolyte or solvent after initial inspection.
► Before removing the test specimen (visual check and smell test), check whether
any contents of the test specimen have leaked out.
► Pay attention to the risks posed by released electrolyte components and their
reaction products.
► Defective test specimens can develop gross leaks during the leak testing. In the
case of test specimens with gross leaks, observe the company's internal regulations
for handling electrolyte and the safety instructions in the safety data sheets.
► Do not pump out toxic or corrosive gases.
► Clean the device regularly and keep it clean at all times.
► Observe the safety instructions in the safety data sheets for the test objects.
► Operate the device only with a connected exhaust air connection and in well-
ventilated rooms. Alternatively, the device may be used in rooms where hazardous
substances under test are monitored.
► When nitrogen or argon is used as a purge gas, it can cause asphyxiation at
dangerous room concentrations. Suitable measures must be taken. The pressure in
the gas line to the purge gas connection must not exceed 100 mbar over
atmospheric pressure. An exhaust gas line must be connected.
WARNING
Fire and explosion hazard
Sharp foreign objects can penetrate into test pieces during the test procedure and
cause a short circuit. Defective test specimens can start a fire, even with a time delay.
The elastomer components of the device are not fire-resistant and cannot prevent the