Translation of the original operating instructions

FTC3000
Flexible test chamber for ELT3000

Catalog No.
600-102
From software version--

mima95en1-04-(2208)

INFICON GmbH
Bonner Strasse 498
50968 Cologne, Germany

INFICON

Table of contents

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

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Table of contents

INFICON7.12 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

iv

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About this manual | 1

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 inleak 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

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1 | About this manual

INFICON

1.3 Definition of terms
Minimum detectable leak rate
The minimum detectable leak rate that can be detected by the leak detector underideal 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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Safety | 2

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 theoperator 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 thispurpose, 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 candamage 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 andshould 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 othertest 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 orprotective 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 safetymeasures• Use outside the technical specifications, see "Technical Data".
• Use in locations with very low humidity.
• Use in radioactive areas.

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2 | Safety

INFICON• 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 andwarning instructions.
• Always follow the complete operating instructions for all work.
• If you have any questions about operation or maintenance that are not answeredin 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 intechnically 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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Safety | 2• 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 thebattery 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 therecognized safety regulations. Nevertheless, improper use may result in risk to life andlimb on the part of the user or third parties, or damage to the unit or other property
may occur.

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2 | Safety

INFICONWARNING
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 ofelectrolyte 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 theirreaction products.
► Defective test specimens can develop gross leaks during the leak testing. In thecase 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 wellventilated 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 overatmospheric 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 andcause 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

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Safety | 2

spread of fire. Reaction products during combustion can lead to further health risks. A
metal tray is installed underneath the device. It catches dripping, hot or burning
plastics.
► Make sure that the test chamber is always free of foreign objects.
► Do not operate the device unattended.
► Only operate the device with the exhaust hose connected.
► Do not pump off explosive gases.
► Carefully place the test specimens in the test chamber so that they do not come into
contact with any parts outside the membrane.

CAUTIONWarning about hand injuries
Danger of crushing by opening the flap if the clearance is too small at the top and rear.
Danger of crushing when closing the test chamber lid in the gap between the test
chamber lid and the test chamber, or between the test chamber rings.
► Ensure that there is sufficient space where the devices are located, see also "Setup[} 16]".
► Only open and close the test chamber when your fingers are outside the test
chamber halves and outside the pivoting range of the test chamber.
► Do not touch the hinge when closing the test chamber.

Measurement inaccuracies due to dirty test chamber
Escaping electrolyte can contaminate the test chamber.
► After detecting leakage, check the elastomer films of the test chamber forcontamination caused by escaping electrolyte.
► Avoid inhaling harmful gases or vapors.
► Keep the gaskets for the test chamber halves clean. Do not use grease or
lubricants.
► Remove coarse soiling with a dust-free cloth. This soiling can falsify themeasurement results. The device features a purging function which can be carriedout in case of minor soiling, see ELT3000 instructions "Purging the device". Use
personal protective equipment.
► Change the membrane supports if they are heavily soiled. See also "Change
membrane support [} 24]".

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3 | Scope of delivery, transport

INFICON

3 Scope of delivery, transport
Scope of delivery

Item

Quantity

Test chamber FTC3000

1

Hoses with filters and angle clamps

2(VENT and INLET)
Stud

4

Knurled nut

4

Operating manual1

Unpacking instructions for FTC3000

1

Hose assembly leaflet for FTC3000

1► Check the scope of delivery after receipt of the product to make sure it iscomplete.
Transport

NOTICE
Damage caused by transport
Transport in unsuitable packaging material can damage the device.
► Keep the original packaging.
► Only transport the device in its original packaging.

Storage

Always store the device in compliance with the technical data, see "Technical Data".

NOTICE
Losses due to overly prolonged storage
The functional safety of the membranes of the measuring chamber will eventually
become impaired.
► Do not store membranes for more than 3 years.
► Store the test chamber and other membranes in a dry place that is not exposed tolight.

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Description | 4

4 Description
2

3

4

5

1

1
1

Fig. 1: FTC3000

1

Stud mount (4x)2Inspection dome

3

Handle for opening the test

4

Top membrane support

chamber
5

Bottom membrane support

4.1 Function
The flexible test chamber, in conjunction with the Gas Control Unit of the ELT3000,
makes it possible to perform leak testing on test objects. The flexible test chambersupports the test object from the outside. Test objects that are not vacuum-tight canthus be tested for leak tightness.
Place the test object between the elastic membranes of the flexible test chamber. By
pumping out the air from the test chamber, a pressure gradient between test object
and test chamber is generated. The flexible membranes wrap around the test object
and support it.
Due to this pressure gradient, gas flows through leakages out of the test object andinto the test chamber. This gas is sent to the GDU (Gas Detection Unit) for analysis.

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4 | Description

INFICON

After the analysis, the result is compared with the setpoint. A distinguishable leakproof/leaky signal is output.

4.2 Markings on the device
The markings on the device have the following meanings:
Device cannot be disposed of as normal domestic waste.

Warning about hand injuries

Read operating instructions

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Description | 4

4.3 Technical data
Mechanical data
Dimensions of closed chamber

590mm x 520mm x 270mm(L x W x H)
Dimensions of open chamber

590mm x 520mm x 660mm(L x W x H)
Installation depth (with filter)

740 mmWeightapprox. 19 kg

Electrical data
Operating voltage

24V DCPower consumption

10 W

Protection class

EN 60529 IP20
UL 50E Type 1

Physical data
Pressure range

1080 hPa to 1 hPa

Switch on until ready for operation

2 min.

Ambient conditions
Temperature range (°C)

10 °C to 40 °C

Permissible storage temperature (°C)

0 °C to 60 °C

Relative humidity (%)

80 % at 30 °C, linear decrease to 50 %at 40 °C

Height above sea level (m)2000 mDegree of contaminationII

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5 | Installation

INFICON

5 Installation
5.1 Setup• In order not to distort the measurement results, select a location where thepossible room temperature for the device is constant.
• Do not expose the device to direct sunlight.
• If the clearance to the top and rear is too small, fingers can be crushed when
opening the flap. The following clearance is required:– Footprint: 1m²– Functional height: 1.5 m above the device– Space required for mounting: 4m²– Movement space at the workplaces: 2m²• The flexible test chamber must be mounted on the GCU of the ELT3000 battery
leak detector by a competent person. Alternatively, the flexible test chamber canalso be mounted on a rack, see operating manual of the ELT3000 battery leakdetector.

WARNING
Danger from moisture and electricity
Moisture entering the device can lead to personal injury due to electric shocks as well
as damage to property due to short circuiting.
► Only operate the device in a dry environment.
► Operate the device away from sources of liquid and moisture.

5.2 Mount the device
NOTICE
Property damage due to improper installation
It is recommended to have the installation carried out by INFICON or by trained
personnel.

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Installation | 5

2

3

1

5

4

Fig. 2: FTC3000 mounted on GCU

1

Rear stud (2x)2Test chamber

3

Knurled nut (4x)

4

GCU

5

Front stud (2x)1

Remove the four screws on the top of the Gas Control Unit.

CAUTION
Injury due to electric shock
To ensure good grounding, the four studs must be correctly fixed in place.
► The tightening torque of the front studs is 7 Nm.
► The tightening torque of the rear studs is 18 Nm.
2

Insert the two front studs into the provided tapped holes on the GCU.

3

Insert the two rear studs into the provided tapped holes on the GCU.

4

Place the test chamber on the studs and fasten the closed chamber with thefront two knurled nuts.

5

Open the chamber and fasten the rear two knurled nuts.

6

Connect the connections with the supplied connecting cables and hoses asshown in "Connect device [} 18]".

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5 | Installation

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5.3 Connect device

1

3

2

4

Fig. 3: Connection of FTC3000 to GCU

1"VENT"

3

Liquid separator

2"INLET"

4

Connection for proximity switch (forautomatic measurement start) with redgreen display and ESD connection.

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Operation | 6

6 Operation
WARNING
Risk of injury from explosion
If both battery poles come into contact with the electrically conductive test chamber, ashort circuit and thus high temperatures can occur in the tested battery.
► Do not perform a battery test without the original insulator.
► Only test obviously undamaged battery cells in this test chamber.
► Make sure that there is no material in the test chamber that could damage thebattery (e.g. pointy, sharp objects).
► Leave batteries in the chamber only during the test period, and not permanently.
► Keep the test chamber clean and wash it regularly.
► No smoking.
► Keep ignition sources away from the test chamber.

WARNING
Respiratory tract irritation
The solvents in lithium-ion batteries can cause respiratory irritation and loss of
consciousness if they leak from the battery.
► To avoid irritating the respiratory tract, avoid contact with and inhalation ofelectrolyte.
► Only place obviously undamaged batteries in the test chamber.

CAUTIONWarning about hand injuries► Only open and close the test chamber when your fingers are outside the test
chamber halves and outside the pivoting range of the test chamber.

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6 | Operation

INFICONCAUTION
Danger due to physical stress / ergonomics
Continuous opening and closing of the test chamber cover can result in fatigue of thearm muscles.
Incorrect setup of the test chamber can impair its moving parts.
► Plan enough breaks to avoid fatigue.
► Set up the test chamber so that there is no impairment of its moving parts.
ð When setting up the test chamber, pay attention to the height and distancefrom the operator.
ð Pay attention to the arrangement of the test object trays.

NOTICE
Property damage due to accumulation or blockage in detachable parts
with solvents
Accumulations or clogging of detachable parts by solvents or electrolyte residues leadto functional problems.
► Replace the liquid separator and particle filter as needed, otherwise annually.
► Replace all gaskets and hoses as necessary, otherwise annually.

NOTICE
Reduction of the service life of the membrane and lip seal
Improper handling of the chamber will shorten the service life of the membrane.
► Avoid sharp edges on test objects. Use protective frames or protective edges for
sharp-edged test objects to avoid damaging the membrane.
► Observe the intended use of the test chamber. Large test objects such as cuboids
or similar should be tested in a suitable test chamber.
► Do not stack test objects in the test chamber.
► In order to distribute the load of the test object evenly on the membrane, place thetest object as centrally as possible and maintain an appropriate distance between
the test object and the edge of the test chamber". .
► Always place the test objects carefully in the test chamber and then remove the test
objects carefully.
► Avoid contamination of the test object and test chamber.
► To prevent the membranes from losing their elasticity, avoid direct sunlight and UV
radiation.

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Operation | 6

6.1 Perform leak test
This test chamber is used to perform leak testing on undamaged test objects (lithiumion batteries).
ü Test chamber and vacuum control unit are properly connected, see also"Installation [} 16]".
ü The vacuum control unit is switched on. The two LEDs flash simultaneously during
startup.
1

Place the test object in the test chamber.

2

When the "Autostart" mode is activated, the proximity switch is actuated byclosing the lid and the measurement is started.
ð The air is pumped out of the test chamber.
ð After the analysis, the result is compared with the configured setpoint.
ð The red LED lights up when a leak greater than the configured setpoint has
been detected.
ð The green LED lights up when a leak less than the configured setpoint has
been detected.

3

You can now open the cover and remove the test object. Skin contact withelectrolyte when cleaning the test chamber or removing test objects that havefailed leak tests should be avoided.

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7 | Cleaning and maintenance

INFICON

7 Cleaning and maintenance
7.1 Sending for repair or maintenance
You can send the device to the manufacturer for repair or maintenance. For further
details see "Sending in the device [} 37]”.

7.2 Cleaning the housing
The surfaces of the device are made of aluminum, IIR (butyl rubber), PMMA, stainlesssteel and PETP
1

Make sure that the ELT3000 basic unit is disconnected from the power supply
by disconnecting the power supply plug.

2

For external cleaning of the test chamber, use an agent that is commonly usedon plastic or metal surfaces (e.g. light-duty household cleaners). Do not use
any solvents that may attack plastic or metal.

3

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Avoid all areas inside the chamber that will be exposed to vacuum.

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Cleaning and maintenance | 7

7.3 Clean membranes and lip gaskets
Black membranes are located at the top and bottom of the measuring chamber andform the interior of the test chamber. The two lip gaskets are located on the upper halfof the chamber.

Fig. 4: FTC3000 with GCU

1Wipe off the membrane and the lip gaskets with a damp cloth. In case of minor
soiling (e.g. dust), use only warm water to moisten it. In case of heavy soiling(e.g. electrolyte residues), use the main solvent of the electrolyte used tomoisten it. Avoid other cleaning agents containing alcohols, greases or oils.

2

Ensure complete drying of the membrane and lip gaskets.

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7 | Cleaning and maintenance

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7.4 Change membrane support
WARNING
Danger to health due to hazardous materials and substances
Burns may occur on contact with defective batteries and electrolyte residues.
► Avoid contact with skin, eyes, or clothing.
► Wear appropriate protective clothing, especially gloves, gowns, and face shields.
► Ensure sufficient ventilation at the installation location.
► Observe the safety instructions in the safety data sheets for the test objects.
Top membrane support

Send in for repair or order, order number
200010776

Bottom membrane support

Send in for repair or order, order number
200010777

Required tools

T25 screwdriver
Wrench, size 16 for counterholding
Wrench, size 12

1

2
4

3

Fig. 5: FTC3000: Back view

1 Upper chamber half

3 "VENT" hose

2 Lower chamber half

4 "INLET" hose

During measurement, two membranes nestle against the test object from above andbelow as air is pumped out.

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Cleaning and maintenance | 7

The membranes may be leaking, so that accurate measurements are no longer
possible. Causes of damage can be sharp edged objects, aging or wear. Remove themembrane support including the damaged membrane.
To repair or replace the membrane support with membrane, contact the
manufacturer's service department. Due to the high quality requirements at the
manufacturer, the membrane support is re-tensioned, the components are tested andthen a leak testing is performed.

Disassemblyü At least one membrane no longer functions properly or has to be replaced forreasons of age.

1

Open the measuring chamber and determine which membrane is damaged.

2Upper membrane support: If necessary, to remove the upper membrane
support including the damaged membrane, unscrew the countersunk screws on
the inside of this membrane support using a T25 screwdriver.

3

Loosen and remove the ratchet clamp by moving the rows of teeth against eachother.

Fig. 6: Ratchet clamp on the top of the measuring chamber

4

Lower membrane support: To remove the lower membrane support including
the damaged membrane if necessary, first disconnect both hoses from thebottom of the measuring chamber and pull them off. To loosen the nuts, use awrench (size 16) for counterholding.

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7 | Cleaning and maintenance

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Fig. 7: Threaded hose connection of lower membrane support

5

Use a T25 screwdriver to unscrew the countersunk screws.

6

Loosen and remove the ratchet clamp by moving the rows of teeth against eachother.

Fig. 8: Ratchet clamp on the underside of the measuring chamber

7

For repair, pack the membrane support, so that it is protected against damage
during transport.

8

Please do not hesitate to contact us and send a completed declaration ofcontamination before sending anything to us, see also "Sending in the device[} 37]”.

Installation• If you sent a membrane support with a defective membrane to the manufacturer,
your membrane support has been equipped with a new membrane and leaktesting has been performed. In the case of an upper membrane support, new lip
gaskets have also been added.
• If you want to take precautions in the event of damage to a membrane, you canpurchase from the manufacturer of the device ready-tensioned upper and lower
replacement membrane supports. Note that the service life of stored membranes
reduced by opening the original packaging and due to light.

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Cleaning and maintenance | 7

ü They feature a separate membrane support with an intact membrane.
1

Attach the existing hose to the new chamber membrane. (This applies to boththe upper and lower halves of the chamber.)Fix the connection from the outside using the ratchet clamp. To do this, insert
the black end piece of the hose into the central connection located on the backof the membrane.

2

To assemble the upper membrane support, hold it with the screw holes above
the thread openings, and screw the countersunk screws hand-tight with a T25
screwdriver. Tighten crosswise with a torque of 4 Nm.

3

To install the lower membrane support, insert the membrane support with thescrew holes over the provided thread holes. To do this thread the hoseconnection through the boreholes in the lower membrane support. There is only
one mounting direction possible.
Use a T25 screwdriver to tighten the countersunk screws hand-tight. Tighten
crosswise with a torque of 4 Nm.

4Mount the lower hose connections to the lower membrane support.

1

2
4

3

Fig. 9: Membrane support

1 Upper chamber half

3 "VENT" hose

2 Lower chamber half

4 "INLET" hose

5Move the black hose guides into a right angle arrangement. This provides strain
relief.

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7 | Cleaning and maintenance

INFICON

7.5 Check liquid separator
WARNING
Danger to health due to hazardous materials and substances
Burns may occur on contact with defective batteries and electrolyte residues.
► Avoid contact with skin, eyes, or clothing.
► Wear appropriate protective clothing, especially gloves, gowns, and face shields.
► Ensure sufficient ventilation at the installation location.
► Observe the safety instructions in the safety data sheets for the test objects.
The function of the test chamber and the measuring accuracy of the leak detector canbe impaired by dirty liquid separators. Check the transparent inspection glass of theliquid separator regularly for electrolyte residues.

1Fig. 10: Check liquid separator

1

Inspection glass
1

Replace the inspection glass if it is clearly dirty.

2

When reinserting the inspection glass, make sure that the gasket is in the liquid
separator.

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Cleaning and maintenance | 7

7.6 Change liquid separator
WARNING
Danger to health due to hazardous materials and substances
Burns may occur on contact with defective batteries and electrolyte residues.
► Avoid contact with skin, eyes, or clothing.
► Wear suitable protective clothing, especially gloves, apron and face protection.
► Ensure sufficient ventilation at the installation location.
► Observe the safety instructions in the safety data sheets for the test objects.
Required tools

Wrench, size 16
Wrench, size 12

1

1Fig. 11: Change liquid separator

1

Union nuts (metal)
1

To change the liquid separator, loosen the union nuts and pull off the hose.

2

Replace the dirty liquid separator with a new liquid separator. Note the directionof mounting.

3

Tighten the union nuts again.

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7 | Cleaning and maintenance

INFICON

7.7 Cleaning hoses
WARNING
Danger to health due to hazardous materials and substances
Burns may occur on contact with defective batteries and electrolyte residues.
► Avoid contact with skin, eyes, or clothing.
► Wear appropriate protective clothing, especially gloves, gowns, and face shields.
► Ensure sufficient ventilation at the installation location.
► Observe the safety instructions in the safety data sheets for the test objects.
During the leak testing, air is extracted from the test chamber via a line in which an
inline filter is integrated, see also "Mount the device [} 16]". The second line is usedfor ventilation.
If there is little liquid ingress or condensation formation, the hoses can be dismantled
by a specialist with technical training.
1

To dismantle the hoses, loosen the threaded connections and pull off the hoses
including the filter cartridge.
ð If a larger amount of liquid has reached the bottom of the hoses, contact theservice department.

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Replace the hoses and filter if necessary, see "Change inline filter [} 31]".

3

Reinsert the hoses with the filter.

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Cleaning and maintenance | 7

7.8 Checking inline filter
The function and measuring accuracy of the leak detector can be impaired bycontaminated filters. Check the transparent filter elements (inline filter) regularly for the
ingress of dust.

1

2

1

Fig. 12: Checking inline filter

1

Union nuts (metal)

2

Filter element► Replace the filter elements if they are clearly dirty.
See also
2 Change inline filter [} 31]

7.9 Change inline filter
WARNING
Danger to health due to hazardous materials and substances
Burns may occur on contact with defective batteries and electrolyte residues.
► Avoid contact with skin, eyes, or clothing.
► Wear appropriate protective clothing, especially gloves, gowns, and face shields.
► Ensure sufficient ventilation at the installation location.
► Observe the safety instructions in the safety data sheets for the test objects.
Filter set

200009854

Required tools

Wrench, size 12 mm

1

To be able to pull the hose off the filter element, loosen the union nuts with awrench, see "Checking inline filter [} 31]".

2

Replace the contaminated filter element with a new filter element. Note thedirection of mounting.

3

Tighten the union nuts of the filter element.

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7 | Cleaning and maintenance

INFICONSee also
2 Maintenance plan FTC3000 [} 35]

7.10 Change the hinges of the test chamber
Hinges for test chamber CS4 (set)Order number 200006381

Required tools

T45 screwdriverü You have a set with two hinges for the replacement.
1

Close the test chamber.

2

Make sure that the device is disconnected from the power supply bydisconnecting the power supply plug.

3

On the rear of the device, unscrew the four hinge screws on the lower test
chamber ring using a T45 screwdriver.

4

Carefully open the test chamber lid and pull it backwards.
ð In this way, the spring is pulled out of the guide of the lower test chamber
ring.

5

In order to avoid scratching the test chamber lid, place it on a soft surface alongwith the dome.

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6

Unscrew the two screws of each hinge on the inside of the test chamber lid.

7

Remove the defective hinges and the spacer plates.

8

Insert the new hinges when reusing the spacer plates.

9

Install in reverse order.

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Cleaning and maintenance | 7

7.11 Change the coil spring of the measuring
chamber
Coil spring for test chamber CS4

Order number 200006389

Required tools• T25 screwdriver• T45 screwdriverü You have an intact coil spring to replace a defective coil spring.
1

Make sure that the device is disconnected from the power supply bydisconnecting the power supply plug.

2

Open the lid of the test chamber.

Fig. 13: Coil spring - Cover3

Using a T25 screwdriver, unscrew the two screws of the black spring housing
and remove the spring housing.

4

Close the test chamber.

Fig. 14: Fastening to lower membrane support

5

Using a T45 screwdriver, remove the two hinge screws of the lower test
chamber on both sides.

6

Carefully lift the upper test chamber lid. Once the spring is unloaded, gently pullon the back of the test chamber lid to remove the spring from the guide on thelower support and pull it backwards.

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7 | Cleaning and maintenance

INFICONð In this way, the spring is pulled out of the guide of the lower test chamber
ring, see also "Change the hinges of the test chamber [} 32]".
7

In order to avoid scratching the test chamber lid with dome, place it on a soft
surface.

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8

Pull out the defective spring and replace it.

9Install in reverse order.

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Cleaning and maintenance | 7

7.12 Service by the manufacturer
Maintenance inside the device should only be performed by the manufacturer. We
recommend having the device serviced every four years by the manufacturer's
service.

7.13 Maintenance plan FTC3000
Material Description

Part number

Assembly

Operating hours / years Repair level

Replacement

200 010 776

FTC3000

2 years/replace if

Membrane Frame

II

necessary

Upper
Replacement

200 010 777

FTC3000

Membrane Frame

2 years/replace ifIInecessary

Lower
Liquid separator set

201 009 857

FTC3000

2 years/replace ifInecessary
Inline Filter

200 009 854

FTC3000

10,000 operating hours /Ireplace if necessary
Hinge Changing

200 063 81

FTC3000

replace if necessary

II

Coil Spring Changing

200 062 89

FTC3000

replace if necessary

II

Table 1: Maintenance plan FTC3000

Repair Level I: Customer
Repair Level II: Customer with technical training by INFICON

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8 | Accessories and spare parts

INFICON

8 Accessories and spare parts
Order number
Complete upper membrane support

200010776

FTC3000
Complete lower membrane support

200010777

FTC3000

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Liquid separator + hoses

200009855

Inline Filter

200009854

Hinges measuring chamber CS4 (Set)

200006381

Spring measuring chamber CS4

200006389

Complete hose set for FTC3000

200010962

Chamber gasket set for FTC3000

200010778

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Decommissioning | 9

9 Decommissioning
9.1 Disposing of the device
The device can either be disposed of by the operator or be sent to the manufacturer.
The device consists of materials that can be recycled. This option should be exercised
to prevent waste and also to protect the environment.
• During disposal, observe the environmental and safety regulations of your country.
The test chamber cannot be disposed of as normal domestic waste.

9.2 Sending in the device
WARNING
Danger due to harmful substances
Contaminated devices could endanger health. The contamination declaration servesto protect all persons who come into contact with the device.
► Fill in the declaration of contamination completely.
1

Contact the manufacturer and send in a completed declaration of contamination
before return shipment.
ð You will then receive a return number and a shipping address.

2

Use the original packaging when returning.

3

Before sending the device, attach a copy of the completed contamination
declaration.

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9 | Decommissioning

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INFICON

FTC3000-Operating-instructions-mima95en1-04-(2208)

INFICONCE Declaration of Conformity | 10

10 CE Declaration of Conformity

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11 | UK Declaration of conformity

INFICON

11 UK Declaration of conformity

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