Efficient Leak Testing with Tracer Gas Methods All over the world governments are Helium Vacuum releasing new regulations to lower emissions and fuel consumption and Helium Sniffing to increase the safety of cars. Hence, many vehicle components Hydrogen (5%) Sniffing must be tested to lower and lower Helium leak rates and sometimes even new Accumulation components are added to the vehicle Hydrogen (5%) design for this purpose. Tracer gas Accumulation leak testing offers very efficient Pressure methods to test for small leak rates Decay Testing with high reliabilty and independant Water Bath Testing of temperature or humidity. Also Values in mbarl/s 100 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 many new technologies like electric Values in sccm 100 10 1 0.1 0.01 0.001 10-4 10-5 10-6 10-7 10-8 10-9 10-10 drive trains and fuel cell propulsion Bubbling rate under 1000 100 10 1 20 no no no no no no no no best conditions bubbles/ bubbles/ bubbles/ second/ seconds/ bubbles bubbles bubbles bubbles bubbles bubbles bubbles bubbles generate new applications for second second second bubble bubble Theoretical Range efficient leak testing ideally met by Practical Range tracer gas methods. SNIFFER METHOD The test component is filled with tracer gas or the operating medium. In case of leaks the tracer gas escapes through the leakage channel and is TRACER GAS detected by a sniffer probe. Probe can be moved manually or automatically via a robot. This method is ideally suited when you need to know the TRACER GAS exact location of the leakage. VACUUM METHOD The test component is filled with tracer gas in an evacuated vacuum Leak Testing in the chamber when using the vacuum method. In case of a leak, the tracer VACUUM gas escapes through the leak path and is measured by a leak detector Automotive Industry which is connected to the vacuum chamber. Leak detection systems in TRACER GAS accordance with the vacuum method are characterized by exceptional measuring sensitivity and extremely short measuring times. Applications for Component Manufacturing and Final Assembly Testing ACCUMULATION METHOD The test component is filled with tracer gas and placed in an accumulation chamber. Tracer gas which escapes through leaks in the chamber is equally distributed throughout the chamber via fans. The leak detector measures the total leakage rate of the test component regardless of the position of the CONCENTRATION TRACER GAS TIME 15 sec. leak. As the test takes place under atmospheric conditions, simple and cost-effective chamber systems can be used. Drivetrain | E-Drivetrain | CNG / LNG Fuel Cell Drive | Fuel System Fuel H2 Drivetrain Cell Drive H2 Automotive Torque Dual fly EGR Charge-air Automotive Fuel cell Fuel cell stack FC pressure Hydrogen Hydrogen Transmisson Fuel cell plate Component converter wheel cooler intercooler Component housing (assembled) sensor gas line fuel tank Sniffing / Accumulation / Accumulation / Accumulation / Vacuum / (Robotic) Sniffing / Vacuum / Sniffing / Testing method Vacuum Testing method Vacuum Vacuum Accumulation Vacuum Vacuum Vacuum Accumulation Accumulation Accumulation Accumulation 10-2 – ...1 mbarl/s ~ 10-4 mbarl/s -4 -5 -2 4 -2 -4 -4 -5 -4 -5 -4 -5 Typical leak rates 10-4 ... 10-5 mbarl/s 10-4 ... 10-5 mbarl/s ~ 10-3 mbarl/s Typical leak rates 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 1 sccm ~ 0.01 sccm Recommended LDS3000 AQ LDS3000 AQ XL3000flex Modul1000 LDS3000 LDS3000 Modul1000 Recommended INFICON XL3000flex XL3000flex Protec P3000(XL) LDS3000 AQ Modul1000 LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 AQ LDS3000 AQ LDS3000 INFICON products Protec P3000(XL) Protec P3000(XL) LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 products Sensistor Sentrac Fuel E 1/1 System Filler Neck E-Drivetrain Automotive Carbon Fuel tank Fuel tank Tank filler neck Tank filler cap Fuel pump Hoses for Component canister sending unit Automotive Assembled Cell cap Battery case electric battery Electric motor Inter-cell cooler Sniffing / Accumulation / Accumulation / Accumulation / Accumulation / Component battery pack Testing method Vacuum cooling Accumulation Vacuum Vacuum Vacuum Vacuum Vacuum / Vacuum / (Robotic) Sniffing / (Robotic) Sniffing / Vacuum / 10-1 – ...1 mbarl/s ~ 10-4 mbarl/s ~ 10-4 mbarl/s Testing method Sniffing Typical leak rates 10-3 ...10-4 mbarl/s 10-4 ...10-5 mbarl/s ~ 10-3 mbarl/s Bombing Accumulation Accumulation Accumulation Accumulation 5 ... 100 sccm ~ 0.01 sccm ~ 0.01 sccm Typical leak rates 10-6 mbarl/s 10-2 ... 10-4 mbarl/s 10-2 ... 10-4 mbarl/s 10-4... 10-5 mbarl/s 10-3 ... 10-5 mbarl/s 10-3 ... 10-5 mbarl/s Recommended LDS3000 LDS3000 AQ Modul1000 LDS3000 AQ LDS3000 AQ Modul1000 INFICON Modul1000 Recommended LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 LDS3000 Modul1000 LDS3000 XL3000flex LDS3000 Protec P3000(XL) INFICON XL3000flex XL3000flex products LDS3000 LDS3000 AQ Protec P3000(XL) LDS3000 AQ products Protec P3000(XL) Protec P3000(XL) EV Automotive High pressure High pressure High pressure Fuel pressure Fuel injector Fuel filter Component fuel pump fuel rail fuel line sensor Automotive Battery module Sub-cooled Cooling Lithium-ion Chiller Accumulation / Accumulation / Accumulation / Accumulation / Component cold plate loop radiator pipeline battery cells Testing method Accumulation Vacuum Vacuum Vacuum Vacuum Vacuum Accumulation / Accumulation / Accumulation / Accumulation / Vacuum / Testing method -4 -4 5 -5 -4 5 -2 -4 6 Vacuum Vacuum Vacuum Sniffing Bombing Typical leak rates ~ 10 mbarl/s 10 ...10 mbarl/s ~ 10 mbarl/s 10 ...10 mbarl/s ~ 10 mbarl/s 10 ...10 mbarl/s Recommended Typical leak rates 10-3 – 10-5 mbarl/s 10-4 – 10-5 mbarl/s 10-4 – 10-5 mbarl/s 10-4 – 10-5 mbarl/s ~ 10-6 mbarl/s LDS3000 AQ LDS3000 AQ LDS3000 AQ Modul1000 INFICON LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 Recommended LDS3000 AQ LDS3000 AQ LDS3000 AQ products XL3000flex Modul1000 INFICON LDS3000 LDS3000 LDS3000 Protec P3000(XL) LDS3000 products Modul1000 Modul1000 Modul1000 Sensistor Sentrac Servo Automotive Swirl pot DEF (“AdBlue“) Power steering Servo oil Brake fluid Component (Diesel) tank housing reservoir reservoir CNG Accumulation / Testing method Accumulation Accumulation Accumulation Accumulation CNG / LNG CNG Vacuum Typical leak rates 10-2 ... 10-4 mbarl/s ~ 10-4 mbarl/s 10-2 ... 10-4 mbarl/s 10-2 ... 10-4 mbarl/s 10-3 ... 10-4 mbarl/s Automotive Natural gas Natural gas Recommended LDS3000 AQ Component engine tank INFICON LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 products Testing method Sniffing Sniffing ~ 10-4 mbarl/s Typical leak rates 10-4 ... 10-5 mbarl/s ~ 0.01 sccm Recommended XL3000flex XL3000flex INFICON Protec P3000(XL) Protec P3000(XL) products Product names and components in bold are linked for further information. Product names and components in bold are linked for further information. Safety Features | AC System | Oil and Water Circuit Various | Final Assembly Safety Features Various Windshield Automotive Vacuum brake Air suspension Automotive Xenon light Brake hoses Brake calipers Air brakes Air brake tank wiper fluid Wheel rims Starter battery Component pump valve Component bulbs container Vacuum / Testing method Accumulation Accumulation Vacuum Vacuum Vacuum Testing method Accumulation Vacuum Sniffling Accumulation Accumulation 10-4 ... 10-5 mbarl/s 10-4 ... 10-5 mbarl/s Typical leak rates ~ 10-2 mbarl/s ~ 10-4 mbarl/s ~ 10-6 mbarl/s ~ 10-3 mbarl/s ~ 10-1 mbarl/s Typical leak rates 10-3 ...10-4 mbarl/s 10-3 ...10-4 mbarl/s 0.03 to 0.03 to ~ 10-5 mbarl/s Recommended 5...20 sccm Modul1000 LDS3000 AQ 0.0006 sccm 0.0006 sccm INFICON LDS3000 AQ Ecotec E3000 LDS3000 Sensistor Sentrac Recommended Modul1000 products Modul1000 Modul1000 Modul1000 INFICON LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 products LDS3000 AQ Final Automotive Air suspension Shock Seat belt Airbag Airbag Power brake Assembly Fuel Component cylinder absorber pretensioner ignitor caps generator booster Cooling circuit Automotive Air conditioning Engine fuel Fuel rail Testing method Vacuum Vacuum Accumulation Bombing Vacuum Accumulation for drive Component systems circuit connections Cold gas: battery 10-6 ... 10-8 mbarl/s 5 g/a of refrigerant 5 g/a of refrigerant Typical leak rates ~ 10-5 mbarl/s ~ 10-4 mbarl/s 10-3 ...10-4 mbarl/s ~ 10-4 mbarl/s 10-3 ... 10-4 mbarl/s Typical leak rates 10-3 ...10-5 mbarl/s ~ 10-4 mbarl/s Hot gas: per joint per joint 10-3 ...10-4 mbarl/s Sensistor Sentrac Recommended Recommended XL3000flex HLD6000 HLD6000 Modul1000 Modul1000 Modul1000 LDS3000 AQ INFICON Ecotec E3000 INFICON LDS3000 AQ LDS3000 AQ Protec P3000(XL) Ecotec E3000 Ecotec E3000 LDS3000 LDS3000 LDS3000 LDS3000 products products Ecotec E3000 AC System FRONT AREAS: Automotive 9 Evaporator Condensor Filling valve Expansion valve AC Hoses Compressor 7 1 Drivetrain Component 8 10 Vacuum / Vacuum / Vacuum / Vacuum / Vacuum / Testing method Accumulation Accumulation Accumulation Accumulation Accumulation Accumulation 2 E-Drivetrain Typical leak rates ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s 1 4 Recommended LDS3000 LDS3000 LDS3000 LDS3000 LDS3000 3 CNG / LNG INFICON LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ products Modul1000 Modul1000 Modul1000 Modul1000 Modul1000 4 Fuel Cell Drive 5 Fuel System Oil & Water REAR 6 Safety Features Pump Circuit 3 5 Automotive Coolant 7 AC System Plastic oil tank Oil cooler Oil pump Water cooler Component expansion tank 6 2 Vacuum / Vacuum / Accumulation / Testing method Accumulation Accumulation 8 Oil & Water Accumulation Accumulation Sniffling 10-2 ... 10-1 mbarl/s 10-2 mbarl/s Typical leak rates ~ 10-1 mbarl/s 10-2 mbarl/s ~ 10-1 mbarl/s 1 ..