RC01-E EV Battery Electrolyte and Air Leak Tester (High & Low Pressure)

RC01-E – Battery Electrolyte & Air Leak Tester

For HV EV Battery Aftersales Service, Repair Workshops and Battery Pack Production

Application and Function – Electrolyte Leakage Detection

The RC01-E Battery Electrolyte Leak Tester is connected to the fully sealed high-voltage battery. Using its integrated vacuum pump, the device extracts air from inside the battery housing and analyzes it for electrolyte vapor concentration (ppm). The permissible threshold can be configured according to OEM specifications. The result is displayed clearly as PASS or FAIL:

• PASS – No electrolyte vapors detected
  The battery can be safely opened and repaired under standard workshop conditions.

• FAIL – Electrolyte vapors detected
  The battery must only be opened in a controlled safety environment, as leaked electrolyte vapors can pose health hazards and indicate internal cell or module damage.

The test duration is typically 10–30 seconds, depending on the battery’s internal air volume.

Quality Assurance After Repair or Service

After completing repair work, the RC01-E can be used to validate the repair by performing a post-repair electrolyte leak test. In addition, the device provides two pressure-based leak testing functions:

• Low-Pressure Leak Test
  Ensures the battery enclosure is airtight by applying a slight under- or over-pressure to detect even very small leaks.

• High-Pressure Leak Test
  Verifies the cooling system integrity (cooling plates, coolant channels, pipe connections) under elevated pressure to ensure proper function of the thermal management system.

All test results are automatically stored in an integrated database, enabling:

• Full traceability of all diagnostic and repair steps

• Quality documentation for customers

• Compliance with OEM and audit requirements

This ensures that every serviced battery meets defined safety, reliability, and performance standards before returning to operation.

Application in Battery Production and Pack Assembly

The RC01-E is also designed for quality assurance in battery manufacturing. During laser welding of battery cells and contact plates, invisible micro-cracks may occur in the cell casing. If a weld seam overheats or burns through, electrolyte may escape — resulting in:

• Health risks for production personnel

• Reduced cell performance or complete cell failure

• Increased rework and production waste

To detect such defects early, the battery module or pack can be placed into an airtight test chamber (standard chamber volume approx. 10 L) and connected to the RC01-E. The device generates a vacuum and analyzes the extracted air for traces of electrolyte vapors — allowing rapid and reliable leak detection before the pack moves to the next production stage or is shipped.

Larger chambers or customized process settings can be configured upon request.

Designed for Both Aftersales Service & Industrial Manufacturing

The RC01-E is therefore a dual-purpose solution:

✔ Battery Electrolyte Tester for EV repair and workshop safety
✔ HV EV Battery Air Leak Tester for production and assembly quality assurance