Fukuda FL-601 Series Operational Manual Download Page 4

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FOR YOUR SAFETY

Descriptions for the icons used in this manual are shown below.

SYMBOLS

DESCRIPTIONS

These points are essential for testing correctly and are reminders to
prevent problems from occurring. It may also highlight instructions

that are necessary to avoid malfunction and incorrect evaluations.

For your reference

Labels that are affixed to the Leak Tester Body

WARNING

MEMO

LABEL

(1) Do not remove the tester unit’s cover.
(2) Some parts inside of the tester carry a high

voltage and may be driven unexpectedly, due to the
tester’s mechanical sequences. Possible electrical
shock or injuries may result. (Only qualified
personnel should perform maintenance and service
procedures.)

DANGER

Summary of Contents for FL-601 Series

Page 1: ...O LTD http www fukuda jp com Thank you for purchasing the All Purpose Air Leak Tester Model FL 601 For best operating results and optimum efficiency read this instruction manual thoroughly to understand the tester s many functions prior to operation Please keep this manual within reach ...

Page 2: ...d useful information Please contact your local FUKUDA distributor if there are any inaccuracies or questions of concern FUKUDA distributor addresses are listed at the back of this manual Reprinting or duplicating this manual partially or completely is prohibited unless permitted by FUKUDA CO LTD Please do not read out analyze or publish this equipment s installed system software Exporting this equ...

Page 3: ...ing equipment may result in injury or possible death CAUTION Ignoring this marking and mishandling equipment may result in possible injury or property damage CAUTION May cause electrical shock TERMS THAT ARE USED IN THIS OPERATIONAL MANUAL TERMS DESCRIPTION Turn off the main switch 1 This implies not only turning off the power switch but also turning off all power supply sources to the equipment f...

Page 4: ... are necessary to avoid malfunction and incorrect evaluations For your reference Labels that are affixed to the Leak Tester Body WARNING MEMO LABEL 1 Do not remove the tester unit s cover 2 Some parts inside of the tester carry a high voltage and may be driven unexpectedly due to the tester s mechanical sequences Possible electrical shock or injuries may result Only qualified personnel should perf...

Page 5: ...wer and pneumatic supply are terminated We recommend employing lock up cylinders to avoid such problems DO NOT PLACE FOREIGN MATERIALS INTO THE TESTER Do not insert foreign materials such as metals or inflammable materials into the tester through the vent hole or other openings It will damage the tester and could possibly cause fire or electrical shocks SYSTEM DESIGN The system is designed with a ...

Page 6: ...tinued use of damaged parts will cause fire electric shock and may rupture piping INTRUSION OF FOREIGN MATERIALS If water oil or other foreign materials enter the tester immediately cut off the main power and the compressed air source Continued operation of damaged testers can cause fire or possible electric shock Contact your local FUKUDA distributor for technical advice DROPPED OR DAMAGED TESTER...

Page 7: ...l leaks Enforce periodic checkups and keep the tester as clean as possible SECURE A PROPER OPERATING ENVIRONMENT Use and keep this tester in an environment which has been specifically designated according to our specifications This tester cannot be used where flammable explosive or vaporizing gas is present Be certain that the power supply meets specifications prior to your initial power connectio...

Page 8: ...STPRESSUREREGULATOR 25P FILTERREGULATOR 25P PNEUMATICREGULATOR 25P ADDITIONALEQUIPMENT 26P THENAMESOFEACHPART 28P MAINBODY 28P CONNECTORPARTS 30P CONTROLKEYS 31P INSTALLATIONINSTRUCTIONS 32P OPERATIONENVIRONMENT 32P ABOUTTHEWORK MASTER 33P ABOUTTHEMASTERTANKHANDLING 33P TRANSPORTATIONINSTRUCTIONS 33P INSTALLATIONSIZES 34P INSTALLATIONMEASUREMENTS 34P MOUNTINGTOOLASSEMBLY 34P BASICPIPING 35P SELECT...

Page 9: ...INGAMANUALCALIBRATOR 76P I OCHECKFUNCTIONS 81P SELF CHECKFUNCTIONS 84P STABILITYCONFIRMATIONFUNCTIONS 87P SOFTWAREVERSIONDISPLAY 89P APUTUNING 91P CALPORTOPEN 94P OPTIONAL EQUIPMENT EXHAUSTBYPASSUNIT 96P CHARGE BYPASSUNIT 99P APUUNIT PNEUMATIC REGULATOR 102P DAILYMAINTENANCE ERRORMANAGEMENT 108P MAINTENANCE INSPECTION 110P DAILYINSPECTIONS 110P PERIODICINSPECTIONS 110P SUPPLEMENT MASTERLESSQ A 112...

Page 10: ...9 OUTLINE ...

Page 11: ... differential pressure air leak testing methods costs are reduced and testing space is minimized Improved detection accuracy By stabilizing the internal air alteration in the fitting side chamber detection sensitivity is greatly improved Improved data compensation technology enables highly sensitive detection without interference from negative environmental factors Can set up to 16 different condi...

Page 12: ...R 52 Filter Regulator Unit Positive Pressure UL Range Precision spec P 200 FR 53 Filter Regulator Unit Positive Pressure L Range Standard spec FR 54 Filter Regulator Unit Positive Pressure L Range Precision spec FR 55 Filter Regulator Unit Positive Pressure L Range Precision spec and High Performance spec Filter FR 56 Filter Regulator Unit Positive Pressure M Range Standard spec FR 57 Filter Regul...

Page 13: ...is not included Testing Sensitivity Standard work of 50ml used for Leak Experiment Result within 5 1ml min Air Pilot Drive Valve Driving Pressure 300 400kPa Display LCD Display with CFL backlight Indication Dot Numbers 128 48 Effective Indication Measurement W90mm D36mm Group Setting 0 15 group 16ch total External Input Output REMOTE 50pin External Control Signal APU SIGNAL 8pin APU Control Signal...

Page 14: ... less than 100kPa and middle pressure by switching even in M range Pressure Control Range Symbol Configuration Note P Positive V Negative The FL 601 will automatically control this range by simply connecting the cables Pressure Range kPa Symbol Pressure Range Note 100 V 70W 90W 130W only 20 UL 90W 130W only 100 L 70W 90W 130W only 700 M 70W 90W only APU Specifically for Use with Leak Testers Symbo...

Page 15: ...ol Pressure Range REMARKS V 5 90 kPa TEST SUP C 10 700 kPa AIR IN Bypass Unit Cable Symbol Cable Length REMARKS 1 5 1 5m ACCESSORY ITEM 3 3 0m OPTIONAL ITEM PRESSURE BYPASS UNIT CBU 600 Range Symbol Pressure Range REMARKS C 10 700 kPa AIR IN Bypass Unit Control Cable Symbol Cable Length REMARKS 1 5 1 5m ACCESSORY ITEM 3 3 0m OPTIONAL ITEM ...

Page 16: ...al Calibrator CAL 0 1 0 1ml F S R 1 8 Manual Calibrator CAL 1 0 1 0ml F S R 1 8 Manual Calibrator CAL 5 0 5 0ml F S R 1 8 Remote Control Dial Regulator 2302 3C Large Leak Source Pressure Regulator APU 70W APU 90W Pneumatic Regulator APU 130W Please refer to page 13 for details and specifications on our various models Pressure Switch PS01 Pressure Switch for Negative Pressure Sensitivity 3 F S Pres...

Page 17: ...16 OUTLINE ADDITIONAL EQUIPMENT MEMO ...

Page 18: ...17 PRINCIPLE ...

Page 19: ...ords how much gas will presumably evaporate into the atmosphere before it becomes dangerous For water valves it is necessary to determine the permissive leak rate that will not affect product performance not only for a short time but also for the lifetime of the product Generally speaking the degree of leak detection and the cost of leak inspections will have an inverse proportional relationship T...

Page 20: ... in running costs and the elimination of post processing Different leak testing conditions and requirements can be easily set according to the test products and setting definite conditions with numeric values enables automated leak testing with consistent objectivity The operation of this equipment can also be controlled by external signals allowing you to extract the testing results thereby allow...

Page 21: ...9 51 101 1kg cm2 9 806 65 104 9 806 65 10 2 7 355 59 102 1 1 104 1mmH2O 9 906 65 9 806 65 10 6 7 355 59 10 2 1 10 4 1 In general the leak tester will not display the leak rate during the detection process The indicated value is the pressure alteration rate often called delta P which is the rate of the resultant pressure decay equal to the leak rate This concept can be easily explained by portrayin...

Page 22: ...ting the constants obtained during this fitting testing are required reducing the length of the detection test Set Item Detect Time SV3 SV2 SV1 MASTER WORK Conventional Circuit Diagram The circuit diagram for conventional leak testing which uses a differential pressure comparison is similar to the diagram shown on the right Testing is conducted by simultaneously pressurizing both the master and wo...

Page 23: ...nd b are recorded through fitting testing With standard testing the recorded c and b constant numbers are given a fixed value through approximation and are later substituted The constant a is calculated using approximation The leak rate is calculated using the constant a The constant b is determined using ambient and work temperatures 3 ｃｂａ constant number fixed fitting FittingSet2 The constants...

Page 24: ...23 POWER ON PROCEDURE ...

Page 25: ...CTURE ACCESSORY ITEMS Operational Manual 1 Inspection Sheet 1 Operational manual includes warranty card Please take care not to lose these items Mounting Metal Fitting 2 Mounting Bits 4 Remote Connector 50 P With case 1 External Valve Control Connector 34 P With Case 1 APU Connector 8P With Case 1 FRONT Main Body Nameplate REAR AC Power Cord Rated 125 V 2 meters 1 Nameplate Master Tank 1 Be noted ...

Page 26: ...rmance Spec Filter FR 56 Positive Pressure M Range Standard spec FR 57 Positive Pressure M Range Precision spec FR 58 Positive Pressure M Range Precision spec and High Performance Spec Filter FR 59 Positive Pressure H Range Standard spec FR 60 Positive Pressure H1 Range Standard spec FR 61 Negative Pressure V Range Standard spec FR 62 Negative Pressure V Range Precision spec P 200 Please contact F...

Page 27: ...232C Cable AR305 1 5m Used to save testing data EXHAUST BYPASS UNIT EBU 600 Use when foreign substances and or liquid are likely to be sucked into the tester EXHAUST BYPASS UNIT FE 20 Use when foreign substances and or liquid are likely to be sucked into the tester PRESSURE BYPASS UNIT CBU 600 Used when an increased pressure is likely to enter the work The following options are also available for ...

Page 28: ... Type Includes coupler 1 0 ml Manual Calibrator 1 0 ml PT Type Includes coupler 5 ml Manual Calibrator 5 ml PT Type Includes coupler 1 Remote Control Dial Regulator With Pressure Gauge 2 Precision Regulator For remote control dial regulator adjustment Regulator for pilot pressure Air Tank VBAT20 20L VBAT30 30L ...

Page 29: ...a to external devices LCD Contrast Adjustment dial for the Liquid Crystal Display JUDGMENT LAMP Indicates judgment results READY LAMP Lights up when tester is ready CPU LAMP Lamp will turn off during power supply input following the beginning of operations and during normal operation It will light up if an error is detected ERROR LAMP Lights up when an error malfunction is detected RUN LAMP Lights...

Page 30: ...lled air pilot valves Supply clean filtered air 300 400kPa AC IN Power Supply connection Connect the power cable here P E Protective earth Ground REMOTE Remote signal Remote connector for external control POWER Power Switch EXT VALVE SIGNAL External optional valve signal Used to control signals such as exhaust valves AIR SUPPLY Test Pressure Air supply port for this tester Be sure to supply clean ...

Page 31: ...TERNAL CONTROL SIGNAL EXH VALVE SIGNAL 34P CONNECTOR HONDA MR 34LF EXTERNAL OPTIONAL VALVE SIGNAL page37 41 APU SIGNAL 8P CONNECTOR HONDA MR 8LM APU CONTROL SIGNAL page41 P E Ground Terminal Protective earth page47 POWER CONNECTOR EXHAUST VALVE SIGNAL EXTERNAL OPTIONAL VALVE SIGNAL APU SIGNAL APU CONTROL SIGNAL REMOTE REMOTE CONTROL SIGNAL REAR PANEL FRONT PANEL RS 232C Danger Be sure to turn off ...

Page 32: ... Execution Press this key in order to conduct actual standard testing SET Setting Used to input setting values FITTING Fitting Used when conducting Fitting testing MAINT Maintenance Confirms status when problems occur Used to measure volume BUBL Retained charging Used when conducting air bubble testing MANUAL Internal REMOTE External Can select manual or remote control After selecting press ENT to...

Page 33: ...er in a stable manner Do not carry the tester by the manifold handle This may cause damage to the tester or to its casing and may result in injury OPERATION ENVIRONMENT For best results and accuracy it is recommended that the operation temperature and environmental humidity conditions are 23 5 55 10 RH If there is an abrupt temperature change noise will be added to the test data producing unreliab...

Page 34: ... are left standing for a period of time be sure to leave the parts close to the leak tester in order to ensure that it is in a similar environment If pre processing causes temperature changes hot water cleansing welding etc wait until the temperature of the test parts acclimate to room temperature It is not possible to obtain accurate test results if the temperature is not consistent Jig Work Test...

Page 35: ...ply has been turned off to avoid the risk of accidents At least 5 cm Please use the provided mounting plates when installing this equipment Please refer to the external diagram for further details 390 145 6 6 4 M5 At least 5cm Follow the remarks listed below for installation There is a cooling fan located on the rear panel of the tester body Leave enough space between the tester and the wall of ad...

Page 36: ... SURGE TANK This tester uses an electro pneumatic regulator APU which allows a large flow rate to be supplied within a shorter processing time In order to obtain the best performance from the tester it is necessary to maintain a sufficient airflow supply AIR SUPPLY Test Pressure Rc1 4 Supply Test Pressure A P SUP Pilot Valve Operation Pressure Rc 1 4 Supply air 300 400kPa Be sure that there is no ...

Page 37: ...ection Contents Mist Separator Use articles with filtration degree less than 0 01 μm 1 Suction Filter Use a filtering degree of less than 30μm and a flow rate of at least 200 liters min 2 Common Decompression Valve Use one that has a larger leak rate capability or higher setting pressure range than the test pressure decompression valve Administer the test pressure at 0 1MPa Minute Decompression Va...

Page 38: ...edbynoiseinterference thewiringfortheinputsignalwithinthefixtureand theoutputsignalpowersourceshouldbeassembledseparately Differentpowersourcewiringfoundinthefixture shouldalsobeassembledseparately Usingashieldcodefortheinputsignalwireisrecommended REMOTE TERMINAL TABLE No SignalName Input Output Pin No SignalName Input Output 1 STOP Input No Signal Name Input Output 33 OK Output 2 START Input 19 ...

Page 39: ...M FloatingCircuitPowerInput EachREMOTEinputterminalemploysafloatingcircuitto avoidinterferencefromexternalperipheral equipment Therefore ifpowerisnotsuppliedtothisterminal thesignalsthatareinputtotheREMOTEterminalscannotbedetected IfthisunitisbeingcontrolledusingPLC supplythepower tothisterminalfromtheconnectedequipmentusingthespecifications listedbelow OK NG NG 2NG B NG P NG TheLeaktestjudgmentis...

Page 40: ...wersource InputCircuit WARNING Donotcombinetheinternalandexternalpowersourcewires Doingsomayresultinfire CAUTION UseDC12 24V 10 fortheexternalpowersource Theinput outputcircuitpowersourcecommonisconsistent Theinputcircuitactuationcurrentis8mAateachpoint ThemaximumloadperunitontheexternalcircuitisDC30V 10mA Themaximumdistanceforthesignaltransfershouldbelessthan10m Dependingonthecableused COM INPUT ...

Page 41: ...seattachedconnectorsinsteadofadustcoverandenclosedmetal partsforcablecramping arerequestedtoremovethemetalportionofthecablecramps andstorethemseparately Wearesorryforanyinconveniencethatthismaycause Ifyoukeepthesurroundingmetalpartsonthecablecramps theterminalsmayshort possiblyresultinginirregularreadoutsandinaccuratemeasurements Alternately ifyoupurchasenewitems constructtheattachedconnectorsandc...

Page 42: ...nalSVsignalshouldbelessthan0 5 A persignal Makesurethat3externalSVsignalscombinedarelessthan1 A MaximumloadvoltageshouldbelessthanDC30 V APU CONTROLTERMINAL TABLE DonotuseotherthanfortheAPUcontrolsignals Pin No SignalName Input Output Pin No SignalName Input Output 1 15V Output Pin No SignalName Input Output 6 15V Output 2 NC 4 12VDC Power Output 7 SGND 3 D AOUT Output 5 GND POWER 8 APPLIEDCONNECT...

Page 43: ...ol Valve ＥＳＶ4 ５５ OK NG NG 2NG BNG PNG RUN RDY END ２ ERR Remote Output Signal M R STOP START FITTING BUBL RETRY GROUP1 ３ GROUP2 ３ GROUP4 ３ GROUP8 ３ Psw ＥＮＧＬＭ1 Remote Input Signal Reading Timing ＬＭ2 1 UseF DETtestingtimeforFittingTesting SignalON SignalOFF 2 EXHwillturnONafter200msec 3 Inputatleast200msecbeforeinputtingtheSTART FITTING Signal 4 Bysettingthelimitswitchsettingto EFFECTIVE thisproces...

Page 44: ...ssurecircuitonpage115 116 isopenedtomakethe workpressureandthemastertankinternalpressureequal Duringthisstage ifthework sinternalpressurebecomeslowerthanthereferencepressure lowerlimitof internalworkpressure itmaybejudgedasalargeleakandthetestwillbeterminated 6 BAL2STAGE Inthisstage thework sinternalairpressureisstabilized During this stage if the pressure difference between the work and the maste...

Page 45: ...Test pressure value Work internal pressure is more than 10 out of the Balance 1 value P NG 3 P NG Differential pressure sensor indicates less than FS B2 NG B2 NG B NG Differential pressure sensor indicates less than FS D NG NG Measurement result NG NG NG NG Measurement result NG OK OK NG Measurement result 2NG NG NG 2NG Measurement result 2NG 2NG NG 2NG Differential pressure sensor indicates more ...

Page 46: ...NG OK OK 2NG Measurement result NG 2NG 2NG NG Measurement result NG NG NG 2NG Differential pressure sensor indicates more than FS D NG NG If the slopes of the first 2 sec and the second 2 sec differ by more than 10Pa min during the last 4sec of fitting detection F NG 2 F NG 2 1 Fittingtestingtimeisthefittingdetectionprocess 2 Judgesonlyduring the fittingtestingtime 3 Thepressure sensorusedfortheP ...

Page 47: ...er body Usethedesignatedpowercordforthisequipment Usethepowercordsuppliedbythemanufacturertopreventpotentialelectricalshock WARNING Use proper grounding arrangements when installing this equipment to prevent potential electricalshock 2 Besurethatthetester spowerswitchisturnedoff 3 Inserttheaccessorypowercordplug female totheAC100Vinlet Powerconnector locatedontherearpanel srightside andturn thecon...

Page 48: ...Useproper exclusivegroundinginstallationfor theP E Protective earth UseaninsulatedtransduceriftheAC100Vsourceis convertedfromAC200V OFFPOWERSWITCH Besurethattheequipmentisproperlyinstalledpriortoturningonthepowerswitch Thepowerswitchislocatedontherearpanel slowerrightside SwitchittotheRightsighttoturnitONandtothe LeftsidetoturnitOFF BesuretoswitchRDYoff Regardingfusereplacement Useafuse with arati...

Page 49: ...ns FITTING LESS LEAK TESTER FL 601 Manual 00 0 kPa Ready Group No 00 Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Charge2 001 0 sec Balance1 001 0 sec Balance2 001 0 sec Maint1 2P Volume Ｍeasurement I Ocheck SelfCheck Stability Check SoftVersion Finishthenecessaryconfigurationpriortothisprocedure SupplytheappropriatepressuretoAIRSUPPLYandA P SUPport Preparations Power ON ...

Page 50: ...49 BASIC OPERATION ...

Page 51: ... changes when selected STOP Returns to READY when selected Err message will be indicated if an error is generated I O check 1 3 INPUT STOP gp 1 Psw START gp 2 ENG FITTING gp 4 LM1 BUBL gp 8 LM2 RETRY cal I O check 2 3 OUTPUT OK PNG NC NG RUN M R NG RDY NG2 END BNG ERR I O check 3 3 OUTPUT SV 1 SV 6 SV 2 SV 7 SV 3 SV 8 SV 4 SV 5 Self Check 1 Cal Port Open 2 Valve Close 3 Press Start Key Software Ve...

Page 52: ...l volume to be input includes the tester and test piping internal volume The FL 601Tester Internal Volume is4 31ml You may also input the value of the work volume for testing operation and maintenance operation 1 000E0 5 000E5 1ml 500L 2 5 M Volume Master Volume Tests the internal volume of the Master Please refer to P 57 for more information 1 000E0 5 000E5 1ml 500L NG NG Setting Sets the NG judg...

Page 53: ...00 9999 5 5 Out Data Data Output Mode Switch Selects the output data contents from the RS 232C Select Mode 4 when using a printer The following data will be output as the process data 0 4 Output Contents Mode Test Result Process Data BCC 0 1 2 DET Process F DET Process 3 CHG1Process CHG2ProcessB BAL1Process BAL2Process DET Process MDET Process 4 CHG1 CHG2 BAL1 Work Internal Pressure BAL2 DET FDET ...

Page 54: ... X If NG Hold is set to 0 The cylinder control valve is unclamped after the exhaust process even if a reject evaluation NG is made If NG Hold is set to 1 The cylinder control valve is not unclamped after the exhaust process If Limit Switch is set to 0 The clamp position is not detected and the unclamp process will not be carried out after the exhaust process If Limit Switch is set to 1 The clamp p...

Page 55: ...Press to go back to the previous page Will proceed to Screen 2 5 Will proceed to Screen 3 5 Ｍanual 000 kPa Ready GroupNo 00 Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Charge2 001 0 sec Balance1 001 0 sec Balance2 001 0 sec Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Charge2 001 0 sec Balance1 001 0 sec Balance2 001 0 sec Pass 0000 2 5p Gp 00 Detect 001 0 sec Exhaust 001 0 se...

Page 56: ...00 01 ml m NG 00 01 ml m F NG 00 01 ml m F NG 00 01 ml m Pass 0000 4 5p Gp 00 Digit 00 00 ml m Lead P 100 kPa Test P 100 kPa FittingSet 0 RevData 00 00 ml m Pass 0000 4 5p Gp 00 Digit 00 00 ml m Lead P 100 kPa Test P 100 kPa FittingSet 0 RevData 00 00 ml m Pass 0000 5 5p Gp 00 OutData 0 RemoteStop 0 UnitChange ml m kPa Cylinder 00 PassWord Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Cha...

Page 57: ... You will then return to the initial screen Master Volume M Volume testing operation will be slightly different For the Master Volume testing operation method please refer to the following page Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Charge2 010 0 sec Balance1 001 0 sec Balance2 001 0 sec Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Charge2 010 0 sec Balance1 001 0 sec Bal...

Page 58: ...e established as the volume 3 The Master internal Volume is established manually Press the key once M Volume 3 has been chosen The cursor will move to the following position The Master Volume will be set up in the same way as W Volume by using the keys 4 Press the ENT key Select the single figure right next to M Volume See Operations 1 to 5 in the previous description for help in navigating to thi...

Page 59: ...58 TESTING OPERATION ...

Page 60: ...tting set 0 1 or 2 and then alter a setting item which influences the measurement conditions the first measurement The 1st time measurement will be a mandatory fitting measurement The setting items which influence measurement conditions are Charge 1 Charge 2 Balance 1 Balance 2 Detect F Detect Lead P Test P and Fitting Set OK 1 000 ml m Exhaust GroupNo 00 Is theAIR SUPPLY Test Pressure being suppl...

Page 61: ...on page 20 does not coincide with actual data If this occurs the constants a b and c from page 20 were not calculated meaning that even if you press START to initiate the next measurement a fitting measurement will be performed first F OK No update Slope 1 000 ml m Exhaust GroupNo 00 Is theAIP SUPPLY Test Pressure being supplied Is theA P SUP Pilot Valve Operation Pressure being supplied Is the wo...

Page 62: ...correct Have you initialized the printer yet You need to Initialize the printer when you use it for the first time Please refer to page 106 for details Preparations Cable Connector Tester Use the thumbscrews to prevent the cable from loosening Cable Connector Printer Use the thumbscrews to prevent the cable from loosening This lamp will light up when the POWER is turned ON This lamp will light up ...

Page 63: ...5 5 8 Use the keys to move the cursor to Out Date Manual 000 kPa Ready GroupNo 00 Pass 0000 1 5p Gp 00 Delay 001 0 sec Charge1 001 0 sec Charge2 001 0 sec Balance1 001 0 sec Balance2 001 0 sec Pass 0000 5 5p Gp 00 OutData 0 RemoteStop 0 UnitChange ml m kPa Cylinder 00 Password Pass 0000 5 5p Gp 00 OutData 0 RemoteStop 0 UnitChange ml m kPa Cylinder 00 Password ...

Page 64: ...utData Data output mode 4 11 Press the ENT key 12 Press the STOP key 13 The tester will return to its initial screen Pass 0000 5 5p Gp 00 OutData 0 RemoteStop 0 UnitChange ml m kPa Cylinder 00 Password Pass 0000 5 5p Gp 00 OutData 0 RemoteStop 0 UnitChange ml m kPa Cylinder 00 Password Manual 000 kPa Ready GroupNo 00 ...

Page 65: ...or paper feeding and other information about the printer please refer to the printer s operational manual for details The printer will output test data even when in REMOTE mode Print sample Group No Judgment SData Normal Testing FData Fitting Testing Test result Test Prs c Constant b Constant 00 OK SData 01 00ml min 403 kPa 3 9929E 2 0072Pa 00 OK SData 01 00ml min 403 kPa 3 9929E 2 0080Pa Manual 0...

Page 66: ... 8 8 5 CTS CS RI 9 9 22 RI CI If the pin configuration of your sequencer etc is different from that of the computer ensure that the appropriate signals are connected The leak tester s RS 232C connector is a D sub 9 Pin female Data Output Mode Setting There are 4 modes for outputting data from the RS232C connector depending on the setting You must set the data output Data Out mode according to your...

Page 67: ...Work Pressure Value kPa CR Differential Pressure Value Pa CR 6 １ 6 １ Item Byte No Data Ex 00 0 0DH Item Byte No Data Ex 00000 0DH Test value transmission The transmitted test value contents include all the setting items for the currently selected group see page 51 53 Transmitted text format Delay sec CR Charge1 sec CR Charge2 sec CR Balance1 sec CR 6 １ 6 1 6 1 6 １ Item Byte No Data side 000 0s 0DH...

Page 68: ...67 MAINTNANCE FUNCTIONS ...

Page 69: ...peratetheFL 601Input Outputportsseparatelywhileconfirmingtheiroperation SelfCheck SelfCheckFunction Thisspecialfunctionallowsthetestertoevaluateinternalvalvesandsensors Ifanerrorisdetected anERRORcodewillindicatethenatureoftheproblem StabilityCheck StabilityConfirmationFunction Checksforinternalleaksinthetesterand oroverallstabilitywhenthemanualvalveisclosed SoftVersion SoftwareVersionIndication I...

Page 70: ...mped The flow master is available as an optional item 2 Display the initial screen 3 Press the MAINT key Be sure that there are no leaks in the coupler Use short piping if possible If using a flow master connect it directly using a coupler Flow Master Connection Manual 000 kPa Ready GroupNo 00 Pass 0000 Maintenance CAUTION Is theAIR SUPPLY Test Pressure being supplied Is theA P SUP Pilot Valve Ope...

Page 71: ...t next to Flow Master press the up down arrows to move the cursor there Upper Key Lower Key 6 Press the ENT key 7 Press the ENT key To allow numerical input Input the Flow Master leak rate Move between digits Cycle through values 0 9 Please input value Flowmaster 00000ml m When inputting numbers it is best to first enter a larger number 0 9 in a higher digit and adjust it using the keys Maint 1 2P...

Page 72: ...ternal volume value 13 Press the STOP key twice This will return to the initial screen OK ml m Exhaust Test results are not relevant OK ml m Exhaust Test results are not relevant Work Volume 7 093E1 ml Startkey Data update Stopkey Cancel Maint 1 2P Volume Measurement I Ocheck SelfCheck StabilityChck SoftVersion Manual 000 kPa Ready GroupNo 00 When the volume measurement result is not stable even a...

Page 73: ...form volume testing while using REMOTE operation Clamp the work and conduct this procedure in Manual mode Is theAIR SUPPLY Test Pressure being supplied Is theA P SUP Pilot Valve Operation Pressure being supplied Is the work bowl valve opened Is the work connected to the work port Are the setting values correct Preparations Ensuring there are no leaks in the connection Fastening Coupler Manual Cali...

Page 74: ...creen 5 Press the MAINT key 6 Enter the password and press the ENT key Confirm that the mark is next to Volume Measurement Use the Up Down keys to move the mark if necessary Up Key Down Key Set the graduation line to 0 Manual 000 kPa Ready GroupNo 00 Pass 0000 Maintenance Maint 1 2P Volume Measurement I Ocheck SelfCheck StabilityCheck SoftVersion ...

Page 75: ... Press the ENT key 10 Press the ENT key Input the calibrator volume 11 For example When 0 50 ml is input Digit movement Numerical Value 0 9 change The decimal place cannot be changed Volume Measurement Flow Master Calibrator Volume Measurement FlowMaster Calibrator Please input value Calibrator 0 000 ml Please input value Calibrator 0 050 ml ...

Page 76: ...te the calibrated differential pressure average 1 To conduct multiple tests repeat procedures 14 16 2 If the calibrated differential pressure value range is at least 100 2000Pa i e the differential pressure is over full scale the buzzer will sound Press the key after confirming the calibrator s volume input value and repeat procedures13 16 Calibration dP 0000Pa Average 0376Pa n 01 Open Calibration...

Page 77: ...t 18 If you use the measurement result to determine the leakage indication please press the START key If you are not doing this please press the STOP key If the START key is pressed the work volume entered into the settings is weighed against the measurement result WorkVolume 5 000E1 ml StartKey DataUpdate StopKey Cancel Indicates the measured work volume ...

Page 78: ...ster using the I O check operation We recommend beginning your testing after using this check function to verify that the sequencer is running normally 1 Display the initial screen 2 Press the MAINT key 3 Enter the Password and press the ENT key 4 Move the to I O check using the keys Ｍanual 000 kPa Ready GroupNo 00 Pass 0000 Maintenance Maint 1 2P Volume Ｍeasurement I Ocheck Selfcheck StabilityChe...

Page 79: ...nding pin of the REMOTE terminal in the same way by using the cursor to move the mark to the desired signal and pressing ENT The sign is then displayed next to the corresponding signal 8 Press the key The screen will display screen 3 3 EXH VALVE SIGNAL output signal The mark will be next to SV1 9 Press the ENT key The SV1 signal will be output Other signals can be output in the same way by using t...

Page 80: ...79 MAINTENANCE FUNCTIONS I O CHECK FUNCTION 10 Press the STOP key twice To return to the initial screen Manual 000 kPa Ready GroupNo 00 ...

Page 81: ...ailure to remove the stopper from the CAL port valve can cause it to shoot out when pressure is applied to the CAL port Be sure to remove it prior to starting this operation 2 Display the initial screen 3 Press the MAINT key Is the AIR SUPPLY Test Pressure being supplied Is the A P SUP Pilot Valve Operation Pressure being supplied Is the work bowl valve in the close position Is the tester in MANUA...

Page 82: ...ress the START key Begins the Self Check 8 The Self Check ends If there are no errors in any of the valves or sensors No error will be displayed Maint1 2P Volume Ｍeasurement I Ocheck SelfCheck StabilityCheck SoftVersion Maint1 2P Volume Ｍeasurement I Ocheck SelfCheck StabilityCheck SoftVersion SelfCheck 1 Cal Port Open 2 ValveClose 3 Press Start Key SelfCheck 0 100 SelfCheck No error ...

Page 83: ... key twice To return to the initial screen If an error is detected in the valves or sensors Err will be displayed Please refer to pages 108 109 for descriptions of the Err codes Manual 000 kPa Ready GroupNo 00 SelfCheck Err204 BalanceValue or DifferencesensorErr ...

Page 84: ...Key 3 Press the ENT key 4 Move the mark next to Stability Check Move the cursor using the Keys Is the AIR SUPPLY Test Pressure being supplied Is the A P SUP Pilot Valve Operation Pressure being supplied Is the work bowl valve closed Preparation Manual 000 kPa Ready GroupNo 00 Pass 0000 Maintenance Maint1 2P Volume Ｍeasurement I Ocheck SelfCheck StabilityCheck SoftVersion Maint1 2P Volume Ｍeasureme...

Page 85: ...ithin the tester s air pressure circuit No error will be displayed 8 Press the STOP key twice To return to the initial screen If an error is detected in the tester s air pressure circuit ERR will be displayed Please refer to pages 108 109 for error descriptions Stability check １ Valve Close ２ Press Start Key Manual 0000Pa 0 ＦＤｅｔｅｃｔ Stability check No error ００００ｍｌｍ End Ｍanual 000 kPa Ready GroupN...

Page 86: ...e 1 Display the initial screen 2 Press the MAINT key 3 Input the password and press ENT 4 Move the mark next to Soft Version Move the cursor with the Keys Manual 000 kPa Ready GroupNo 00 Pass 0000 Maintenance Maint1 2P Volume Ｍeasurement I Ocheck SelfCheck StabilityCheck SoftVersion Maint1 2P VolumeＭeasurement I Ocheck SelfCheck StabilityCheck SoftVersion ...

Page 87: ...CTIONS SOFTWARE VERSION DISPLAY 5 Press the ENT key The Software version will be displayed 6 Press the STOP key twice To return to the initial screen SoftwareVarsion 1 Range Ｍ RemoteMode 0 Ｍanual 000 kPa Ready GroupNo 00 ...

Page 88: ... Up Key Down Key Is the APU connected Is the source pressure being supplied Is the A P SUP Pilot Valve Operation Pressure being supplied Is the Work Bowl Valve opened Is the work connected to the work port Are the setting values correct Preparations Pass 0000 Maintenance Maint1 2p Volume Measurement I Ocheck Selfcheck Stability Check Soft Version Maint2 2p Date Loadsave APU tuning Cal Open Test ...

Page 89: ...ayed on LCD is different from the setting value you must adjust the pressure Press the key The test pressure on the display will read 000kPa 7 Press the START key Adjust test pressure APU tuning Tuning ５００ｋＰａ key Zero key Span StartKey Tuning APU tuning ０００ｋＰａ key Zero key Span StartKey Tuning Will be displayed during adjustment APU tuning ０００ｋＰａ key Zero key Span StartKey Tuning APU tuning ５００...

Page 90: ... pressure indication will be within 1 of the set test pressure 10 Press the key The test pressure will read 000kPa 11 Press the STOP key twice To return to the initial screen APU tuning ５００ｋＰａ key Zero key Span StartKey Tuning APU tuning ５００ｋＰａ key Zero key Span StartKey Tuning APU tuning ０００ｋＰａ key Zero key Span StartKey Tuning Ｍanual ０００ｋＰａ Ready GroupNo 00 ...

Page 91: ...sor with the Keys and choose Cal Open Test Maint screen 2 2 4 Press the ENT key If Data Mode is set at 0 2 while the Master Data is unreserved it will produce an error Refer to P 52 for details 5 Press the START key Begins a normal test with the CAL PORT open 6 After the test is completed Press the STOP key To return to Maint screen 2 2 CAUTION If the CAL PORT is opened while nothing is connected ...

Page 92: ...91 OPTIONAL EQUIPMENT ...

Page 93: ...ster is a standard part If foreign material could enter into the master such as from the work or work comparison take proper precautions to ensure that this does not happen This option is not available in the H1 range External View Installation Dimensions Not including projecting items For more details please refer to the Exhaust Bypass Unit External View supplement in the back of this manual EXT ...

Page 94: ...ns Front Rear FL 601L1 L2 M Rear EBU 600 Work Source Pressure EXH VALVE SIGNAL Cable Supply 300 400kPa air Connect the Exhaust Bypass Unit blind plug included to the EXH port Please refer to page 35 for piping information warnings Side Panel Do not cover This is used for the pilot operation valve Master ...

Page 95: ...upply 300 400kPa air lease adjust the pressure to match the test pressure Side Panel Do not cover Used for the pilot operation valve exhaust port When using a V specification exhaust bypass unit the main body of the FL 601 needs to be altered Please contact your FUKUDA distributor after purchasing the tester to help perform this adjustment WARNING Please refer to P 35 for piping information warnin...

Page 96: ...can eliminate the intrusion of foreign substances but since the air charged into the work is then released into the atmosphere through the air leak tester any water oil etc inside the work will be released into the air leak tester along with the exhausted air Because of this we recommend using an exhaust bypass unit to prevent intrusion related problems from occurring 1 FE 20 〇External dimensions ...

Page 97: ...XHAUST BYPASS UNIT 2 FE 20V 〇External dimensions and connecting instructions Unit mm ＡＣ１００ＶＡＩＲＳＵＰＥＸＨＥＸＨＡＵＳＴＰＯＲＴ１３９１３０８５２７０７０４０１９１７５１５１５１２１１５１２３０２１５４xφ５Ｒｃ１４Ｒｃ１８２xＲｃ１８ ...

Page 98: ... ERR003 as invalid If you do not do this you may get an ERR003 error when measurement is completed For details on ERR003 please refer to page 108 FL 601 ＵＬＬ M Rear Panel Source Pressure EXH VALVE SIGNAL Cable Supply 300 400kPa of air Connect the blind plug to the EBU EXH Port Please refer to page 35 for piping information warnings Front Panel Rear Panel Master Work Exhaust Port ＦＥ２０ Coupler ...

Page 99: ...set ERR003 as invalid If you do not do this you may get an ERR003 error when measurement is completed For details on ERR003 please refer to page 108 Source Pressure IN OUT 〇 FL 601 Rear Panel Vacuum Pump EXH VALVE SIGNAL Cable Provide pressure to the tester Please refer to page 35 for piping information warnings ＡＣ１００ＶＡＩＲＳＵＰＥＸＨＥＸＨＡＵＳＴＰＯＲＴ Supply 300 400kPa of air Master Work ＦＥ２０Ｖ ...

Page 100: ...mensions Not including projecting items For details please refer to the Charge Bypass Unit External View supplement in the back of this manual EXT VALVE SIGNAL Cable Wiring Connection Tester Side EXH SIGNAL Charge Bypass Side EXH SIGNAL Applied Connector MR 34LF JR16WR 7P Remarks １１２３２ Pressure Valve ２３２４４ Exhaust Valve １０１３１９ Pin Number ３２ Applied Connector Included Plug JR16WR 7P Recepta...

Page 101: ...Connect the Charge Bypass blind plug included to the EXH port SX 100D WORK Use the shortest piping possible for the APU APU Do not close Used as a pilot operation valve exhaust port For more information on setting the APU source pressure see page 101 OUT IN For warnings regarding test wiring please refer to page 35 in the operational manual For APU wiring please refer to APU unit Basic wiring on p...

Page 102: ...t 5 Shield Line Ｅ Shield Line GND 6 F 15V Pin Number 7 E GND Applied Connector Included MR 8LM Tester Side RO3 PB8F APU Side Applied Cable At least 0 3 SQ with a shield Twisted pair cable Wiring Precautions 1 Use pin numbers 1 and 6 to pair joint wires 2 Shield joint wire pin number 5 3 Make sure that the length of the cable is as short as possible Cable length within 5m AnAPU connecting cable len...

Page 103: ...emarks Tank Volume 20L Air Tank Tank Volume 38L Precision Regulator Remote Control Dial Regulator With Pressure Gauge Standard Regulator Pneumatic Regulator Pressure Sensor SX 100D Included withAPU APU Control Cable WORK Adjust the pressure to 300 400kPa Source Pressure Air Tank Use the shortest piping possible for theAPU OUT OUT Warning 1 OUT Pressure sensor cable FL 601 Rear Panel IN IN IN For t...

Page 104: ...lume 38L Standard Regulator Pneumatic Regulator Pressure Sensor SX 100D Included withAPU APU Control Cable WORK Adjust the pressure to 300 400kPa Vacuum Pump Air Tank Use the shortest piping with the largest possible diameter with theAPU OUT IN Pressure Sensor Cable FL 601 Rear Panel Source Pressure OUT IN For test wiring warnings please refer to page 35 in the operations manual ...

Page 105: ...r Remote Control Dial Regulator Standard Regulator Pneumatic Regulator Pressure Sensor SX 100D Included withAPU Charge Bypass Unit CBU 600C WORK Connect the Charge Bypass blind plug included to the EXH port Pressure Sensor Cable APU Control Cable Adjust the pressure to 300 400kPa Source Pressure EXH VALVE SIGNAL Cable Air Tank Source Pressure Rear Panel OUT IN Warning 1 Be sure to use the shortest...

Page 106: ...IN OUT Source Pressure IN OUT Adjust pressure to 300 400kPa Use as the shortest piping with the largest possible diameter with theAPU Front Panel PressureSensorCable APU Control Cable WORK EXH VALVE SIGNAL Cable Rear Panel When using a V specification exhaust bypass unit the main body of the FL 601 needs to be altered Please contact your FUKUDA distributor after purchasing the tester to help to pe...

Page 107: ...a Bit Length Setting7 Whether Parity is necessary or not Setting8 Data Control Mode Setting9 Paper Selection Setting10 Upright Inverted Printing Setting Setting11 Auto Power off option Setting12 Graphic Low Speed Mode Setting13 Interior Status If the printed result is different from that mentioned below change the settings accordingly Setting1 When you received the unit from your supplier it was s...

Page 108: ...111 SUPPLEMENT ...

Page 109: ...eat radiation leading the leak tester to express the heat radiation curve as a pattern Although this pattern conforms to basic principles other factors are added to the noise These are the individual elements composing the noise 1 Peripheral temperature changes 2 Source pressure changes 3 Internal changes according to work construction and material the O ring moving for example 4 Internal leaks de...

Page 110: ...l decrease as time progresses For this reason collecting data that expresses a rapid differential pressure change allows for more efficient fitting At this point you can allocate BAL2 process time to the DET process but make sure to not let the differential pressure sensor go above its range Past Testers Fitting Leak Tester BAL process DET process BAL Process DET Process Wait for the differential ...

Page 111: ...results in noise Changes in work shape or seal shape from the compressed air will result in a in volume change and so will the temperature change due to the air compressed and insulation However all of these conditions will converge and stabilize over time Therefore if you allocate a sufficient amount of time it is possible to conduct a test without this noise interference measuring differential p...

Page 112: ...111 SUPPLEMENT ...

Page 113: ...eat radiation leading the leak tester to express the heat radiation curve as a pattern Although this pattern conforms to basic principles other factors are added to the noise These are the individual elements composing the noise 1 Peripheral temperature changes 2 Source pressure changes 3 Internal changes according to work construction and material the O ring moving for example 4 Internal leaks de...

Page 114: ...l decrease as time progresses For this reason collecting data that expresses a rapid differential pressure change allows for more efficient fitting At this point you can allocate BAL2 process time to the DET process but make sure to not let the differential pressure sensor go above its range Past Testers Fitting Leak Tester BAL process DET process BAL Process DET Process Wait for the differential ...

Page 115: ...results in noise Changes in work shape or seal shape from the compressed air will result in a in volume change and so will the temperature change due to the air compressed and insulation However all of these conditions will converge and stabilize over time Therefore if you allocate a sufficient amount of time it is possible to conduct a test without this noise interference measuring differential p...

Page 116: ...115 SUPPLEMENT Pneumatic Circuit Diagram ＦＬ６０１ＵＬＬＭＨ１Pneumatic Circuit Diagram ...

Page 117: ...lessleaktester ＦＬ６０１Ｖ WAINING When an Exhaust Bypass Unit for negative pressure is connected with the Pressure Range V Vacuum Pressure Specifications the internal pneumatic circuit diagram for the equipment is different from what is indicated above ...

Page 118: ...ressurePort SV4 PilotPressure OperationValve APV2 ExhaustValve F1 Filtered Nipple BV1 AIROUTBowlValve TESTP TestPressure Port EBU 600V A PSUPPilot Pressure SupplyPort SV4 PilotPressure OperationValve APV2 ExhaustValve F1 Filtered Nipple AIRIN Pressure Supply Port EXH ExhaustPort EBU 600C BV 1 AirOutBallValve ...

Page 119: ...118 SUPPLEMENT Pneumatic Circuit Diagram ChargeBypassUnit ＣＢＵ６００Ｃ Exhaust Valve ...

Page 120: ...119 SUPPLEMENT External Dimensions Air Leak Tester FL 601 External Diagram Mounting bracket dimension Body mounting bracket Dimension with rubber pad ...

Page 121: ...120 SUPPLEMENT External Dimensions ExhaustBypassUnit ＥＢＵ６００ ChargeBypassUnit ＣＢＵ６００ External dimensions below are only for the CBU 600 142 5 Rc1 8 ...

Page 122: ...nd lightening and other natural disasters D Destruction malfunctions and other damages caused by applying inappropriate voltage and current Unstable voltage source is included E If this Warranty is not submitted F If it is not possible to determine the model number serial number and date of purchase 4 This warranty is effective only when FUKUDA s official distributors validate your purchase 5 This...

Page 123: ...h 1st Road Chi Tu Dist 206 Keelung Taiwan R O C TEL 886 2 2456 6663 FAX 886 2 2455 2129 Representative in India SYSCON INSTRUMENTS PRIVATE LTD Plot No 66 Electronics City Hosur Road Bangalore 560 100 India TEL 91 80 2852 0772 FAX 91 80 2852 0775 Representative in the U S A FUKUDA USA INC 3625 Del Amo Boulevard Suite 235 Torrance CA 90503 U S A TEL 1 310 793 9898 FAX 1 310 793 9899 Representative i...

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