Fukuda FL-601 Series Quick start guide

10491-T-001E-1
MULTIPUROSE AIR LEAK TESTER
OPERATIONAL MANUAL
FL-601SERIES
FUKUDA CO., 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.

1
Introduction
Introduction Thank you for purchasing the Fukuda FL-601 series masterless air leak tester.
This manual is designed to provide FL-601 users with details on basic functions,
operating procedures, and safety guidelines. 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.
・
The contents of this manual may be modified without notice due to function
and performance improvements.
The tester’s actual external appearance may differ from the pictures
indicated in this manual.
This manual is written and explained based on example specifications for
the FL-601. However, the operating principles may be the same for other
specifications as well.
・
This manual has been written with care to provide the user with helpful and
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 equipment requires permission from the Japanese
government in accordance to standards of the International Currency
Regulation and International Trade Control Law.
・For best operating results and optimum efficiency, read this instruction
manual thoroughly to understand the tester’s many functions prior to
operation.
Declaration
・The text in this manual is written according to FL-601 software version 1.**
Don’t use this tester for any purpose other than testing air leaks.
・Company names and product names being used in this manual are the
registered trademarks of their respective holders.
Trademark
・This air leak tester’s testing method is currently patent pending.

2
FOR YOUR SAFETY
Please read the “Safety Precautions” section thoroughly prior to operating this
equipment.
In this operation manual, pictographs and markings are used to indicate situations that may cause
injury to operators or other personnel, or cause potential damage to property. Descriptions of
each pictograph and symbol are indicated below. Please read this manual in its entirety prior to
handling the equipment and be sure to keep it handy at all times during operation.
PICTOGRAPHS THAT ARE USED IN THIS OPERATION MANUAL
PICTOGRAPHS DESCRIPTIONS
DANGER
Ignoring this warning and mishandling equipment may
result in serious injury or possible death.
WARNING
Ignoring this warning and mishandling 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 from other fixtures.
This is to prevent current from other machines from reaching the
air leak tester through its power terminal or other connections.
(2) When the equipment is being used independently, it implies that
the power plug should be disconnected from the power.
Turn off the Air
Pressure Source
This implies not only terminating the air pressure supply into the
equipment but also suspending the air pressure supply source and
making sure that there is no pressure remaining in the equipment.

3
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

4
FOR YOUR SAFETY
●DURING OPERATION
■ ONLYUSEWITHTHESPECIFIEDVOLTAGEANDPRESSURE
・Do not apply electrical voltage other than what is designated for this equipment. Neglecting
this warning may result in fire, electric shock, or equipment malfunction.
・ Do not apply pressure other than what is designated for this equipment. It may cause an
explosion or damage the equipment.
■ DO NOT REMOVE THE COVER
・There are high temperature, high voltage, and high pressure areas within the equipment.
Removing the cover may result in electric shock, burns or other injuries. Contact our service
personnel regarding periodic or routine maintenance. Only qualified personnel should perform
maintenance and service procedures. If maintenance is to be performed, turn off the main
power and the compressed air source, and ensure that the air leak tester is in a stable
environment.
■ CYLINDER CONTROL
・When controlling clamp cylinder actuation via signals from the air leak tester, provide an
area sensor to help alleviate injuries. Cylinders may move unexpectedly due to gravity and
the weight of the jigs when the main power and pneumatic supply are terminated. We
recommend employing lock-up cylinders to avoid such problems.
■ DONOTPLACEFOREIGNMATERIALSINTOTHETESTER
・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.
■ SYSTEMDESIGN
・The system is designed with a protection/security circuit to ensure that the system remains
secured in emergency situations such as tester malfunction or breakdown.
■ POWER SUPPLY FRAMEGROUND
・Provide class 3 grounding for the power supply FG terminal. Potential electric shock may occur
if grounding is not properly secured.
■ DONOTSTEPONTHETESTER
・Do not play on the tester or use it as a step or footstool. The tester may fall down or break, and
cause possible injuries.
・Do not place anything on the tester. Items may fall and cause injuries.
■ DO NOT DISCONNECT THE COMPRESSED AIR SUPPLY UNLESS NECESSARY
・Do not disconnect the compressed air supply connected to the fixture, air filter, and pressure
regulator while they carry compressed air. An inadvertent disconnection will cause a large
amount of compressed air to spurt out, and may cause possible injuries and eye impairment
that could lead to blindness.
WARNING
CAUTION

5
FOR YOUR SAFETY
■ DO NOT OPERATE UNDER INCOMPLETE SYSTEM CONDITIONS
・Do not operate the tester unless under ideal working conditions. Factors such as lack of
workspace, incomplete piping or unsuitable conditions may cause the tester to spurt out a large
amount of compressed air, and could cause injuries and/or eye impairment that could lead to
blindness.
・Do not open/close the ball valves on the rear panel while they are under pressure. It may cause
compressed air or residual pressure to spurt out unexpectedly when unclamping. It may also
cause possible injury or eye impairment that could lead to blindness.
■ LONGTERMSHUTDOWN
・Be sure to turn off the main power source and to cut off the air source for safety.
●MISCELLANEOUS
■ WHEN DAMAGED POWER CORDS, WIRING AND/OR PIPING ARE FOUND
・When damaged power cords, wiring and/or piping are found, cut off the main power and
compressed air source immediately, and replace the damaged parts. Continued use of
damaged parts will cause fire, electric shock, and may rupture piping.
■ INTRUSIONOFFOREIGNMATERIALS
・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 TESTERS
・When a tester is dropped, inadvertently falls, or breaks, cut off the main power and compressed
air source immediately. Continued operation of damaged testers can cause fire or possible
electric shock. For repair, contact your local FUKUDA distributor.
■ CONTINUEDUSEOFDAMAGEDTESTERSWILL…
・Continued use of damaged testers will cause irregular conditions such as smoke discharge, other
odd smells, or unusual sounds, and may lead to fire or electrical shock. Immediately cut off the
main power and compressed air sources, and make sure that it is no longer smoking. (Make
sure that it does not start a fire. If necessary, notify people nearby about this potential danger).
For maintenance and repair, contact your local FUKUDA distributor.
WARNING

6
FOR YOUR SAFETY
■ ENFORCING PERIODIC CHECKUPS FOR YOUR FUKUDA TESTER
・This tester requires periodic checkups, maintenance and overhaul to maintain reliable test
results and precision. Regular cleaning to remove accumulated dust and lint inside of the
tester will eliminate the possibility of fire or electrical leaks. Accumulated dust, lint and oil in
the power plug outlet, tester connector, and terminal board may also result in fire or electrical
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 connection.
・Using a welder close to this tester may damage it and is not recommended. Do not press the
touch panel or control keys on this tester with sharp objects.
・Do not wipe the tester with paint thinner or other solvents for cleaning purposes.
CAUTION

7
CONTENTS
INTRODUCTIO
N
1 P
FOR YOUR
SAFETY
2 P
CONTENTS 7 P
OUTLINE TESTER CHARACTERISTICS 10 P
TESTER MODEL 11 P
TESTER SPECIFICATIONS 12 P
EXCLUSIVE OPTION (APU) MODEL, & SPEC 13 P
(EXHAUST BYPASS & CHARGE BYPASS UNITS ) MODEL, & SPEC 14 P
ADDITIONAL EQUIPMENT 15 P
PRINCIPLE WHAT ISAN AIR LEAK TESTER? 18 P
THE IMPORTANCE OF LEAK TESTING AND THE PERMISSIVE LEAK
RATE
18 P
LEAK TESTER DETECTION LIMITS 18 P
LEAK TESTING PRINCIPLES 19 P
THE RELATION SHIP BETWEEN INDICATION AND LEAK RATE 20P
WHAT IS MASTER-LESS LEAK TESTER? 21P
CONVENTIONAL METHOD 21 P
MASTERING TESTING 21 P
POWER ON
PROCEDURE
DO YOU HAVE EVERYTHING? 24 P
TESTER STRUCTURE 24 P
ACCESSORY ITEMS 24 P
TEST PRESSURE REGULATOR 25 P
FILTER REGULATOR 25 P
PNEUMATIC REGULATOR 25 P
ADDITIONAL EQUIPMENT 26 P
THE NAMES OF EACH PART 28 P
MAIN BODY 28 P
CONNECTOR PARTS 30 P
CONTROL KEYS 31 P
INSTALLATION INSTRUCTIONS 32 P
OPERATION ENVIRONMENT 32 P
ABOUT THE WORK/MASTER 33 P
ABOUT THE MASTER TANK HANDLING 33 P
TRANSPORTATION INSTRUCTIONS 33 P
INSTALLATION SIZES 34 P
INSTALLATION MEASUREMENTS 34 P
MOUNTING TOOLASSEMBLY 34 P
BASIC PIPING 35 P
SELECTING REMOTE EQUIPMENT 36 P
CONNECTION TO EXTERNAL EQUIPMENT 37 P
REMOTE TERMINAL CHART 37 P
SEQUENCER CONNECTION EXAMPLE 39 P, 40 P
SWITCH CONNECTION EXAMPLE 39 P, 40 P
EXH. VALVE SIGNAL TERMINAL CHART 41 P
EXTERNAL SV CONNECTION
APU CONNECTION TERMINAL CHART 41 P
TIME CHART 42 P
OPERATION STAGES 43 P
REMOTE JUDGMENT CHART 44 P
POWER CONNECTION 46 P
POWER CORD CONNECTION 46 p
CONNECTING THE POWER CORD 46 P
OFF POWER SWITCH 47 P
ABOUT FUSE REPLACEMENT 47 P

8
CONTENTS
BASIC OPERATION BASIC OPERATION 50 P
SETTING CONTENTS 51 P
SETTING PROCEDURES 53 P
TESTING OPERATION ORDINARY TESTING FUNCTION 58 P
MASTERING TESTING FUNCTION 61P
PRINTER OPERATION 64P
RS-232C OUTPUT 68 P
MAINTENANCE FUNCTIONS WHAT ARE MAINTENANCE FUNCTIONS? 72 P
VOLUME MEASUREMENT USING AFLOW MASTER 73 P
VOLUME MEASUREMENT USING AMANUAL CALIBRATOR 76 P
I/O CHECK FUNCTIONS 81P
SELF-CHECK FUNCTIONS 84 P
STABILITY CONFIRMATION FUNCTIONS 87P
SOFTWARE VERSION DISPLAY 89P
APU TUNING 91 P
CAL PORT OPEN 94 P
OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT 96 P
CHARGE BYPASS UNIT 99 P
APU UNIT (PNEUMATIC REGULATOR) 102P
DAILY MAINTENANCE ERROR MANAGEMENT 108 P
MAINTENANCE & INSPECTION 110 P
DAILY INSPECTIONS 110 P
PERIODIC INSPECTIONS 110 P
SUPPLEMENT MASTERLESS Q&A 112 P
PNEUMATIC CIRCUIT DIAGRAM 117P
EXTERNAL DIMENSIONS 120 P
WARRANTY REPAIR REGULATIONS
WARRANTY
FUKUDADISTRIBUTORS LIST

9
OUTLINE