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Fukuda FL-601 Series Operational Manual

Multipurose air leak tester
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10491-T-001E-1
MULTIPUROSE AIR LEAK TESTER
OPERATIONAL MANUAL
FL-601 SERIES
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.
FUKUDA CO., LTD.
http://www.fukuda-jp.com

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Do you have a question about the FL-601 Series and is the answer not in the manual?

Questions and answers

Sandeep
May 12, 2025

How to take test value in print tell me the full wiring diagram

0
1 comments:
Mr. Anderson
May 20, 2025

To take the test value from the Fukuda FL-601 Series:

1. Use the RS-232C connector on the front panel.
2. The test data (including fitting test results and test settings) is output through this port.
3. Communication specifications:
- Speed: 19200 bps
- Data length: 8 bits
- Start bit: 1
- Stop bit: 2
- Parity: None
- Error check: BCC (horizontal parity)
- Text encoding: ASCII
- Handshake: RTS/CTS
- Transmission: Non-procedural, asynchronous

RS-232C Wiring Diagram:

| Tester Pin | Signal Name | Computer Pin (D-Sub 9) | D-Sub 25 Equivalent |
|------------|-------------|-------------------------|----------------------|
| 1 | DCD | 1 | 8 |
| 2 | TxD | 2 | 3 |
| 3 | RxD | 3 | 2 |
| 4 | DSR | 4 | 20 |
| 5 | SG (GND) | 5 | 7 |
| 6 | DTR | 6 | 6 |
| 7 | CTS | 7 | 4 |
| 8 | RTS | 8 | 5 |
| 9 | RI | 9 | 22 |

This RS-232C connection allows the tester to send test values to a connected device like a computer.

This answer is automatically generated

0

Related Manuals for Fukuda FL-601 Series

Summary of Contents for Fukuda FL-601 Series

  • Page 1 10491-T-001E-1 MULTIPUROSE AIR LEAK TESTER OPERATIONAL MANUAL FL-601 SERIES 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 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.
  • Page 3 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.
  • Page 4 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. WARNING For your reference MEMO...
  • Page 5 FOR YOUR SAFETY ●DURING OPERATION WARNING ONLY USE WITH THE SPECIFIED VOLTAGE AND PRESSURE ■ ・ 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. ・...
  • Page 6 ・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 ■...
  • Page 7 FOR YOUR SAFETY CAUTION 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.
  • Page 8 CONTENTS INTRODUCTIO YOUR SAFETY CONTENTS 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 IS AN AIR LEAK TESTER?
  • Page 9 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 FUKUDA DISTRIBUTORS LIST...
  • Page 10 OUTLINE...
  • Page 11 OUTLINE TESTER CHARACTERISTICS/ TRAITS ■ TESTER CHARACTERISTICS The FL-601 is an air leak tester which has improved performance by using fitting technology to provide the most efficient air leak testing performance. This equipment has the following characteristics: (1) A restricted function set allows highly efficient leak testing at reasonable costs. (2) Compact size allows installation of more than one unit without consuming too much space.
  • Page 12 OUTLINE TESTER MODEL TESTER MODEL ■ ＦＬ－６０１➊－➋－➌ ➊ PRESSURE RANGE Applied Pressure Setting Pressure Range Indicated Pressure Range Model Ｖ -5.0 ～ -90.0 kPa 0.0 ～ -90.0 kPa 0.0 ～ -90.0 kPa ＵＬ 5.0 ～ 20.0 kPa 0.0 ～ 20.0 kPa 0.0 ～...
  • Page 13 OUTLINE TESTER SPECIFICATIONS ■ TESTER SPECIFICATIONS Work/ Work Comparison, Work/ Master Comparison, Work/ Fixed Testing Method Master Comparison, Differential Pressure Method Air Leak Tester By employing a flow master, Volume testing and calibration can be Volume Testing done according to actual leak standards. VR-55A（2CD）...
  • Page 14 OUTLINE EXCLUSIVE OPTION ■ PNEUMATIC REGULATOR (APU) SPECIFICATIONS Please refer to the following when connecting the APU to be used in combination with the FL-601. ＡＰＵ－➊ ➋－(➌)－➍－➎－➏ ➊ Configuration Applicable work volume guidelines*1 Configuration Symbol V *2 M *3 φ 70 mm ～200ml ～2L ～2L...
  • Page 15 OUTLINE EXCLUSIVE OPTIONS ■ EXHAUST / PRESSURE BYPASS UNIT (EBU-600 / CBU-600) MODELS AND SPECIFICATIONS EXHAUST BYPASS UNIT EBU-600➊－➋ ➊ Range Pressure Range REMARKS Symbol -5 ～ -90 kPa TEST.SUP 10～ 700 kPa AIR IN ➋ Bypass Unit Cable Cable Length REMARKS Symbol 1.5m...

  • Page 16: Additional Equipment

    OUTLINE ADDITIONAL EQUIPMENT ADDITIONAL EQUIPMENT ■ PRODUCT NAME MODEL Remarks BL－80RSⅡ Printer Body RS232C Straight Cable 9P female - 25P male AR305/1.5 1.5m Printer UR－121+NC－LSC01 BL-80RSⅡBattery + Battery Charger BL-80RSⅡAC adapter BL－100W+AC－100J FE－20 (Vacuum) FE－20C (Positive) Exhaust Bypass Unit EBU－600 V－□( Vacuum) Please refer to page14 for EBU－600C－□...
  • Page 17 OUTLINE ADDITIONAL EQUIPMENT MEMO...
  • Page 18 PRINCIPLE...
  • Page 19 □ Leak Tester Detection Limits FUKUDA Air Leak Testers are designed to use compressed air as its testing media in order to detect a small quantity of pressure alteration (caused by a leak in the work,) to automatically evaluate the existence of a leak.
  • Page 20 FUKUDA Air Leak Testers use an original, highly sensitive differential pressure sensor, which allows testing minute leaks in a shorter period of time. By using air as its testing media, not only can one expect high accuracy and sensitivity but also a reduction in running costs and the elimination of post-processing.
  • Page 21 PRINCIPLE WHAT IS AN AIR LEAK TESTER? □ The Relationship Between the Indication and the Leak Rate In general, the leak tester will not display the leak rate during the detection process. Indication The indicated value is the pressure alteration during Detection rate (often called delta P), which is the rate of...
  • Page 22 PRINCIPLE FITTING TESTER CONVENTIONAL METHOD The circuit diagram for conventional leak testing, which uses a differential pressure 【Conventional Circuit Diagram】 comparison, is similar to the diagram shown on the right. IR Regulator Testing is conducted by simultaneously MASTER pressurizing both the master and work parts then closing solenoid valves SV2 and SV3.
  • Page 23 PRINCIPLE Fitting Testing By selecting Fitting Set on the FL-601, you can elect to use previously recorded constant numbers. The recorded constants (formula 1) are substituted, becoming the fixed constant value. By doing this, the level (fitting level) of the approximation calculations during the standard testing procedure can be changed.
  • Page 24 POWER ON PROCEDURE...
  • Page 25 FUKUDA agent. (The distributor list is provided at the back of this manual). Please compare the model numbers described below with the number indicated on the tester’s nameplate.
  • Page 26 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 FUKUDA sales for the specification of filter regulator ■Pneumatic Regulator ・Pneumatic Regulator Body (Photo shows only APU－90W□－□-X005) ・With APU control cable (This cable is to connect the APU Signal and the APU Input.)
  • Page 27 POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? ADDITIONAL EQUIPMENT The following options are also available for your convenience. ・ FLOW MASTER (FFM-100) Used to test actual leaks and/or for internal volume testing. ・ PRINTER SET Printer (BL-80RSⅡ) BL-100Ｗ+AC-100J (Printer AC Adapter) RS-232C Cable (AR305/ 1.5m) Used to save testing data.
  • Page 28 POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? ・0.1 ml Manual Calibrator (0.1 ml PT 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 ・Regulator for primary pressure (1) Remote Control Dial Regulator (With Pressure Gauge) (2) Precision Regulator (For remote control dial regulator adjustment)
  • Page 29 POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? THE NAMES OF EACH PART ■ ○ MAIN BODY 【 FRONT 】 LIQUID CRYSTAL DISPLAY ERROR LAMP Indicates testing status and Lights up when an error/ settings. malfunction is detected. JUDGMENT LAMP Indicates judgment results.
  • Page 30 POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? Be sure to turn off the electrical power supply and air source supply when disconnecting the piping. Failure to do so may result in accident and/or injury. Danger 【 REAR 】 A.P. SUP AIR SUPPLY (Test Pressure) (Pilot Valve Operation Pressure) Air supply port for this tester.
  • Page 31 POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? Be sure to turn off the electrical power supply and the air supply when disconnecting the piping. Failure to do so may result in accident and/or injury. Danger CONNECTOR PARTS ○ 【 FRONT PANEL 】 RS-232C APU SIGNAL (APU CONTROL SIGNAL)
  • Page 32 POWER ON PROCEDURE THE NAMES OF EACH PART ○ CONTROL KEYS BUBL (Retained charging) MAINT (Maintenance) Used when conducting air Confirms status when bubble testing. problems occur Used to measure volume. SET (Setting) Used to input setting values. MANUAL (Internal) REMOTE GROUP (External)

  • Page 33: Installation Instructions

    POWER ON PROCEDURE INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS ■ Air leak testers detect leaks by detecting precise variations in pressure (air condition.) Therefore, it requires handling instructions that are different from standard precision equipment. Tester must be in a stable position. ・...
  • Page 34 POWER ON PROCEDURE INSTALLATION INSTRUCTIONS ABOUT THE WORK / MASTER ○ ・ Try to eliminate temperature differences between the work, the master parts and the surrounding environment. If some work parts are left standing for a period of 20℃ time, be sure to leave the parts close to the leak tester FL-601 in order to ensure that it is in a similar environment.
  • Page 35 POWER ON PROCEDURE INSTALLATION INSTRUCTIONS INSTALLATION SIZES ○ Please use the provided mounting plates when installing this equipment. Please refer to the external diagram for further details. 4-M5 At least At least INSTALLATION MEASURMENT ○ 5 cm Follow remarks listed below installation.
  • Page 36 POWER ON PROCEDURE BASIC PIPING BASIC PIPING ■ Clamp Fixture To ensure safety during piping procedures. Inadequate clamping pressure will cause sealing materials to deform, destroy work ・Do not touch the I/C board or start piping procedures while power is supplied into parts or cause leaks.
  • Page 37 POWER ON PROCEDURE SELECTING REMOTE EQUIPMENT ■SELECTING REMOTE EQUIPMENT Please refer to the following chart when selecting filters and decompression valves for the FL-601. ( This explains in detail how to select the decompression valve and filters (1)～(5), which is mentioned in ”How to do piping”...
  • Page 38 POWER ON PROCEDURE Connection to external equipment ■ Connection to external equipment To ensure safety during wiring procedures ・Do not touch the I/C board or start wiring procedures while power is being supplied into the equipment. Doing so may cause an electric shock. ・Do not start wiring procedures while connected to the air supply source.
  • Page 39 POWER ON PROCEDURE Connection to external equipment Greater than 200 msec Stop signal for leak testing. STOP Rising pulse signal greater than 200msec Start signal for leak testing. Greater than 200 msec START Rising pulse signal greater than 200msec. Start signal for fitting testing. Greater than 200 msec FITTING Rising pulse signal greater than 200msec...
  • Page 40 POWER ON PROCEDURE Connection to external equipment SEQUENCER CONNECTION EXAMPLE ○ 【REMOTE TERMINAL】 +COM INPUT LOAD OUTPUT －COM Between + COM and – COM, please supply the external power source (DC 24V) Please be sure to connect both leads simultaneously. SEQUENCER FL-601 MAIN BODY SWITCH CONNECTION EXAMPLE...
  • Page 41 POWER ON PROCEDURE Connection to external equipment SEQUENCER CONNECTION EXAMPLE ○ SEQUENCER For the circuit diagram above, the layout for each signal for the FL-601 and the REMOTE terminal chart（on page 39）is described below. Signal REMOTE Terminal, Number +COM 19～24 -COM 27～32 Input Terminal...
  • Page 42 ＋ optional FUKUDA External SV products. Please look at pages 10-13 and 19-32 for details － FL－601 MAIN BODY ・Maximum load for the external SV signal should be less than 0.5(A) per signal.
  • Page 43 POWER ON PROCEDURE Connection to external equipment ○Time Chart In this section, the Masterless Leak Tester’ s remote testing signal operation will be explained. ( Conventional Testing and Mastering Testing Operation Time Chart ) CHG 2 BAL 1 BAL 2 DET *1 EXH UnClamp*4 HOLD Test Progress CHG 1 Pressure Valve...
  • Page 44 POWER ON PROCEDURE Connection to External Equipment OPERATION STAGES ON THE T IME CHART The Masterless Leak Tester conducts testing through the 8 operation stages described by the standard operation time chart. The following section explains each operation stage. (1) RDY STAGE The preparation is done and the unit is READY for the test to start.
  • Page 45 POWER ON PROCEDURE Connection to External Equipment REMOTE JUDGMENT CHART ■ ・The timing and explanation for the judgment results that are indicated on the main display and/or output from the REMOTE Terminal. Judgment Ｆ P.NG No update Result +00.0 Hold Group No 00 Judgment Status...
  • Page 46 POWER ON PROCEDURE Connection to External Equipment Judgment Judging timing Status result shown REMOTE △：Judging point ←→：Judging range Terminal Pressure Pressure Balance Balance Detect Setting Contents Exhaust display １ １ (*1) Differential pressure sensor D-NG indicates less than –FS. Measurement result ≦...
  • Page 47 POWER ON PROCEDURE Power Connection ■ POWER CORD CONNECTION ■ Check the voltage supply Be sure that proper voltage is being supplied into the equipment before connecting the power cord to the tester body. WARNING ■ Be sure that the tester’s power switch is turned off before connecting the power cord to the tester body.
  • Page 48 POWER ON PROCEDURE Power Connection ● Be cautious of potential noise interference and provide preventive countermeasures. If the equipment is located near a welder or other machinery , there may be possible noise interference. Provide a noise filter or other preventive devices. While wiring, separate the input signal, the output signal, and the AC 100V wire bundles within the fixture.
  • Page 49 POWER ON PROCEDURE Power Connection ○ POWER ON Preparations ・Finish the necessary configuration prior to this procedure. ・Supply the appropriate pressure to AIR SUPPLY and A.P.SUP port. Power ON Pass 0000 1/5p Gp 00 FITTING LESS Delay 001.0 sec LEAK TESTER Charge1 001.0 sec Charge2...

  • Page 50: Basic Operation

    BASIC OPERATION...
  • Page 51 BASIC OPERATION ■ BASIC OPERATION INITIAL SCREEN Initial Screen Operation Indicates Each Key ※ Possible Manual RDY Lamp On +100 MANUAL Operation Status Ready Group No 00 Pass 0000 3/5p Gp 00 Pass 0000 4/5p Gp 00 Pass 0000 2/5p Gp 00 Pass 0000 1/5p Gp 00 00.01 ml/m Digit...
  • Page 52 BASIC OPERATION SETTING CONTENTS ■ SETTING CONTENTS The FL-601 has the following setting items: Setting ITEM CONTENTS TESTING RANGE Display Page Delay Process Sets the delay time from when testing is first 0.0 ～ 999.9 sec Delay initiated until actual pressurization begins. Time Sets the lead pressure pressurizing time for TURBO.
  • Page 53 BASIC OPERATION SETTING CONTENTS Setting ITEM CONTENTS TESTING RANGE Display Page Decimal Set the decimal point for the leak value or the +NG .0000, 0.000, 00.00, 000.0 Digit point judgment value indicated on the display 0000. setting Sets the lead supply pressure for the TURBO test time. 0 ～...
  • Page 54 BASIC OPERATIONS SETTING PROCEDURES It switches the logic for determining how the STOP signal at the remote control will affect the measurement. Switches Mode Logic Remote behavior 0～1 Suspend measurement when STOP Stop signal is on. STOP Suspend measurement when STOP signal signal is off.
  • Page 55 BASIC OPERATIONS SETTING PROCEDURES ■ SETTING PROCEDURES Procedures to input Process times, NG ranges and other settings are explained below. Preparations ・Has the proper GROUP number been selected? The Group number can be set on the initial screen or on the setting screen. ・Is it in MANUAL mode? 1.
  • Page 56 BASIC OPERATIONS SETTING PROCEDURES Will proceed to Screen 3/5 Will proceed to Screen 4/5. Press Pass 0000 3/5p Gp 00 Pass 0000 4/5p Gp 00 to proceed 00.01 ml/m to the next Digit 00.00 ml/m page. +2NG 00.01 ml/m Lead.P 100 kPa - NG -00.01 ml/m...
  • Page 57 BASIC OPERATIONS SETTING PROCEDURES 8. Enter 10.0 Digit movement Change numerical values 0～9 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 9. Press the ENT key. (To store 10.0 in memory.) The cursor will move back to the setting name. Pass 0000 1/5p...
  • Page 58 BASIC OPERATIONS SETTING PROCEDURES ■ Master Volume Entry This is an explanation of how to modify the Master Volume (M. Volume) setting items, which differs from the above description. Use the keys to move the cursor to M. Volume. Pass 0000 2/5p Gp 00 Detect...
  • Page 59 TESTING OPERATION...
  • Page 60 BASIC OPERATIONS SETTING PROCEDURES ■ Ordinary Testing Procedure Preparations ・Is the AIR SUPPLY(Test 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 each of the setting values correct? 1.
  • Page 61 FITTING TESTING SETTING PROCEDURES ■ Fitting Testing Procedure Preparations ・Is the AIP SUPPLY(Test 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 each of the setting values correct? 1.
  • Page 62 BASIC OPERATION PRINTER OPERATION ■ Printer Operations Preparations ・Is the leak tester in Manual mode? ・Are each of the setting values 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.) 1.
  • Page 63 BASIC OPERATION PRINTER OPERATION 3. Display the initial screen. Manual +000 Read y GroupNo 00 4. Press the SET key. 5. Enter password. 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 6.
  • Page 64 BASIC OPERATION PRINTER OPERATION 9. Press the ENT key. (Enables numeric entry mode) Pass 0000 5/5p Gp 00 OutData RemoteStop UnitChange ml/m kPa Cylinder ＊＊＊＊ Password 10. Use the keys to input 4 for OutData (Data output mode 4) Pass 0000 5/5p Gp 00 OutData RemoteStop...
  • Page 65 BASIC OPERATION PRINTER OPERATION 14. Press either the START or the FITTING keys. (Starts either the normal test or the fitting test.) Manual －0000Pa － ＋ Detect GroupNo 00 15. The tester will display and print the test results when the testing is concluded. Display indicates the judgment result.
  • Page 66 RS-232C OUTPUT BASIC OPERATIONS ■RS-232C Output Data is output from the RS-232C connector on the front panel. Types of data transmitted: ・ Setting data saved in the tester. ・ Test results (including the fitting test results) and test data. ○ Specifications for the RS-232C communications: 19200 bps ・Speed ・Start Bit...
  • Page 67 RS232C OPERATIONS BASIC OPERATIONS 2. Out Data 2 (Detection Process (DET、MDET) data, test result transmission) A differential pressure value (Pa value) is transmitted every 0.1 sec during the DET phase. The test result data is transmitted during the EXH process, after the testing is complete. (The format of the text transmitted for the test result is the same as with Out Data 1) Format of transmitted text (Detection Process (DET, MDET) data) Item...
  • Page 68 MAINTNANCE FUNCTIONS...
  • Page 69 MAINTENANCE FUNCTIONS WHAT ARE MAINTENANCE FUNCTIONS? ■ MAINTENANCE FUNCTIONS The FL-601 is equipped with the following maintenance and inspection functions. Volume Measurement (Work Volume Test Function) You must connect a calculated leak rate nozzle (like a Flow Master) into the CAL PORT to perform this function. This then allows you to measure the work’s volume, which can be input into the Work Volume setting.
  • Page 70 MAINTENANCE FUNCTIONS Work Volume Measurement Using a Flow Master ■ Work Volume Measurement using a Flow Preparations ・Is the AIR SUPPLY (Test Pressure) being supplied? ・Is the A.P. SUP (Pilot Valve Operation Pressure) being supplied? ・Is the work bowl valve opened? ・Has a work been connected to the work port? ・Have the appropriate setting values been input? ・Are all the setting values correct?
  • Page 71 MAINTENANCE FUNCTIONS Work Volume Measurement Using Flow Master 4. Enter the password and press the ENT key. Verify that the * symbol is next to Volume Measurement. If the * symbol is not next to volume measurement, use the up/down arrows to move the cursor there and press the ENT key.
  • Page 72 MAINTENANCE FUNCTIONS Work Volume Measurement Using Flow Master 8. Press the ENT key. 9. Press the START key. This will begin by testing a non-leaking item. (Volume testing start) ＊＊＊＊＊＊＊ ml/m Test results are not relevant. Exhaust 10. It then begins testing a leaking item. (Volume testing start) ＊＊＊＊＊＊＊...
  • Page 73 OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator ■ Manual Calibrator ○ Summary: The manual calibrator is used to measure the internal volume of the work. ○ Measuring Method Preparations ・Is the AIR SUPPLY (Test Pressure) being supplied? ・Is the A.P. SUP (Pilot Valve Operation Pressure) being supplied? ・...
  • Page 74 OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 3. Adjust the graduation line on the calibrator to 0. Set the graduation line to 0 4. Display the initial screen. Manual +000 Ready GroupNo 00 5. Press the MAINT key. Pass 0000 Maintenance 6.
  • Page 75 OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 7. Press the ENT key. Volume Measurement ＊Flow Master Calibrator 8. Use the Up/ Down keys to move the * to Calibrator. Volume Measurement FlowMaster ＊Calibrator 9. Press the ENT key. 10.
  • Page 76 OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 12. Press the ENT key. 13. Press the START key. Calibration = +0000 Pa Average Open 14. Adjust the graduation line on the calibrator so it lines up with 0. Due to elasticity in the internal O ring, overturn clockwise and adjust to zero by turning counter clockwise. Press the key.
  • Page 77 OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 17. Press the START key. (This will indicate the result of the work internal volume test) Indicates the measured work WorkVolume 5.000E1 ml volume StartKey → DataUpdate StopKey → Cancel 18. If you use the measurement result to determine the leakage indication, please press the START key.
  • Page 78 MAINTENANCE FUNCTIONS I/O CHECK FUNCTION ■ I/O Check Function You can check the external equipment interface by monitoring the signals received from the REMOTE terminal or by forcing signals to be output. ・Sequencer operation can be verified by forcing a signal output from the tester using the I/O check operation.
  • Page 79 MAINTENANCE FUNCTIONS I/O CHECK FUNCTION 5. Press the ENT key. The LCD will display screen 1/3. (REMOTE Input/Output signal) The ◆ will light up when signals are being input from an external source. I/Ocheck INPUT ◆ stop start fitting bubl retry 6.
  • Page 80 MAINTENANCE FUNCTIONS I/O CHECK FUNCTION 10. Press the STOP key twice. (To return to the initial screen) Manual +000 Ready GroupNo 00...
  • Page 81 MAINTENANCE FUNCTIONS SELF-CHECK FUNCTION ■ SELF-CHECK FUNTION This section explains the self-check function, which is used to check for failures such as internal valve malfunctions and sensor wiring errors. (This function is not available when optional accessories like the EBU-600 or the CBU-600 are installed.) Preparations ・Is the AIR SUPPLY (Test Pressure) being supplied?
  • Page 82 MAINTENANCE FUNCTIONS SELF-CHECK FUNCTION 4. Enter the password and press the ENT key. Maint1/2P ＊Volume Ｍeasurement I/Ocheck SelfCheck StabilityCheck SoftVersion 5. Move the * mark next to Self-check. You can move the cursor using the Keys. Maint1/2P Volume Ｍeasurement I/Ocheck ＊SelfCheck StabilityCheck SoftVersion...
  • Page 83 MAINTENANCE FUNCTIONS SELF-CHECK FUNCTION 9. Press the STOP key twice. (To return to the initial screen) Manual +000 Ready GroupNo 00 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.) SelfCheck Err204 BalanceValue or...
  • Page 84 MAINTENANCE FUNTIONS STABILITY CONFIRMATION FUNCTION ■ STABILITY CONFIRMATION FUNCTION Instructions on how to confirm the stability of the tester’s internal air pressure circuit are described below. Preparation ・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? 1.
  • Page 85 MAINTENANCE FUNTIONS STABILITY CONFIRMATION FUNCTION 5. Press the ENT key. Stability check １ Valve Close ２ Press Start Key 6. Press the START key. (Begins the stability check function process) Manual －0000Pa － ＋ ＦＤｅｔｅｃｔ 7. The stability check function process will be completed in about one minute. (If there are no errors within the tester’s air pressure circuit, “No error”...
  • Page 86 MAINTENANCE FUNCTIONS SOFTWARE VERSION DISPLAY ■ SOFTWARE VERSION DISPLAY This section explains how to display the tester’s software version and model range. 1. Display the initial screen. Manual +000 Ready GroupNo 00 2. Press the MAINT key. Pass 0000 Maintenance 3.
  • Page 87 MAINTENANCE FUNCTIONS SOFTWARE VERSION DISPLAY 5. Press the ENT key. (The Software version will be displayed.) SoftwareVarsion 1.＊＊ Range Ｍ RemoteMode 6. Press the STOP key twice. (To return to the initial screen) Ｍanual +000 Ready GroupNo 00...
  • Page 88 MAINTENANCE FUNCTIONS APU TUNING ■ APU TUNING Preparations ・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? 1.
  • Page 89 MAINTENANCE FUNCTIONS APU TUNING 4. Press the ENT key. APU tuning ０００ ｋＰａ key→Zero key→Span StartKey→Tuning 5. Press the key. (The test pressure will be indicated on the display.) APU tuning ５００ ｋＰａ key→Zero key→Span StartKey→Tuning ※If the APU is hunting, please refer to the APU operations manual for more information.
  • Page 90 MAINTENANCE FUNCTIONS APU TUNING 8. The Tuning indication will disappear. (Test pressure adjustment is completed.) APU tuning ５００ ｋＰａ key→Zero key→Span StartKey→Tuning 9. Press the key. (Confirms the test pressure) (The test pressure indication will be within ±1% of the set test pressure. ) APU tuning ５００...
  • Page 91 MAINTENANCE FUNCTIONS CAL PORT OPEN ■ CAL PORT OPEN This function opens the CALPORT on the front panel. This is ideal for checking your work volume settings or for determining a suitable tact time. If you take a normal measurement by connecting a good work to the CALPORT using a flow master, it will produce an NG error.
  • Page 92 OPTIONAL EQUIPMENT...
  • Page 93 OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT ■ Optional Equipment Exhaust Bypass Unit (EBU-600) ○ Summary: The exhaust bypass unit prevents water/ oil remaining in the work part from entering the air leak tester. Air leak testers require high sensitivity and accuracy in order to detect very minute leaks, therefore it is important that we only use clean air.
  • Page 94 OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT ○ Basic Piping (From the tester to the work) (UL, L. M. Specifications) Supply 300～400kPa air Source Pressure EXH VALVE SIGNAL Cable FL-601L1/L2/M Rear Rear Front EBU-600 Work Master Please refer to page 35 for piping information/ warnings. Connect the Exhaust Bypass Unit blind plug (included) to the EXH port Side Panel...
  • Page 95 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 WARNING...
  • Page 96 OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT ■Optional Equipment Exhaust Bypass Unit (FE-20, FE-20V) ○ Summary: The exhaust bypass unit prevents water/ oil remaining in the work part from entering the air leak tester. Air leak testers require high sensitivity and accuracy in order to detect very minute leaks, therefore it is necessary that the air used is clean.
  • Page 97 OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT （2）FE-20V 〇External dimensions and connecting instructions Unit: mm ４xφ５ １ ３ ０ １ ３ ９ １ ５ １ ５ Ｒｃ１/８ Ｅ ＸＨ Ａ Ｕ Ｓ Ｔ　 Ｐ Ｏ Ｒ Ｔ Ａ Ｃ １ ００ Ｖ Ｅ...
  • Page 98 OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT (1) Basic piping for FE-20 (Tester-Work) (UL, L, M Specifications) Supply 300～400kPa of air. Source Pressure FL-601 ＵＬ，Ｌ，M Rear Panel EXH VALVE SIGNAL Cable Front Panel Rear Panel ＦＥ－２０ Please refer to page 35 Work for piping information/ warnings.
  • Page 99 OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT (1) Basic piping for FE-20V (Tester-Work) (V Specifications) Provide pressure to the tester Supply 300～400kPa of air. Pump Vacuum Source Pressure 〇 FL-601 Rear Panel EXH VALVE SIGNAL Cable ＦＥ－２０Ｖ ＥＸＨＡＵＳＴ　ＰＯＲＴ ＡＣ１００Ｖ ＥＸＨ ＡＩＲ　ＳＵＰ Master Please refer to page 35 for piping Work information/ warnings...
  • Page 100 OPTIONAL EQUIPMENT CHARGE BYPASS UNIT ■Optional Equipment Charge Bypass Unit (CBU-600) ○ Summary: The Charge Bypass Unit is used when the work’s internal volume is large, requiring a large amount of charged air in order to maintain testing stability with a shortened testing time. Explanations in this manual are done under the assumption that the master is a standard part.
  • Page 101 OPTIONALEQUIPMENT CHARGE BYPASS UNIT ○ Basic Piping (Tester to Work) For APU wiring, please refer to APU unit (UL, L. M. Specifications) “Basic wiring” on page 102. Vacuum Pump Please supply 300～400kPa air For more information on setting source Source Pressure pressure, see page 101.
  • Page 102 OPTIONAL EQUIPMENT APU UNIT ■ Optional Equipment APU (Pneumatic Regulator) ○ Summary : By using an optional APU unit (pneumatic regulator), a stable test pressure (charge) can be obtained in a shortened time. Use a dedicated APU unit (type number X005) with the FL-601. See page 13 for details.
  • Page 103 OPTIONAL EQUIPMENT APU UNIT ○Basic Piping (1) Recommended piping circuit for work volumes up to 2 L ② (UL, L. M. specifications) ③ Source Pressure ① Air Tank Adjust the pressure to 300～400kPa Warning 1 Pressure sensor cable ⑥ ④ ⑤...
  • Page 104 OPTIONAL EQUIPMENT APU UNIT ○ Basic Piping (2) Recommended piping circuit for work volumes up to 2L. (V Specifications) Vacuum Pump Adjust the pressure to ①Air Tank 300～400kPa Source Pressure Pressure Sensor Cable ④ ② ③ APU Control Cable WORK Use the shortest piping with the largest possible diameter with the APU.
  • Page 105 OPTIONAL EQUIPMENT APU UNIT (3) Recommended piping circuit for work volumes of at least 2 L ② (UL, L. M. Specifications) Be sure to use the shortest piping possible for the APU ③ Source Pressure ①Air Tank Warning 1 Adjust the pressure to 300～400kPa ④...
  • Page 106 35 in the operations manual 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 perform this adjustment. WARNING...
  • Page 107 OPTIONAL EQUIPMENT APU UNIT In order to print, you need to initialize the tester and the printer. * This setting is not done automatically. Please understand that you cannot print correctly if this initial procedure is not followed. ■ Initial tester settings ①...
  • Page 108 SUPPLEMENT...
  • Page 109 SUPPLEMENT MASTERLESS Q&A Q1 : How is Fitting testing different from Mastering testing? A1: When a variety of works are tested on the same line, the same master cannot not be modified for the different works, creating an imbalance between the work and the master. Consequently, even if there are no leaks, a differential pressure will be generated. Both the Master and Fitting tests are methods we use to solve this problem.
  • Page 110 SUPPLEMENT MASTERLESS Q&A Q3: Do you have any advice on how to use the fitting leak tester correctly? A3: The fitting test analyzes the changes in detected differential pressure data, but an input that expresses these changes in differential pressure well will allow for a more accurate fit. Curves in which the differential pressure is stable (influenced by heat radiation) will, as shown below, change greatly in the beginning and the rate of change will decrease as time progresses.
  • Page 111 SUPPLEMENT MASTERLESS Q&A Q4: Is it necessary to use a work that does not have a leak for fitting testing? A4: Any good, inline work can be used. Stable domain Fitting Detection Process With the Masterless leak tester, the differential pressure generated from non-leak sources is stored as “Master Data.”...
  • Page 112 SUPPLEMENT...
  • Page 113 SUPPLEMENT MASTERLESS Q&A Q1 : How is Fitting testing different from Mastering testing? A1: When a variety of works are tested on the same line, the same master cannot not be modified for the different works, creating an imbalance between the work and the master. Consequently, even if there are no leaks, a differential pressure will be generated. Both the Master and Fitting tests are methods we use to solve this problem.
  • Page 114 SUPPLEMENT MASTERLESS Q&A Q3: Do you have any advice on how to use the fitting leak tester correctly? A3: The fitting test analyzes the changes in detected differential pressure data, but an input that expresses these changes in differential pressure well will allow for a more accurate fit. Curves in which the differential pressure is stable (influenced by heat radiation) will, as shown below, change greatly in the beginning and the rate of change will decrease as time progresses.
  • Page 115 SUPPLEMENT MASTERLESS Q&A Q4: Is it necessary to use a work that does not have a leak for fitting testing? A4: Any good, inline work can be used. Stable domain Fitting Detection Process With the Masterless leak tester, the differential pressure generated from non-leak sources is stored as “Master Data.”...
  • Page 116 SUPPLEMENT Pneumatic Circuit Diagram ■ ＦＬ－６０１ＵＬ，Ｌ、Ｍ、Ｈ１Pneumatic Circuit Diagram...
  • Page 117 SUPPLEMENT Pneumatic Circuit Diagram Masterless leak tester ＦＬ－６０１Ｖ－□ 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 WAINING indicated above.
  • Page 118 SUPPLEMENT Pneumatic Circuit Diagram Exhaust Bypass Unit ＥＢＵ－６００□ EBU - 600V Pilot Pressure Operation Valve A.P SUP Pilot Pressure Supply Port APV 2 ( Exhaust Valve ) Filtered AIR OUT Bowl Valve Nipple TEST P Test Pressure Port AIR IN Pressure Port EBU-600C Pilot Pressure...
  • Page 119 SUPPLEMENT Pneumatic Circuit Diagram Charge Bypass Unit ＣＢＵ－６００Ｃ Exhaust Valve...
  • Page 120 SUPPLEMENT External Dimensions Air Leak Tester FL-601 External Diagram ■ Mounting bracket dimension Body mounting bracket Dimension with rubber pad...
  • Page 121 SUPPLEMENT External Dimensions Exhaust Bypass Unit ＥＢＵ－６００□ Charge Bypass Unit ＣＢＵ－６００□ (External dimensions below are only for the CBU-600□)
  • Page 122 PRODUCT WARRANTTY If the product indicates any malfunction under appropriate use, FUKUDA will provide service for the product at no cost. (A) When malfunction is indicated, please contact your FUKUDA agent along with your purchase details. When the product is relocated from the original location at the time of purchase, please contact your nearest FUKUDA agent for service.
  • Page 123 Head Office: FUKUDA CO., LTD 3-16-5, Nukui, Nerima-ku, Tokyo, 〒176-0021 Japan TEL: (81)-3-3577-1111 FAX: (81)-3-3970-7218 Peoples Republic of NAGANO FUKUDA (TIANJIN) INSTRUMENTS CO.,LTD. China Branch: 10, 1st Muning Ave., TEDA, Tianjin, China TEL: (86)-22-6620-4348 FAX: (86)-22-2532-6649 Representative in Korea: KI SUNG TECHNOLOGY CO.,LTD...