Fukuda FL-601 Series Kurzanleitung

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.

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.

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.

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

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

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

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

CONTENTS

INTRODUCTIO

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

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

OUTLINE

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