10491-T-001E-1

MULTIPUROSE AIR LEAK TESTER

OPERATIONAL MANUAL

FL-601 SERIES

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 ■ 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. ・ 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.

■ 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 protection/security circuit to ensure that the system remains

secured in emergency situations such as tester malfunction or breakdown.

■ POWER SUPPLY FRAME GROUND ・Provide class 3 grounding for the power supply FG terminal. Potential electric shock may occur

if grounding is not properly secured.

■ DO NOT STEP ON THE TESTER ・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.

■ LONG TERM SHUT DOWN ・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.

■ 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 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.

■ CONTINUED USE OF DAMAGED TESTERS WILL… ・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 INTRODUCTION

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 IS AN 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 TOOL ASSEMBLY 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 A FLOW MASTER 73 P VOLUME MEASUREMENT USING A MANUAL 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 FUKUDA DISTRIBUTORS LIST

9

OUTLINE

10

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. (3) Operational data/information is displayed on an LCD, enabling easy operation.

Furthermore, the FL-601 features the following functions:

• No Master Required (A no-leak standard)

By eliminating the master used in 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 conditions Capable of setting up to 16 different processing conditions.

•Self –check function

The self-check function notifies you of any malfunctions that occur in any valve or miscommunications made by the sensors. It is also possible to detect sensor malfunctions triggered by deterioration.

• Data control function It is possible to transmit data to external devices via RS-232C. Transferred data can then be analyzed using software such as LOTUS or EXCEL.

11

OUTLINE TESTER MODEL

■ TESTER MODEL

ＦＬ－６０１➊－➋－➌

➊ PRESSURE RANGE

Model Applied Pressure Setting Pressure Range Indicated Pressure Range

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 ～ 50.0 kPa

Ｌ 10.0～ 99.9 kPa 00.0 ～ 99.9 kPa 00.0 ～ 99.9 kPa

Ｍ 100 ～ 700 kPa 0 ～ 700 kPa 0 ～ 999 kPa

Ｈ 300 ～ 990 kPa 0 ～ 990 kPa 0 ～ 999 kPa

Ｈ１ 0.50～ 2.00 MPa 0.00 ～ 2.00 MPa 0 ～ 2.00 MPa

Please consult your nearest representative for pressures lower than the UL range.

➋ POWER SUPPLY VOLTAGE

Model POWER SUPPLY VOLTAGE

２ AC90 ～ 110V 200 ～ 240V

➌ EXTERNAL OPTION

Model Product Name Note

FR-51 Filter/ Regulator Unit Positive Pressure UL Range Standard spec. R5

FR-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/ Regulator Unit Positive Pressure M Range Precision spec.

FR-58 Filter/ Regulator Unit Positive Pressure M Range Precision spec. and

High Performance spec. Filter

FR-59 Filter/ Regulator Unit Positive Pressure H Range Standard spec.

FR-60 Filter/ Regulator Unit Positive Pressure H1 Range Standard spec.

FR-61 Filter/ Regulator Unit Negative Pressure V Range Standard spec.

FR-62 Filter/ Regulator Unit Negative Pressure V Range Precision spec. P-200

12

OUTLINE TESTER SPECIFICATIONS ■ TESTER SPECIFICATIONS

Testing Method Work/ Work Comparison, Work/ Master Comparison, Work/ Fixed Master Comparison, Differential Pressure Method Air Leak Tester

Volume Testing By employing a flow master, Volume testing and calibration can be done according to actual leak standards.

Differential Pressure Sensor

VR-55A（2CD） F.S.2000Pa/5V Work Side Accuracy±1% , Master Side Accuracy±2%

V Range -101 kPa Accuracy±2％FS UL Range 50 kPa Accuracy±2％FS L Range 100 kPa Accuracy±2％FS M Range 1 MPa Accuracy±2％FS H Range 1 MPa Accuracy±2％FS

Applied Pressure Sensor (Semiconductor sensor)

H1 Range 2 MPa Accuracy±2％FS

Work Side Volume V,UL,L,M Range Approx. 4.1 ml H1 Range Approx. 3.6ml

Calibration port about 4.2ml.

Master Side Volume V,UL,L,M,H Range Approx. 3.8ml H1 Range Approx. 3.2ml

Master Tank Inner volume 28ml (Hi Range Pressure 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) EXT VALV SIGNAL 34pin (Externally Mounted Option Valve Signal) RS-232C 9pin (Data Output Signal)

Operation Temperature/ Humidity Range 0～40℃, 45～85%RH with no condensation

Power Supply Voltage AC90～110V, 200～240V

Consumption Current Approx. 100VA

Air Specifications

Please supply clean , stable , and dry air Recommended Condition: Based on JISB8392-1:2000 Compressed Air Quality Class1,3,1

Class Article Reference 1 Maximum Particle Diameter 0.1μm

3 Minimum Pressure Dew-point -20℃

1 Maximum Oil Content 0.01mg/mm3

External Dimensions W162×H256×D345 (Not including protruding objects) For External Dimension Diagram, please refer to page 119.

Weight Approx. 7.5kg

13

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

Symbol Configuration V *2 UL L M *3

70W φ 70 mm ～200ml ～2L ～2L 90W φ 90 mm ～400ml ～2L ～4L More than 2L

130W φ 130 mm More than More than 2 More than 4 *1 These values are only to be used as guidelines. Please use these as a reference, as the actual values

will vary depending on the margin degree of the cycle time, the source pressure (including the primary pressure decrease valve) supply capacity, the test pressure and the work structure, etc.

*2 Do not select the APU-70W series for small pressure applications (less than -30kPa,) even for works with a small volume.

*3 Select neither APU-70W series nor 1% sensor in case of using the low pressure (less than 100kPa) and middle pressure by switching even in M range.

➋ Pressure Control Range

Symbol Configuration Note P Positive V Negative

The FL-601 will automatically control this range by simply connecting the cables.

➌ 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

➍ APU Specifically for Use with Leak Testers

Symbol Note

X005

This model is specifically for use with air leak testers. The charge pressure characteristics are different from standard APUs. Please use caution when purchasing this model separately or when replacing parts. (Other functions, including its control, are consistent with other models.)

➎ Sensor Models and Accuracy

Symbol Model Accuracy C SX-100D ±0.15% of F.S. E SX-34 ±1.0% of F.S.

➏ APU Control Cable

Symbol Length of Cable Note 1.5 1.5m Standard Attachment 3 3.0m Option

*This cable is used to connect the FL-601(APU SIGNAL) to the APU (INPUT) *Refer to the APU series catalogue or user manual for common specifications other than those described here.

14

OUTLINE EXCLUSIVE OPTIONS

■ EXHAUST / PRESSURE BYPASS UNIT (EBU-600 / CBU-600) MODELS AND SPECIFICATIONS

EXHAUST BYPASS UNIT

EBU-600➊－➋

➊ Range

Symbol Pressure Range REMARKS

V -5 ～ -90 kPa TEST.SUP C 10～ 700 kPa AIR IN

➋ Bypass Unit Cable

Symbol Cable Length REMARKS

1.5 1.5m ACCESSORY ITEM 3 3.0m OPTIONAL ITEM

PRESSURE BYPASS UNIT

CBU-600➊－➋

➊ Range

Symbol Pressure Range REMARKS

C 10～ 700 kPa AIR IN ➋ Bypass Unit Control Cable

Symbol Cable Length REMARKS

1.5 1.5m ACCESSORY ITEM 3 3.0m OPTIONAL ITEM

15

OUTLINE ADDITIONAL EQUIPMENT

■ ADDITIONAL EQUIPMENT PRODUCT NAME MODEL Remarks

BL－80RSⅡ Printer Body

AR305/1.5 RS232C Straight Cable 9P female - 25P male 1.5m

UR－121+NC－LSC01 BL-80RSⅡBattery + Battery Charger Printer

BL－100W+AC－100J BL-80RSⅡAC adapter

FE－20 (Vacuum)

FE－20C (Positive)

EBU－600 V－□(Vacuum) Exhaust Bypass Unit

EBU－600C－□(Positive)

Charge Bypass Unit CBU－600C－□(Positive)

Please refer to page14 for ordering details/specifications.

Flow Master FFM－100 Please specify your test pressure and leak rate when you fill out your purchase order.

Master Tank capacity:28ml

Manual 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. Pressure Preset Capacity: -101kPa ～ 0 kPa

PS02 Pressure Switch for Positive Pressure Sensitivity ±3%F.S. Pressure Preset Capacity: 0 kPa ～ 100 kPa

PS03 Pressure Switch for Positive Pressure Sensitivity ±3%F.S. Pressure Preset Capacity: 0 MPa ～ 0.97 MPa

Air Tank Tank volume 20 Liters (Works up to 2L)

Air Tank Tank volume 38 Liters (Works at least 2L)

Tank to stabilize the source pressure

16

OUTLINE ADDITIONAL EQUIPMENT

MEMO

17

PRINCIPLE

18

PRINCIPLE WHAT IS AN AIR LEAK TESTER? ■ What Is Air Leak Testing? □ The Importance of Leak Testing and the Permissive Leak Rate A “leak” in a product may cause a variety of problems depending on the industry. For example, the existence of a leak in gasoline valves may cause fire or explosion, while a leak in a water valve may cause corrosion and be responsible for performance deterioration. From these examples, we can conclude that every product would, under ideal circumstances, not leak or have “zero” leak. Although “zero” leak is highly desirable, it is nearly impossible, or very difficult to achieve, therefore it becomes necessary to determine the most reasonable leak rate (permissive leak rate) while foreseeing potential damages and effects that may originate from a leak problem. This permissive leak rate differs from product to product, and industry to industry. For example, a leak in a gasoline valve may cause a fire or explosion, making it necessary to define what a non-risky leak rate is. In other words, 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. The pursuit of “zero” leak often results in production cost increases and often prolongs production time. Thus, the permissive leak rate is determined based on the function and performance characteristic of the inspected product and the amount of leak inspection costs that manufacturers are allowed to invest. □ 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. Considering various restrictions, the minimum detection sensitivity of the leak is roughly expressed as follows. For more detailed information, refer to the following pages.

Minute leak detection sensitivity (ml/min) =( )

Time(min)10mleWork volum -3×

19

PRINCIPLE WHAT IS AIR LEAK TESTING?

■ What Is Air Leak Testing? Some traditional methods of leak testing employed by manufacturers included the hydraulic submersion method, which involved immersing work parts into water to observe bubble formation, and the soap water application method, which consists of applying soap water on the surface of the work part in order to observe bubble formation. Although these methods were commonly practiced, they most often received a great deal of interference from outside sources and the results were mostly determined by the subjectivity and experience of the operator. These methods also required a long processing time and evaluation was terminated if bubbles were not found during this period. Additionally, the care required to properly execute these methods, such as cleaning and drying, caused many manufactures unnecessary problems and headaches. The Helium leak testing method is another method that some manufacturers have employed. This method is costly in that not only is the initial investment of having to purchase the Helium leak tester expensive, but running costs and maintenance become prohibitive. 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. 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 allowing full automation of the production process and a subsequent reduction in labor costs. □ Leak Testing Principles

と

Please consider a balance scale used for measuring small amounts of medicine. The balance scale is an instrument used to precisely measure the weight of a certain value by comparing the object against a reference weight. Fukuda air leak testers use this same underlying principle for our testing method. When the test is started, the same amount of air pressure is injected into the master and the work. The tester then examines the leak amount by observing a change in the balance over a certain period of time. If the test part has no leak, the charged pressure amount will not alter and the balance between the reference value and test parts will be maintained. However, if a leak is present, the pressure within the test part will decline as time lapses, causing a pressure imbalance between the two. The speed with which the imbalance develops depends on the size of the leak.

Reference weight (master)

Medicine

Reference parts (with no master) Work

Measuring medicine using a balance scale

Apply the same pressure to both and

observe the pressure balance

Imbalance occurs with presence of a leak

20

PRINCIPLE WHAT IS AN AIR LEAK TESTER? □ The Relationship Between the Indication and the Leak Rate Equation to calculate the leak rate: Definitions of the symbols used in the equation are shown below:

△VL ：Leak rate（ml/sec） Ｔ ：Detection time （sec）

△P ：Differential pressure rate generated in detection time T（Pa or ㎜H20） Po ：Atmospheric pressure （101325Pa or 1.033×104㎜H20） VＷ ：Work side internal volume（ml） VＳ ：Master side internal volume （ml）

k ：Sensor coefficient（ 0.4 x 10-5ml/Pa or 0.4×10-４ml/㎜H20） PT ：Test pressure (gauge)（ Pa or kg/cm2G＝×104㎜H20）

【Reference】Pressure units and conversion chart

1Pa 1MPa 1mmHg 1km/cm2 1mmH2O

1Pa 1 1 ×10-6 7.500 62×10-3 1.019 72×10-5 1.019 72×10-1

1MPa 1×106 1 7.500 62×103 1.019 72×10-1 1.019 72×105

1mmHg 1.333 22×102 1.333 22×10-4 1 1.359 91×10-3 1.359 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 portraying water leaking from buckets. Compare two buckets full of water, with one bucket leaking. The difference of the level of the bucket which is not leaking (the standard) and that of the bucket being evaluated is indicated on the leak tester. From this, one can calculate the amount which had leaked. In order to get the proper leak rate output from the air leak tester, we need to convert this value.

Indication during

Detection

Test

Pre

ssur

e In

dica

tion

Minute volume change with

pressure change.

Leak Rate Differential

Pressure Sensor

( )⎪⎭

⎪⎬⎫

⎪⎩

⎪⎨⎧

+⎜⎜⎝

⎛⎟⎟⎠

⎞++

⋅Δ

=Δ T0S

WW

0L PP

VV1k V

PTPV

21

PRINCIPLE FITTING TESTER

CONVENTIONAL METHOD FITTING TESTING

Detection Time A conventional tester intentionally makes the pressurization time and the balancing time longer to arrive in this stable zone and therefore it cannot take an accurate leak rate measurement in a short amount of time. An optional Master Tank (Stability Tank) has been provided for the FL-601. By connecting this stability tank to the Master Port, the differential pressure generated in the unstable zone on the master side is minimized. By doing this, only the actual properties of the work side are sampled. The FL-601 uses an approximation of these properties for operation. The leak is calculated by using the actual data and the constant number generated when fitting conditions (consistent characteristic property) are satisfied. Y=aX + b(1 - ecx)------(formula 1） a; leak rate b; differential pressure convergence without leak c; work coefficient X; detection time Y; calculated differential pressure Through fitting testing, one can determine the constants for (formula 1) a, b, and c. By recording this constant as being a characteristic of the work, it is possible to conduct your testing in a short amount of time. (The constants are determined by using the FittingSet option in the leak tester settings). While using this fitting testing method, since all the data collected during the detection process (Setting item FDetect Time) is calculated using approximations, the more data that is available, the more accurate the constants will become. With standard testing, 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 work parts then closing solenoid valves SV2 and SV3. After that, the tester determines the leak rate by observing the pressure alteration in both the master and work chambers by using a differential pressure sensor.

IR Regulator

With the pressure comparison leak testing method, when the conditions of the work and master parts (such as volume and shape) are different, a large amount of differential pressure tends to be generated at the beginning of the testing process. （unstable zone ） After sufficient pressurization, it enters a stable zone in which pressure only varies when there is a leak present.

Master data

Gen

erat

ed d

iffer

entia

l pre

ssur

e

Unstable zone Environmental

factor + leak

Stable zone Differential pressure

generated by leak

Masteri ng data Actual leak rate

Estimated leak rate

Assuming the work and master conditions are the same, external environmental variation or pressure variation caused by insufficient pressurization affect both equally, canceling any adverse effects. Therefore, the differential pressure sensor does not react and testing time is reduced. (In reality, it is difficult to keep both the work and the master under the same conditions, due to equipment restrictions or the requirements of various models, giving this differential pressure variation a certain margin of error).

b Constant number

22

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. Select the Fitting Level through the FittingSet (Setting Item Fitting Set) The following 5 sets are available under Fitting Set. FittingSet 0 → ｃConstant number fixed fitting FittingSet 1 → ｃ、ｂConstant number fixed fitting FittingSet 2 → ｃ、ｂ、ａConstant number fixed fitting FittingSet 3 → Recurring straight line calculation FittingSet 4 → No Fixed constant number fitting (Free Fitting) Configure the Fitting Level by selecting Fitting Set 0~2 and 4. FittingSet 3 can be tested using the stable domain or the differential pressure comparison methods. (1)ｃ Constant number fixed fitting（FittingSet0）

Fitting testing (Testing according to the F Detect Time setting) will only record the constant c. With standard testing, the recorded constant c is given a fixed value through approximation and

is modified later. The constants a and b are approximated, where a is used to calculate the leak rate. The constant c is mostly dependent on the material quality of the work.

(2) ｃ、ｂ Constant number fixed fitting (FittingSet1） Constants c and 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) ｃ、ｂ、ａ constant number fixed fitting (FittingSet2) The constants c, b and a are determined through fitting testing. The recorded c, b and a constant numbers are given an approximate fixed value during Standard

Testing , and are later substituted. The leak rate (a constant number,) is calculated using standard testing by calculating the

difference between the actual data and the approximated data. (4) Recurring straight line calculation（FittingSet3） Fitting testing is not available（FITTING key not available） Using standard testing, the leak rate is calculated from the recurring straight line slope of the

differential pressure data which is observed during the detection process. (5) Free Fitting (FittingSet4) Does not record any constants. Uses the same calculation as the fitting testing and the standard testing methods.

The only difference between the fitting testing and standard testing is the set time (difference between F Detect Set Time and Detect Set Time) during the detection process.

Gen

erat

ed d

iffer

entia

l pre

ssur

e

Detection time

Master data

Unstable zone

Environmental factor + Leak

Stable zone Differential pressure

gener ated by leak only

Test data Actual leak rate

Testing data – master data = actual leak

t

23

POWER ON PROCEDURE

24

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? DO YOU HAVE EVERYTHING? Confirm the following points prior to operating the tester. If there are any problems with the delivered items such as incorrect specifications, missing accessory parts or damages, please contact your 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. Please specify the SER (serial number) when contacting your FUKUDA agent. TESTER STRUCTURE 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 that the H1 pressure range is not attached)

＊ Regarding the APU Connector: when purchasing an optional APU, the APU control cable will be included and the connector itself will not be attached.

Power plug converter (1)

* If it is not suited to your area or it will not interface with your outlet, please prepare an adequate substitute.

25

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? Regulator for test pressure The following optional equipment is available in order to sustain reliable testing results. ■ Filter Regulator

Model Specification

FR-51 Positive Pressure UL Range Standard spec. R5

FR-52 Positive Pressure UL Range Precision spec. P-200

FR-53 Positive Pressure L Range Standard spec.

FR-54 Positive Pressure L Range Precision spec.

FR-55 Positive Pressure L Range Precision spec. and High Performance 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 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.) * See page 13 for details on APU regulator variations.

26

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ? ADDITIONAL EQUIPMENT

・ 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.

・ 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 your convenience.

27

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ?

・Regulator for primary pressure

・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

(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)

28

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ?

■ THE NAMES OF EACH PART ○ MAIN BODY

【 FRONT 】

CONTROL KEYS Value input and control

CAL PORT Used to measure the internal volume of the test parts.

LIQUID CRYSTAL DISPLAY Indicates testing status and settings.

RS232-C Used to transfer testing data 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 up during testing. Lights up during testing operation. (It also lights up during BUBL)

29

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ?

【 REAR 】

Piping Position (Connection Port) Contents

Piping Position (Connection Port)

Connection Bolt Size Contents Reference

Pages

AIR SUPPLY Rc1/4 Test Pressure Supply Port

A.P. SUP Rc1/4 Pilot Valve Operation Pressure Supply Port

WORK MASTER Rc1/4 Work Connection Port

EXH Rc1/4 Exhaust Port

page 35

SPAN ZERO Sensor Adjustment Volume Used to adjust the internal sensor. Do not touch unless otherwise directed.

MASTER＆WORK MASTER＆Work parts connector

EXH(Exhaust) Vent for exhausting air.

A.P. SUP (Pilot Valve Operation Pressure) Air supply for internally installed 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, filtered air.

APU SIGNAL (APU Control Signal) Used when controlling the APU (Electro-pneumatic regulator)

*Be sure to cut off the power supply and air pressure supply source when disconnecting the piping. Failure to do so may result in injury.

Danger

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.

30

POWER ON PROCEDURE DO YOU HAVE EVERYTHING ?

○ CONNECTOR PARTS

P.E

（Protective earth/Ground）

CONNECTOR CONTENTS CONNECTOR

NAME CONNECTOR DESCRIPTION REFERENCE PAGES

POWER CONNECTOR POWER CONNECTOR TESTER POWER SUPPLY page46

RS-232C RS-232C CONNECTOR

TEST RESULT DETAILS OUTPUT SIGNALS page65～66.

REMOTE 50P CONNECTOR HONDA MR-50LF

EXTERNAL 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 the electrical power supply and the air supply when disconnecting the piping. Failure to do so may result in accident and/or injury.

31

POWER ON PROCEDURE THE NAMES OF EACH PART

○ CONTROL KEYS

SUPPLEMENT: Note to use REMOTE（external）mode When used in REMOTE (external) mode, internal settings functions (and maintenance, etc.) will not work until the unit is switched back to MANUAL (Internal). After completing these internal functions, make sure to switch back to REMOTE (External) mode and press the ENT key.

ENT Enter Press enter to activate the input value.

STOP Used to suspend operation. *If this key is pressed while inputting settings (instead of ENT), the setting value will not be stored into the system. Be sure to press ENTER to store the setting value.

START (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 store your selection. Even if the power is shut off, the tester can resume using this stored value. (Refer to supplement.)

GROUP Used to change group settings. *When you push this button on the regular screen, the Group No. value (in the lower right portion of the screen) will blink. While it is blinking, you can use the up and down arrows to change the group.

ARROW KEYS To change the position of the cursor during value input.

32

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. ・ Be sure to instal l the tester on a level surface.

Vibrations or earthquakes may cause the tester to fall and cause injury to operators.

WARNING Do not place anything on top of the tester. ・ Do not place anything on top of the tester.

Fall ing objects may result in injury. Do not install the tester in the following locations: ・ High moisture or dusty areas. ・ Areas in which oi l and water can cause contamination. ・ Areas directly exposed to sunlight. ・ Outdoors

This may result in f ire or electric shock. ・ Areas with obstructions or places in which the tester ’s fanning

system may be blocked. The tester may overheat and may cause a f ire .

CAUTION

Moving the Tester: ・ Be sure to shut o f f the power, unplug any cords, shut of f the

pneumatic source and remove any piping. ・ Be sure to carry the tester in a stable manner.

(Do not carry the tester by the manifold handle. ) This may cause damage to the tester or to i ts 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 unreliable results. ・Transferring the tester rapidly from high to low temperature locations and/or

humidity locations may cause condensation. When such cases cannot be avoided, leave the tester in the environment for at least an hour in order for it to adjust to the surrounding temperature.

FL-601

・Do not install the tester near windows or other locations affected by direct sunlight.

・Ambient Temperature: 0~40℃ ・Ambient Humidity: 45~80% RH with no condensation. ・Install the tester where it will not receive any influences

from temperature or humidity changes, such as at the center of the facility.

FL-601

・Do not install the tester where it will receive direct influence from wind or blown air.

・Install the tester in a location where air from air conditioning units, etc will not affect the tester’s performance.

Provide a cover for the tester and/or other fixtures if necessary.

WARNING

33

POWER ON PROCEDURE INSTALLATION INSTRUCTIONS ○ ABOUT THE WORK / MASTER ・Try to eliminate temperature differences between the work, the master parts and the surrounding

environment.

When handling thin material or high temperature transmission parts such as radiator parts, avoid using your bare hands.

○ TRANSPORTATION INSTRUCTIONS

Do not handle the tester using the points indicated by the Handling these parts may cause damages, malfunction or injury. Points indicated by the are fragile. Use extra caution to avoid damage.

【FRONT】 【REAR】

10℃

20℃ FL-601

If some work parts 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) Parts ・Minimize the internal volume of the work parts.

In order to increase testing sensitivity, minimize the internal volume of the work (including piping) by reducing the length of the pipe or by using a core.

･ Master parts, (mastering standard) are not necessary when using a Masterless Leak Tester.

CAUTION

Be sure to carry the equipment securely using both hands.

34

POWER ON PROCEDURE INSTALLATION INSTRUCTIONS

○ INSTALLATION SIZES

○ INSTALLATION MEASURMENT

○ MOUNTING TOOL ASSEMBLY

・Mount the metal fittings to the tap holes located on the bottom of the tester’s main body. Secure

it with the specified screws. ・Prior to any installation procedures, it is important that the power source and pneumatic supply

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 adjacent fixtures to maintain the air ventilation effect.

・Leave a sufficient amount of space (as shown on the right) for connection cables.

POWER ON PROCEDURE BASIC PIPING

■ BASIC PIPING

35

注 意

To ensure safety during piping procedures. ・Do not touch the I/C board or start piping procedures while power is supplied into

the equipment. Doing so may cause electric shock. ・Do not start piping procedures while connected to an air supply source. Large

amounts of compressed air may be emitted and cause injury. Secure a safe operation environment and then begin the procedures.

Things to Consider: ・Choose non-leaking, non-deforming pipes for the test circuit piping. (Pipes

that do not change in form or size when pressurized.) ・Choose non-leaking connectors such as bite type connectors for high

pressure applications. ・Allow piping to be short in length and large in diameter. ・Be sure that the piping is not attached to or close to heat generating objects

such as coils for solenoid valves. ・Provide temperature-protecting countermeasures. Wrap thermal

resistance material around the pipes if necessary. (Spiral tubes are also effective)

Be sure that the piping does not move during the testing process. Piping for the master side should be equal to the work side piping. Do not connect any unnecessary objects to the test circuit piping. Please use an Exhaust Bypass Unit (Optional) if there is a possibility that oil and other foreign substances may enter the work.

Clamp Fixture Inadequate clamping pressure will cause sealing materials to deform, destroy work parts or cause leaks. If there is over 20% of pressure tolerance against the set pressure, provide a compressor or increase the pressure supply. Arranging a surge tank between the passages may also be effective. Provide a separate regulator for cylinder actuation pressure adjustment. Pressure tolerance for the cylinder actuation may interfere with the pressure supply or shift the clamping force for multiple cylinders causing unsuitable testing.

Solenoid Valves

for Control

Non-Return Valve

Regulator Lubricator

Clamp Cylinder

Work 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 pressure decrease during the charge process

WORK Rc1/4 Connect the work(test) part. This piping will be a part of the test piping (circuit).

EXH (Exhaust) Rc 1/4 Silencer mounting hole.

Test Piping

① ② ③

④ ⑤

Regulate the test pressure to +100kPa

Filters ①～⑤ Please refer to page 36 for further details on decompression valves.

WARNING

Pressure Source ・Use clean, stable air as the air supply source. The primary reason for sensor

malfunction is caused by water and /oil intrusion. Please provide an air filter. An air dryer or air purification device is also recommended if necessary.

・Air leak testers detect leaks by reading out precise pressure alteration. Thus, the piping instructions for air leak testers are different than those for standard air piping.

・Follow the instructions below for highly accurate leak testing.

ALARM

ALARM

ALARM

ALARM

WARNING

MASTER (Master) Rc 1/4 Use to connect the Master Work. This piping is testing piping.

About the Master Comparison leak testing method The FL-601 conducts leak testing using the master comparison method. Please connect the master to the master port. Leak accuracy will change according to master volume, shape and connection method. Although it is recommended to use a master with the same shape, same material, same piping and same connecting method, if this is not available please consider the following points.

Item Best Method Alternative Method

Master Work with no leak (Identical conditions)

A rigid tank smaller than the work (Speeds up stability)

Position Near the work at the same height Same height. Surround the periphery (No fluctuations when the temperature is the same.)

Piping Together with the work piping Piping is the same length as on the work side. (If there is temperature influence, shorten the length)

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” on page 35. ・AIR SUPPLY (TEST PRESSURE)

・A.P. SUP (Pilot Pressure Operational Pressure)

When testing works with small internal volumes, the pressure flow rate can be small as well. (The standard shown in the catalog is sufficient). However, you should select a decompression valve which can accommodate the response time and source pressure fluctuation.

36

No. Product Name Recommended Selection Contents

Mist Separator Use articles with filtration degree less than 0.01μm.

(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 Valve

(3) Vacuum Decompression Valve

Use one that has a high setting sensitivity and/or high repeatability.

Administer the test pressure.

* Specifications for V are not necessary

Compatible Equipment (SMC Model) No. Product Name Recommended Selection Contents

Model

(4) Air Filter Use articles with a filtration degree less than 5μm. AFM Series

(5) Common Decompression Valve

Use a test pressure that can be administered in the 300～400kPa range. AR Series

（Note）Common to each range.

37

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. Large amounts of

compressed air may be emitted and cause injury. Secure a safe operation environment and then start the procedure.

WARNING Do not damage the power cord. ・Do not damage the power cord or apply heat to it. ・ Placing heavy items or pulling on the power cord may cause fire or electric shock.

CAUTION

Wiring Procedure ・Select appropriate cables depending on the applied signals and their purpose. Ignoring cable

specifications may cause fire or electric shock. Ground ・Carry out grounding construction for the tester’s F.G. terminal.(Better than class 3)

Ignoring this may cause fire or electric shock. ・In order to prevent malfunctions caused by noise interference, the wiring for the input signal within the fixture and

the output signal power source should be assembled separately. Different power source wiring found in the fixture should also be assembled separately.

・Using a shield code for the input signal wire is recommended. ○ REMOTE TERMINAL TABLE

No Signal Name Input/Output Pin No. Signal Name Input

/Output 1 STOP Input No Signal Name

Input /Output 33 OK Output

2 START Input 19 +COM Input 34 +NG Output

3 FITTING Input 20 +COM Input 35 -NG Output

4 BUBL Input 21 +COM Input 36 2NG Output

5 RETRY Input 22 +COM Input 37 BNG Output

6 GROUP 1 Input 23 +COM Input 38 PNG Output

7 GROUP 2 Input 24 +COM Input 39 RUN Output

8 GROUP 4 Input 25 NC － 40 RDY Output

9 GROUP 8 Input 26 NC － 41 END Output

10 CAL Input 27 －COM Input 42 ERR Output

11 Psw Input 28 －COM Input 43 NC Output

12 ENG Input 29 －COM Input 44 M/R Output

13 LM 1 Input 30 －COM Input 45 NC －

14 LM 2 Input 31 －COM Input 46 NC －

15 NC － 32 －COM Input 47 NC －

16 NC － 48 NC －

17 DC+24V Power Output 49 GND POWER

18 DC+24V Power Output

50 GND POWER

APPLIED CONNECTOR:HONDA MR-50LF APPLIED CABLE: Larger than 0.2SQ ＊NC in the above list means no connection.

38

POWER ON PROCEDURE Connection to external equipment

STOP

Stop signal for leak testing. Rising pulse signal greater than 200msec

START Start signal for leak testing. Rising pulse signal greater than 200msec.

FITTING Start signal for fitting testing. Rising pulse signal greater than 200msec Operates in ready status.

BUBL Only pressurizes the leak test circuit. Rising pulse signal Progresses to Exhaust when the signal is turned OFF Operates in ready status.

RETRY Re-outputs data from the RS-232C. Operates in ready status.

GROUP Selects the GROUP which will be tested. 4 signals out of Group Numbers 1~8 will be input as binary digits.

CAL If the CAL signal is input while testing (mastering) is being conducted, it will be executed while the calibration port is being ventilated.

Psw

External pressure switch input signals ・Mount a pressure switch to confirm the Open/Close status of the work port stop valve. To prevent a potential problem, configure the wiring to input the ON signal when the valve is closed. ・ERR 002 will be displayed on the LCD if it senses the valve is closed.

ENG External Pressure Value Input Signal ・Connect a valve with a pressure sensor to the work port and configure the wiring. If the supplied pressure does not reach the tester’s specified test pressure, it will send out a P. NG error to prevent a potential problem. ・The detection timing is same as with Psw.

LM1 LM2

Cylinder Clamp Position Input Signal ・ When a clamp cylinder is controlled by this unit, this signal can be utilized to detect the Up/Down alignment position of the clamp cylinder.

IN

+COM -COM

Floating Circuit Power Input ・ Each REMOTE input terminal employs a floating circuit to avoid interference from external peripheral equipment. Therefore, if power is not supplied to this terminal, the signals that are input to the REMOTE terminals cannot be detected. ・ If this unit is being controlled using PLC, supply the power to this terminal from the connected equipment using the specifications listed below.

OK +NG -NG 2NG B.NG P.NG

The Leak test judgment is output. This Judgment is output during the EXH process. The test result signal will be output.

RUN Output during operation. (Test/Fitting/ BUBL testing etc.) RDY Output during the Ready Status. (When operation can be accepted)

END Output at the end of operation. ・Outputs upon the completion of testing. ・Read the detection results at this time.

ERR This error signal is output when the tester is in error mode. ERR will be indicated by code number on the display. (See ERR reference chart on page 109~110)

M/R Outputs from MANUAL/REMOTE ・Outputs on remote movement.

OUT

DC+24V

DC+24V is output ・ If you desire a hand switch for START/STOP operation, but it is difficult to supply an external power source, (When using the manual switch) it is possible to supply power to the floating circuit by using a wiring scheme as described on the right.

Outputs signal at the start of the exhaust progress

Connect DC+24V to +COM Connect GND to –COM

Input at least 200msec before inputting the START (MASTER) signal

Input at least 200msec before inputting the START (MASTER) signal

Greater than 200 msec

Configure +24V to +COM Configure 0V to –COM

Greater than 200 msec

Greater than 200 msec

The maintenance label signifies continued pressure maintenance

Greater than 200 msec

LM1: The clamp cylinder is clamped LM2: The clamp cylinder is unclamped

39

POWER ON PROCEDURE Connection to external equipment ○ SEQUENCER CONNECTION EXAMPLE

【REMOTE TERMINAL】

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 【REMOTE TERMINAL】

It is possible to easily connect an external switch using the internal power source ＜Input Circuit＞

WARNING

Do not combine the internal and external power source wires. Doing so may result in fire.

CAUTION

・Use DC 12~24 V ±10% for the external power source. ・The input/ output circuit power source common is consistent. ・The input circuit actuation current is 8mA at each point. ・The maximum load per unit on the external circuit is DC 30V 10 mA ・The maximum distance for the signal transfer should be less than 10 m. (Depending on the cable used .)

+COM

INPUT

OUTPUT

－COM

LOAD

MANUAL SWITCH FL-601 MAIN BODY

DC+24V

+COM

STOP

－COM

GND

－COM

START

－COM

18

19

1

27

2

28

32

50

STOP SWITCH

START SWITCH

40

POWER ON PROCEDURE Connection to external equipment

○ SEQUENCER CONNECTION EXAMPLE

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 1～14 Output Terminal 33～44

CAUTION

Customers who use attached connectors instead of a dust cover and enclosed metal parts for cable cramping, are requested to remove the metal portion of the cable cramps and store them separately. We are sorry for any inconvenience that this may cause. If you keep the surrounding metal parts on the cable cramps, the terminals may short, possibly resulting in irregular readouts and inaccurate measurements. Alternately, if you purchase new items, construct the attached connectors and cover, without using the surrounding metal parts for the cable cramps. Instead, keep them stored separately.

SEQUENCER

41

POWER ON PROCEDURE Connection to external equipment ○ EXH VALVE SIGNAL TERMINAL TABLE No

Signal Name Input/Output Pin No. Signal Name

Input/Output

. 1 *ESV1 +OUT Pin

No. Signal Name

Input/ Output 23 *ESV 1 －OUT

2 *ESV2 +OUT 13 +COM IN 24 *ESV2 －OUT 3 *ESV3 +OUT 14 +COM IN 25 *ESV 3 －OUT 4 *ESV4 +OUT 15 +COM IN 26 *ESV 4 －OUT 5 *EXV5 +OUT 16 +COM IN 27 *ESV5 －OUT 6 *ESV6 +OUT 17 NC － 28 *ESV6 －OUT 7 *ESV7 +OUT 18 NC － 29 *ESV7 －OUT 8 *ESV8 +OUT 19 －COM IN 30 *ESV 8 －OUT 9 NC － 20 －COM IN 31 NC － 10 DC+24V Power Output 21 －COM IN 32 GND POWER 11 DC+24V Power Output 22 －COM IN 33 GND POWER 12 DC+24V Power Output 34 GND POWER

○ EXTERNAL SV CONNECTION EXAMPLE

CAUTION

・Maximum load for the external SV signal should be less than 0.5(A) per signal. ・ Make sure that 3 external SV signals combined are less than 1(A). ・Maximum load voltage should be less than DC 30(V).

○ APU CONTROL TERMINAL TABLE (Do not use other than for the APU control signals.)

Pin.No Signal Name Input/

Output Pin

No Signal Name Input/ Output

1 +15V Output Pin No. Signal Name Input/

Output 6 －15V Output

2 NC － 4 +12 VDC Power Output 7 S GND

3 D/A OUT Output 5 GND POWER 8 － － APPLIED CONNECTOR: HONDA MR-8LM APPLIED CABLE: Larger than 0.2 SQ

＋

DC + 24V

－COM

External SV

GND

+COM

10

13

1

23

19

32

FL－601 MAIN BODY

You may be able to use an internal power outlet when using optional FUKUDA products. Please look at pages 10-13 and 19-32 for details

*ESV 1(External Pressure Valve) *ESV 2 (External Exhaust Valve) *ESV 3 (Pressure Change-Over Valve) *ESV 4 (Cylinder Control Signal) * ESV 5~8 (Not I n Use)

APPLIED CONNECTOR: HONDA MR-34LF APPLIED CABLE: Larger than 0.2 SQ

42

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 )

Test Progress RDY DLY CHG 1 CHG 2 BAL 1 BAL 2 DET *1 EXH UnClamp*4 HOLD

Pressure Valve (SV1) ＮＣ

Exhaust Valve (APV2) ＮＯ

Balance Valve (APV3) ＮＯ

Internal Electro-Magnetic

Valve

CAL Port Valve (APV4) ＮＣ

External Pressure Valve ( ESV1)

External Exhaust Valve (ＥSV2)

External Electro-Magnetic

Valve

External Pressure ChangeOver Valve (ＥSV3)

Cylinder Control Valve（ＥＳＶ4） ＊５ ＊５

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

ＥＮＧ

ＬＭ1

Remote Input Signal Reading Tim

ing

ＬＭ2

＊ 1. Use F. DET testing time for Fitting Testing. Signal ON Signal OFF

＊ 2. EXH will turn ON after 200 msec. ＊ 3. Input at least 200 msec before inputting the START (FITTING) Signal. ＊ 4. By setting the limit switch setting to “EFFECTIVE”, this process will be added to the sequence. (refer to Cylinder Setting page 53 for detail). (The actuation timing is same as with the DLY process). ＊ 5. By setting the NG Hold to “EFFECTIVE”, this process will be added to the sequence. (refer to Cylinder setting page 53 for detail).

Signal output of the judgment results.

Input the group to be tested in 2 sequential codes

Input for at least 200msec.

43

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. The input pressure value or the former test result is displayed on the LCD.

(2) DLY STAGE The real test start is delayed waiting for the test start signal. This is used to accommodate things such as the cylinder clamp up/down time.

(3) CHG 1 STAGE Lead pressure (higher than the test pressure) is applied. This will allow more stable, accurate leak detection in

a shorter processing time. (4) CHG 2 STAGE

Test pressure is applied to the product being tested. (5) BAL 1 STAGE

The charge valve is closed and the APV3 valve ( see air pressure circuit on page 115,116) is opened to make the work pressure and the master tank internal pressure equal. During this stage, if the work’s internal pressure becomes lower than the reference pressure, （lower limit of internal work pressure）it may be judged as a large leak and the test will be terminated.

(6) BAL 2 STAGE In this stage, the work’s internal air pressure is stabilized. During this stage, if the pressure difference between the work and the master becomes larger than the reference pressure, it may be judged as a large leak and the test will be terminated.

(7) DET STAGE (F DET STAGE)

The differential pressure sensor detects the pressure difference between the work and the master tank. We then use this value to calculate the leak amount in the work. (The F. DET stage calculates the fitting constant). While this stage is being performed if the internal pressure of the work lowers and the differential pressure is rejected, a large leak judgment is made and the test is terminated.

(8) EXH STAGE

Exhausts the air within the work. Leak test results are indicated and output.

44

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.

Status Judging timing △：Judging point ←→ ：Judging range

Setting Contents Pressure １ Pressure 2 Balance １ Balance 2Detection

(*1) Exhaust

Judgment

result shown

on LCD

display

REMOTE

Terminal

LEAD.P =

Lead

pressure

value

Work internal pressure is

more than ±10% out of

the Lead setting value.

P.NG(*3) P.NG

TEST.P =

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

than +FS.

D+NG +2NG

Differential pressure

sensor indicates less

than –FS.

D-NG -NG

Measurement result≦

-NG -NG -NG

-NG ＜ Measurement

result＜+NG・+2NG OK OK

+NG・+2NG≦Measurement

result

+2NG +2NG

+NG＝

+2NG

Differential pressure

sensor indicates more

than +FS.

D+NG +2NG

Judgment Result

Ｆ P.NG No update

+00.0 kPa Hold Group No 00

45

POWER ON PROCEDURE Connection to External Equipment

Status Judging timing △：Judging point ←→：Judging range

Setting Contents Pressure

１

Pressure

2

Balance

１

Balance

2

Detect

(*1) Exhaust

Judgment

result shown

on LCD

display

REMOTE

Terminal

Differential pressure sensor

indicates less than –FS.

D-NG -NG

Measurement result≦-NG -NG -NG

-NG＜Measurement result＜+2NG 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 .Fitting testing time is the fitting detection process. ＊ 2 . Judges only during the fitting testing time. ＊ 3 . The pressure sensor used for the P.NG judgment is the same as the TD3 work pressure sensor shown on the Pneumatic Pressure Circuit Diagram on P.117. ＊4 .2NG is ignored if the 2NG setting is set to be zero.

46

POWER ON PROCEDURE Power Connection

■ POWER CORD CONNECTION

○ Connecting the Power Cord 1.Use the provided power cord

・Advice regarding the FL-601□-2 specification optional AC power cord (Rated 250 V) The male end of the optional 200V power cord meets EEC standards. (European Electronic Equipment Unification Safety Standard). If the supplied power cord does not fit into the electrical outlet in your facility, please select another, more appropriate cord. (The customer must make these arrangements independently)

■ Check the voltage supply Be sure that proper voltage is being supplied into the equipment before connecting the power cord to the tester body.

■ Be sure that the tester’s power switch is turned off before connecting the power cord to the tester body.

■ Use the designated power cord for this equipment. Use the power cord supplied by the manufacturer to prevent potential electrical shock.

WARNING

■ Use proper grounding arrangements when installing this equipment to prevent potential electrical shock.

2. Be sure that the tester’s power switch is turned off. 3.Insert the accessory power cord plug (female) to the AC 100V inlet (Power connector) located on the rear panel’s right side, and turn the connector knob to fasten tightly.

AC Power Cord

(Rated 250 V)

Tester Power connector side

plug (Female Plug)

MAIN Power Side PLUG （Male PLUG）EEC Standards. If the plug does not fit correctly, please use a different plug. (Customer must make their own arrangements)

When changing the main power connection cord (Male Plug), be sure to take unplug the cord on the tester and take precautionary actions to ensure safety.

Warning When changing the main power connection cord, be sure to select a plug that

meets or exceeds the specified voltage.

47

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.

● Use proper, exclusive grounding installation for the P.E(Protective earth)

● Use an insulated transducer if the AC 100V source is converted from AC 200V.

○ OFF POWER SWITCH ・Be sure that the equipment is properly installed prior to turning on the power switch. ・The power switch is located on the rear panel’s lower right side. Switch it to the Right sight to turn it ON and to the

Left side to turn it OFF. Be sure to switch RDY off.

○ Regarding fuse replacement Use a fuse with a rating and type of: φ5 ×20mm 3.15A

AC100V AC200V

AC100V Ｌ

AC100V Ｎ

F.G

Open these two fuseholders using a slotted (flat) screwdriver and replace the fuses.

48

POWER ON PROCEDURE Power Connection ○ POWER ON

Refer to Page 59 for testing instructions.

Press the SET key to assign conditions for each setting category.

Refer to Page 68 for maintenance instructions.

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

・Finish the necessary configuration prior to this procedure. ・Supply the appropriate pressure to AIR SUPPLY and A.P.SUP port.

Preparations

Power ON

49

BASIC OPERATION

50

BASIC OPERATION ■ BASIC OPERATION INITIAL SCREEN ※ Indicates Each Key

Manual

+100 kPa Ready Group No 00

RDY Lamp On MANUAL Operation Status

Initial Screen Operation Possible

SET Pass 0000 1/5p Gp 00 Delay 000.1 sec Charge1 000.1 sec Charge2 000.1 sec Balance1 000.1 sec Balance2 000.1 sec

Pass 0000 2/5p Gp 00 Detect 00.1 sec Exhaust 001.0 sec F Detect 008.0 sec W. Volume 5.000E2 ml M.Volume0 2.997E1ml

Pass 0000 3/5p Gp 00 +NG 00.01 ml/m +2NG 00.01 ml/m -NG -00.01 ml/m F+NG 00.01ml/m F-NG -00.01ml/m

Pass 0000 4/5p Gp 00 Digit 00.0 ml/m Lead P 100 kPa Test P 100 kPa Fitting Set 0 RevData +00.00ml/m

BUBL 100 kPa

Bubl

MAINT Pass 0000 Maintenance

ENT

ENT

ENT

Maint 1/2P *Volume Measurement I/O Check Self Check Stability Check Soft Version

Please input value Flow Master ????? ml/m

ENT Input the Flow Master’s current FS value

START 1st Time: Work Variation condition measurement 2nd Time: Actual leak measured by the Flow

Master

Volume ????E? ml Start key → Data Update Stop key → Cancel

START：Input value 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 Version 1.＊＊ Range M

ENT

ENT

ENT

ENT

START: Starts the self-check process *ERR is indicated if a malfunction is detected.

Stability Check 1 Valve Close 2 Press Start Key

ENT START: Element stability confirmation

FITTING Fitting Testing Test result

START Ordinary Testing Test result

Maint 2/2P *Data Load APU tuning CalOpen Test

ENT

Outputs the test data

Volume Measurement * Flow Master

Calibrator ENT ENT

When the cursor points at the item:

Move to upper item Move back to the previous item.

Moves to the following item.

Move to lower item

When the cursor points at the item.

Raise numerical value

Lower numerical value

Move up one row

Move down one row

MANUAL & READY STATUS

Pressure at START, stop at STOP

Pass 0000 5/5p Gp 00 OutData 0 Remote Stop 0 UnitChange ml/min kPa Cylinder 00 Password ＊＊＊＊

ENT

51

BASIC OPERATION SETTING CONTENTS

■ SETTING CONTENTS

The FL-601 has the following setting items: Setting Display Page

ITEM CONTENTS TESTING RANGE

Delay Delay Process Time

Sets the delay time from when testing is first initiated until actual pressurization begins. 0.0 ～ 999.9 sec

Charge1 Charge 1 Process Time

Sets the lead pressure pressurizing time for TURBO. If it is set to “0”, the TURBO function does not operate. It is necessary to use an external pressure conversion valve (ESV3) when using the TURBO function.

0.0 ～ 999.9 sec

Charge2 Charge 2 Process Time

Sets the test pressure charging time. 0.5 ～ 999.9 sec

Balance1 Balance 1 Process Time

Sets the time for stabilizing the air in both the work and the internal master after the pressure is cut off.

0.5 ～ 999.9 sec

1/5

Balance2 Balance 2 Process Time

Sets the time for stabilizing the internal pressure of the air for both the work and the master. 0.5 ～ 999.9 sec

If Fitting Set is 4 5 ～ 20.0 sec

Detect Detection Process Time

Sets the duration of the leak detection process.

If Fitting Set is 3 and Unit Change is Pa 0.5 ～ 999.9 sec

Exhaust Exhaust Process Time

Sets the amount of time given to exhaust the air within the work parts. 0.5 ～ 999.9 sec

F Detect Fitting

Detection Process Time

Sets the amount of time used to detect the air during the Fitting test. (This is invalid when FittingSet is set to 3).

5.0 ～ 200.0 sec

W. Volume Work Volume

Sets the internal volume of the work to be tested. The work’s internal 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 judgment setting value. Evaluated as +NG when the set value and test value are the same.

0001 ～ 9999 ml/min Digit set designates the decimal point location.

+2NG +2NG Setting

Sets a failure value other than the +NG judgment value. For example, +NG can be used for small leaks and +2NG for large leaks. It is evaluated as +2NG when the set value and test value are the same.

0001 ～ 9999 ml/min Digit set designates the decimal point location.

-NG -NG Setting Sets the –NG judgment setting value. Evaluated as -NG when the set value and test value are the same.

0001 ～ 9999 ml/min Digit set designates the decimal point location.

F+NG F+NG Setting Sets the +NG judgment setting value during the fitting test. Evaluated as F+NG when the set value and test value are the same.

0001 ～ 9999 ml/min Digit set designates the decimal point location.

3/5

F-NG F-NG Setting Sets the -NG judgment setting value during the fitting test. Evaluated as F-NG when the set value and test value are the same.

0001 ～ 9999 ml/min Digit set designates the decimal point location.

The Work Volume setting is used when changing the leak differential pressure（Pa/min）detected by the tester to the leak rate（ml/min）. Be aware that when an incorrect value is input, testing will be conducted with that value.

～

～

WARNING

52

BASIC OPERATION SETTING CONTENTS

Setting Display Page

ITEM CONTENTS TESTING RANGE

Digit Decimal

point setting

Set the decimal point for the leak value or the +NG judgment value indicated on the display

.0000, 0.000, 00.00, 000.0 0000.

Lead.P Lead

Pressure Setting

Sets the lead supply pressure for the TURBO test time. If the pressure is±10% over the set pressure following the Charge 1 Process, a P.NG judgment will be conducted. Judgment will not occur if the test value is set to “0”.

Test.P Test

Pressure Setting

Sets the supplied test pressure. If the pressure is±10％ over the set pressure following the Charge 2 Process, a P.NG judgment will be conducted. Judgment will not occur if the test value is set to “0”.

V 0 ～ -90.0 kPa L 0 ～ 99.9 kPa M 0～700kPa UL 0～20kPa H1 0 ～ 20MPa

Fitting set

Fitting setting switch

Sets the test setting. Use “0” for ordinary testing.

0 ～ 4

4/5

RevData Set fixed

correction. value

Set the fixed correction value which is deducted from the measured value ±.0000～±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 CHG2ProcessBBAL1Process BAL2Process DET Process (MDET Process)

○

4 ○ × ×

CHG1：CHG2：BAL1 Work Internal Pressure

BAL2：DET：.FDET Differential Pressure

Set Contents

0 Conduct fitting test, calculate and save c constant, perform fitting calculation in the next normal test by fixing c constant.

1 Conduct fitting calculation by fixing c and b constants.

2 Conduct fitting calculation by fixing c, b and a constants.

3

During the detection process, calculate the data’s regression line and obtain the test result using its slope. Fitting key becomes disabled and the test is performed only using normal measurement (DetectTime).

4

Calculate the c, b and a constants for each test. Perform the same calculation both during the fitting test and the normal test. The only difference is the setting detection time (F DetectTime, DetectTime).

Normally use set “0”.

V 0 ～ -90.0 kPa L 0 ～ 99.9 kPa M 0～700kPa UL 0～20kPa H1 0 ～ 20MPa

53

BASIC OPERATIONS SETTING PROCEDURES

Remote Stop

Switches the behavior of the STOP signal

It switches the logic for determining how the STOP signal at the remote control will affect the measurement.

0～1

Unit Change

Unit Change

Changes the units of the Test Results. When shipped, it is set to ml/min. If you want to use 「Pa」, set Digit (point of decimal point) to 「0000.」. Otherwise, this is invalid.

ml/min Pa/min ml/sec Pa/sec

Pa

Cylinder Cylinder Settings

If you use this equipment to control a clamp cylinder, provide the settings for actuations and the status check function. SetValue X 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 position is detected then the unclamp process will carried out after the exhaust process.

00, 10, 01, 11 5/5

Password Password

Sets the password required to input settings. Default value is “0000”. * *This password will be invalid when a new password is set.

0000 ～ 9999

NG Hold Limit Switch

Mode Logic

0 Suspend measurement when STOP signal is on.

1 Suspend measurement when STOP signal is off.

54

BASIC OPERATIONS SETTING PROCEDURES

■ SETTING PROCEDURES Procedures to input Process times, NG ranges and other settings are explained below.

1. Start from the initial screen.

2. Press the SET key. 3. Enter the password, and press the ENT key.

4. Press the keys to display the desired setting page.

Will proceed to Screen 1/5. Will proceed to Screen 2/5

Press

・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?

Preparations

Press to proceed to the next page.

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 sec FDetect 008.0 sec W.Volume 5.000E2 ml M.Volume 2.997E1 ml

Pass 0000 2/5p Gp 00 Detect 001.0 sec Exhaust 001.0 sec FDetect 008.0 sec W.Volume 5.000E2 ml M.Volume 2.997E1 ml

Pass 0000 3/5p Gp 00 +NG 00.01 ml/m +2NG 00.01 ml/m - NG -00.01 ml/m F+NG 00.01 ml/m F-NG -00.01 ml/m to go back to the

previous page

Press to proceed to the next page.

55

BASIC OPERATIONS SETTING PROCEDURES

PressPress

5. For example: When entering 10.0 sec for Charge 2, go to Screen 1/5

6. Use the keys to move the cursor to Charge 2.

7. Press the ENT key .(The cursor will indicate that it is ready for numerical input.)

Will proceed to Screen 3/5 Will proceed to Screen 4/5. Press

to proceed to the next page.

Press to go back to the previous page.

Will proceed to Screen 4/5. Will proceed to Screen 5/5. Press

to proceed to the next page.

Press

Pass 0000 3/5p Gp 00 +NG 00.01 ml/m +2NG 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 00Digit 00.00 ml/m Lead.P 100 kPa Test.P 100 kPa FittingSet 0 RevData +00.00 ml/m

Pass 0000 4/5p Gp 00Digit 00.00 ml/m Lead.P 100 kPa Test.P 100 kPa FittingSet 0 RevData +00.00 ml/m

Pass 0000 5/5p Gp 00OutData 0 RemoteStop 0 UnitChange ml/m kPa Cylinder 00 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

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

to go back to the previous page.

56

BASIC OPERATIONS SETTING PROCEDURES 8. Enter 10.0 Digit movement Change numerical values 0～9

9. Press the ENT key. (To store 10.0 in memory.) The cursor will move back to the setting name.

10. Press the STOP key. (Press this following each setting procedure.) 11. 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 Balance2 001.0 sec

Manual

+000 kPa

Ready GroupNo 00

CAUTION

57

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.

1. Use the keys to move the cursor to M. Volume. 2. Press the ENT key.

(Select the single-figure next to M. Volume using the cursor) 3. Use the keys to select a number from 0 to 3. 0：A fixed value of 3.77ml( this occurs when the master valve is closed) will be established as the Master

Volume. 1：A fixed value of 29.97 ml (this occurs when the accessory master tank is connected) will be established

as the volume. 2：A fixed value of 53.33 ml (this occurs when the optional master tank is connected) will be 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 this screen.

Pass 0000 2/5p Gp 00 Detect 001.0 sec Exhaust 001.0 sec F Detect 008.0 sec W.Volume 5.000E2 ml M.Volume0 2.997E1ml

Pass 0000 2/5p Gp 00 Detect 001.0 sec Exhaust 001.0 sec F Detect 008.0 sec W.Volume 5.000E2 ml M.Volume0 1.000E1ml

Pass 0000 2/5p Gp 00 Detect 001.0 sec Exhaust 001.0 sec F Detect 008.0 sec W.Volume 5.000E2 ml M.Volume3 1.000E1 ml

Pass 0000 2/5p Gp 00 Detect 001.0 sec Exhaust 001.0 sec F Detect 008.0 sec W.Volume 5.000E2 ml M.Volume3 1.000E1 ml

58

TESTING OPERATION

59

BASIC OPERATIONS SETTING PROCEDURES ■ Ordinary Testing Procedure 1. Press the START key．(Testing starts) (If using a Remote, input the START signal from the REMOTE connector.) 2. The test result will be output when the testing is concluded.

(＊1) For operations 1~10, once the settings are set, there is no need to repeat that process for each test. When setting values are changed, the first test will always be a mandatory fitting testing.

（＊2）If you choose fitting 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 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?

Preparations

Test Value

Judgment Result

Manual －0000Pa － 0 ＋ Detect GroupNo 00

60

FITTING TESTING SETTING PROCEDURES ■ Fitting Testing Procedure 1. Press the FITTING key. (It begins reading the Fitting Data) 2. The test result will be displayed when the testing has concluded.

If fitting set 0, 1 or 2 is selected, there will be an indication in the upper-left side of the screen that tells you if the value was determined freely, or using the slope. If it indicates that the slope was used, this means that the result of formula 1 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 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?

Preparations

Testing Value

Judgment Result

Indicates that the unit is currently performing Fitting testing

F Manual －0000Pa － 0 ＋ FDetect GroupNo 00

61

BASIC OPERATION PRINTER OPERATION

■ Printer Operations

1. Connect the printer to the tester’s RS-232C Connector using the appropriate cable. 2. Turn the printer’s POWER switch ON. Press the SELECT button.

・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.)

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 when the SELECT button is pressed.

Printer

POWER Switch

SELECT button

62

BASIC OPERATION PRINTER OPERATION 3. Display the initial screen. 4. Press the SET key. 5. Enter password. 6. Press the ENT key. 7. Press the key and proceed to screen 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 ＊＊＊＊

63

BASIC OPERATION PRINTER OPERATION 9. Press the ENT key. (Enables numeric entry mode) 10. Use the keys to input 4 for OutData (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

64

BASIC OPERATION PRINTER OPERATION 14. Press either the START or the FITTING keys. (Starts either the normal test or the fitting test.) 15. The tester will display and print the test results when the testing is concluded. Display indicates the judgment result.

※ For 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 －0000Pa － 0 ＋ Detect GroupNo 00

OK

1.000 ml/m Exhaust GroupNo 00

65

BASIC OPERATIONS RS-232C OUTPUT ■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:

・Speed 19200 bps ・Start Bit 1 bit ・Stop Bit 2 bit ・Data length 8 bit ・Parity None ・Error Check BCC (Horizontal parity) ・Text Encoding ASCII ・Communication mode RTS・CTS Hand Shake ・Transmission Process Non-procedural, asynchronous ・Connector 9Pin D-SUB

○ Connector Chart and Wiring RS232C Wiring

Tester Computer

Signal Name Pin

Number D-Sub 9

Connection Pin

Number D-Sub 9

Pin Number D-Sub 25

Signal Name (JIS)

DCD 1 1 8 DCD (CD) TxD 2 2 3 RxD (RD) RxD 3 3 2 TxD (SD) DSR 4 4 20 DTR (ER) SG 5 5 7 SG (GND)

DTR 6 6 6 DSR (DR) CTS 7 7 4 RTS (RS) RTS 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 needs. (See page 52 for more details.)

○ Test Value Transmission 1. Mode 1 Test value transmission (If OutData is set to 1)

The test result data is transmitted during the EHX process, after the test is completed. Transmission Text Type

Group Number Comma Judg Comma Data Type Comma 2 1 4 1 5 1

Item Byte No. Data Ex. 00 , +2NG , Mdata ,

Test Result Comma Work Internal Pres. Comma C Invariable

13 1 9 1 10

+0.000-ml/min , +10.0-kPa , -7.8441E-3

Comma b Constant Comma ETX BCC CR 1 10 1 1 1 1

, +0072-Pa-- , 03H 0DH * The [_] mark signifies a space, ETX is equal to 03h, CR is equal to a Carriage Return(0dh), and BCC is horizontal parity.

66

BASIC OPERATIONS RS232C 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) Differential

Pressure Value（Pa） CR 6 １

Item Byte No. Data side +00000 0DH

3. Out Data 3 (Transmits data and test results from the beginning of the CHG1 phase through the

DET (MDET) phase. A work pressure value (kPa value) is transmitted every 0.1 sec during the CHG1, CHG2, and BAL 1 processes, and a differential pressure value (Pa value) is transmitted every 0.1 sec during the BAL2 and DET (MDET) processes.

(The format of the text transmitted for the test result is the same as with Out Data 1) Transmitted text format Transmitted text format

(Work Pressure value) (Differential Pressure value） 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 １Item Byte No. Data side 000.0s 0DH 000.0s 0DH 002.0s 0DH 001.0s 0DH

Balance2(sec) CR Detect(sec) CR Exhaust(sec) CR FDetect(sec) CR

6 １ 6 1 6 1 6 １

001.0s 0DH 002.0 0DH 001.0s 0DH 030.0s 0DH

WorkVolume(ml) CR Master volume(ml)

CR +NG(ml/min) CR +2NG(ml/min) CR

7 1 12 1 6 1 6 １

1.000E2 0DH 1.000E2----- 0DH +1.000 0DH +2.000 0DH

-NG(ml/min) CR +FNG(ml/min) CR -FNG(ml/min) CR UnitChange CR 6 1 6 1 6 1 6 1

-1.000 0DH +1.000 0DH -1.000 0DH ml-kPa 0DH

Lead.P(kPa) CR Test.P(kPa) CR Fitting Set CR Out Data CR 6 １ 6 １ 1 1 1 1

+000. - 0DH +000. - 0DH 0 0DH 0 0DH

Remote Stop CR UnitChange CR Cylinder CR 2 1 6 1 2 1

0- 0DH ml-kPa 0DH 00- 0DH

ETX Space CR 1 1 １

03H 20H 0DH

The transmission process is shown below. 1. Press the MAINT key at the initial screen. 2. Input the password and press the ENT key. Select Data Load on page 2/2 using the key. 3. Press the ENT key. 4. Press the START key.

67

MAINTNANCE FUNCTIONS

68

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.

I/O check (Input/ Output Check Function) Allows you to operate the FL-601 Input/ Output ports separately while confirming their operation.

Self Check (Self Check Function) This special function allows the tester to evaluate internal valves and sensors. If an error is detected, an ERROR code will indicate the nature of the problem.

Stability Check (Stability Confirmation Function)

Checks for internal leaks in the tester and/or overall stability when the manual valve is closed.

Soft Version (Software Version Indication) Indicates the currently installed software version and the model range.

Data Load

Outputs test data over the RS-232C connection.

APU Tuning Allows you to tune the APU pressure to coincide with the setting value. (The test pressure displayed on the setting screen).

69

MAINTENANCE FUNCTIONS Work Volume Measurement Using a Flow Master ■ Work Volume Measurement using a Flow

・You cannot measure volume using a flow master in the H1 range. You must perform the volume measurement using a calibrator.

*If you continue volume testing in the same work, please be sure to set enough exhaustion time. 1. Connect the Flow Master to the CAL PORT ※ Volume testing cannot be performed while the tester is in Remote mode. ※ Keep the work clamped. ※ 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 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? ・Have you prepared the pseudo leak master (Flow Master)?

Preparations

70

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. Upper Key/ Lower Key 5. On the next page, verify that the * symbol is next to Flow Master. If the * symbol is not 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 ＊Volume Measurement

I/Ocheck SelfCheck StabilityCheck SoftVersion

Volume Measurement

＊FlowMaster Calibrator

Please input value Flowmaster 00.00ml/m

Please input value Flowmaster 00.00ml/m

71

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) 10. It then begins testing a leaking item. (Volume testing start) 11. It will indicate the volume following the test. 12. Press the START key. (This will record the internal 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 after repeated measurement, perform the following procedure:

(1)Extend the exhaust time. (2)Exchange the flow master with a large leak amount.

72

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

1. Connect the fastening coupler to the manual calibrator.

2. Connect the manual calibrator to the CAL port on the front panel. * You cannot perform volume testing while using REMOTE operation.

Clamp the work and conduct this procedure in Manual mode.

・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 the setting values correct?

Preparations

Ensuring there are no leaks in the connection.

Fastening Coupler

Manual Calibrator connection.

Connect to the CAL port, making sure that there are no leaks. Use the shortest piping possible.

Manual Calibrator

73

OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 3. Adjust the graduation line on the calibrator to 0. 4. Display the initial screen. 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

74

OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 7. Press the ENT key. 8. Use the Up/ Down keys to move the * to Calibrator.

9. 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

75

OPTIONAL EQUIPMENT Work Volume Measurement Using a Manual Calibrator 12. Press the ENT key. 13. Press the START key. 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. 15. Press the key. When “Close” is indicated on the display, you must adjust the calibrator volume. (Calibrator adjustment volume input value) * If the calibration difference value is less than 100Pa, increase the volume of the calibrator.. 16 Press the ENT key. (Calculate 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 dP = +0379Pa Average = Pa n = Close

By turning the knob on the calibrator towards the front, you can adjust the volume.

The calibrated differential pressure will be indicated.

When “Close” is indicated on the display, you must adjust the calibrator volume.

Indicates the test number

Calibrated differential pressure average

Calibration dP = +0000 Pa Average = Pa n = Open

76

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)

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

77

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.

CAUTION

・Sequencer operation can be verified by forcing a signal output from the tester 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 StabilityCheck SoftVersion

Maint 1/2P VolumeＭeasurement ＊I/Ocheck Selfcheck StabilityCheck SoftVersion

78

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. 6. Press the key. The screen will display screen 2/3. (REMOTE Output Signal) The * mark will be on OK 7. Pressing the ENT key will display a ◆ sign next to the OK label, and output an OK signal

from the corresponding pin of the REMOTE terminal. Other signals can be output from the corresponding 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 the cursor to move the

* mark to the desired signal and pressing the ENT key.

I/Ocheck 1/3 INPUT stop ◆ gp1 Psw start gp2 ENG

fitting gp4 LM1 bubl gp8 LM2 retry cal

I/Ocheck 2/3 OUTPUT OK PNG NC +NG RUN M/R

-NG RDY NG2 END BNG ERR

＊

I/Ocheck 3/3 OUTPUT ＊ SV1 SV6 SV2 SV7 SV3 SV8 SV4 SV5

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

80

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.)

1. Remove the stopper from the CAL port on the front panel.

WARNING

Failure 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 MANUAL mode?

Preparations

Please remove the stopper. A proper Self-check function cannot be conducted if the stopper is left intact.

Manual

+100 kPa Ready GroupNo 00

Pass 0000

Maintenance

81

MAINTENANCE FUNCTIONS SELF-CHECK FUNCTION 4. Enter the password and press the ENT key. 5. Move the * mark next to Self-check. You can move the cursor using the Keys. 6. Press the ENT key. 7. Press 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

82

MAINTENANCE FUNCTIONS SELF-CHECK FUNCTION 9. Press the STOP 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

83

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.

1. Display the initial screen. 2. Press the MAINT 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 Ｍeasurement

I/Ocheck SelfCheck ＊StabilityCheck SoftVersion

84

MAINTENANCE FUNTIONS STABILITY CONFIRMATION FUNCTION 5. Press the ENT key. 6. Press the START key. (Begins the stability check function process) 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” 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

－０．０００ｍｌ／ｍ

End

Ｍanual

+000 kPa Ready GroupNo 00

Stability check Err306 +NG

＋０．１５０ｍｌ／ｍ End

85

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. 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

86

MAINTENANCE FUNCTIONS 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

87

MAINTENANCE FUNCTIONS APU TUNING ■ APU TUNING

1. Press the MAINT key. 2. Enter the password and press the ENT key. 3. Move the *mark next to APU tuning. (Maint 2/2 p) Use the Up/Down keys to move the * mark.

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

88

MAINTENANCE FUNCTIONS APU TUNING 4. Press the ENT key. 5. Press the key. (The test pressure will be indicated on the display.)

※If the APU is hunting, please refer to the APU operations manual for more information.

6. If the test pressure displayed 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

５００ ｋＰａ key→Zero key→Span StartKey→Tuning

APU tuning

０００ ｋＰａ key→Zero key→Span StartKey→Tuning

Will be displayed during adjustment.

APU tuning

０００ ｋＰａ key→Zero key→Span StartKey→Tuning

APU tuning

５００ ｋＰａ key→Zero key→Span StartKey→Tuning

89

MAINTENANCE FUNCTIONS APU TUNING 8. The Tuning indication will disappear. (Test pressure adjustment is completed.) 9. Press the key. (Confirms the test pressure) (The test 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

５００ ｋＰａ key→Zero key→Span StartKey→Tuning

APU tuning

５００ ｋＰａ key→Zero key→Span StartKey→Tuning

APU tuning

０００ ｋＰａ key→Zero key→Span StartKey→Tuning

Ｍanual

０００ ｋＰａ Ready GroupNo 00

90

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. Knowing this will allow you to observe the resulting leak measurement and determine if the work volume value and tact time are appropriate.

1. Press the MAINT Key. 2. Input the password and press the ENT key. 3.Move the cursor 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, air will spurt out, possibly causing injuries and/or eye impairment that could lead to blindness.

・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

Maint2/2p Date Loadsave

APU tuning ＊Cal Open Test

Cal Open Test

1 Set CalPort 2 Press StartKey

91

OPTIONAL EQUIPMENT

92

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. Connecting an air filter to the air supply port 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. Explanations in this manual are done under the assumption that the master 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 VALVE SIGNAL Cable Wire

Connection Tester Side (EXH VALVE SIGNAL)

Exhaust Bypass Side

(EXT SIGNAL) Applied Connector MR-34LF

JR16WR-7P

Remarks

２ － ３ ２４ － ４

External Valve

１０ １３ １９

Pin Number

３２

Applied Connector (Included)

Plug JR16WR-7P Receptacle JR16WP-7S

Applied Cable Cable at least 0.3SQ

Label

Caution

・Do not remove the EBU cover. ・Some parts within the EBU carry a high voltage and

may be driven unexpectedly due to the tester’s mechanical sequences. Possible electric shock and injuries may occur if this warning is ignored. Only qualified maintenance personnel should service these machines.

142.5

82

４－Ｍ５

Approx 41

128

64

Height 113mm

Jumper

93

OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT ○ Basic Piping (From the tester to the work) (UL, L. M. Specifications)

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

94

OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT ○ Basic Piping (Tester to Work) (V specification)

Front Panel Rear Panel

FL-601V Rear Panel

EBU-600

WORK

Source Pressure

Vacuum Pump IN OUT

EXH VALVE SIGNAL Cable

Please supply 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/ warnings.

MASTER

95

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. Connecting an air filter to the air supply port 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 and connecting instructions. Unit: mm

Ｍ ， Ｗ接 続 ポ ー ト Ｒ ｃ １ ／ ８

４ － φ ５ ．５

７５

３１

８ ２ ２ ０ ０

８０

１０

６０

１０

２ ０

１ ０ １ ８ ０ １０

EBU Valve Drive Pressure IN

Terminal Board (Exhaust Valve) M,W piping connection port(Rc 1/8)

96

OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT

（2）FE-20V

〇External dimensions and connecting instructions Unit: mm

Ａ Ｃ１００Ｖ

ＡＩ Ｒ　ＳＵＰＥ ＸＨ

ＥＸＨＡＵＳ Ｔ　ＰＯＲＴ

１ ３９

１ ３０

８５

．２

７０

７０

４０

１９

１７

．５

１ ５ １ ５

１ ２ １ １５ １ ２

３ ０２１ ． ５

４xφ５

Ｒｃ１/４

Ｒｃ１/８

２xＲｃ１/８

97

OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT (1) Basic piping for FE-20 (Tester-Work) (UL, L, M Specifications)

WARNING

If you use this circuit, please set the exhaust time setting to be 0.5 seconds, and 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.

FL-601 ＵＬ，Ｌ，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

ＦＥ－２０

Coupler

98

OPTIONAL EQUIPMENT EXHAUST BYPASS UNIT

(1) Basic piping for FE-20V (Tester-Work) (V Specifications)

WARNING

If you use this circuit, please set the exhaust time setting to be 0.5 seconds, and 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

ＡＣ１００Ｖ

ＡＩＲ　ＳＵＰＥＸＨ

ＥＸＨＡＵＳＴ　ＰＯＲＴ

Supply 300～400kPa of air.

Master

Work

ＦＥ－２０Ｖ

99

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. 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 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

１ － １ ２３ － ２

Pressure Valve

２ － ３ ２４ － ４

Exhaust Valve

１０ １３ １９

Pin Number

３２

Applied Connector (Included)

Plug JR16WR-7P Receptacle JR16WP-7S

Applied Cable At least 0.3SQ

Label

Warning

・Do not remove the CBU cover. ・Some parts within the CBU carry a high voltage and

may be driven unexpectedly due to the tester’s mechanical sequences. Possible electric shock and injuries may occur if this warning is ignored. Only qualified maintenance personnel should service this machine.

82

４－Ｍ５

Approx 41

128

142.5

64

Height 113mm

Jumper

100

OPTIONALEQUIPMENT CHARGE BYPASS UNIT ○ Basic Piping (Tester to Work) (UL, L. M. Specifications) Side Panel Drawing

Vacuum Pump

Source Pressure

Please supply 300～400kPa air

EXH VALVE SIGNAL Cable

Front Panel Rear Panel

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 page 102.

MASTER

101

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.

○ Installation directions： Figure in ( ) is only for use with 70W ○ APU Control Cable Wiring

Connection Tester Side (APU SIGNAL)

APU Side (IN PUT)

Applied Connector MR-8LM

RO3-PB8F Remarks

1 ― D +15V 3 ― B Analog Input

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)

An APU connecting cable (length 1.5 m) is included with the purchase of the APU-□-X005 SERIES．

APU－70W□-□-X005

APU－90W□-□-X005

APU－130W□-□-X005

Height170（164）㎜ Height 220㎜

165

145

115

100

4‐φ7 4‐φ6(5)

110(90)

92(80)

70（66）

60(50)

1 6

4

2 7

5

3 8

A Ｇ B Ｈ F C

Ｄ E

ＭＲ－８ＬＭ Rear panel terminal

Ｒ０３－ＰＢ８Ｆ Rear panel terminal

Shield Line

102

OPTIONAL EQUIPMENT APU UNIT ○Basic Piping (1) Recommended piping circuit for work volumes up to 2 L (UL, L. M. specifications) MASTER Note 1: Adjust the remote control dial regulator ③ pressure to be equal to a test pressure of +100kPa using the decompression

valve ②.

No. Product Name Remarks Tank Volume 20L

① Air Tank Tank Volume 38L

② Precision Regulator ③ Remote Control Dial Regulator With Pressure Gauge ④ Standard Regulator ⑤ Pneumatic Regulator ⑥ Pressure Sensor SX-100D Included with APU

APU Control Cable

WORK

Adjust the pressure to 300～400kPa

Source Pressure

① Air Tank

Use the shortest piping possible for the APU

OUT

⑥

⑤

OUT

Warning 1

OUT

Pressure sensor cable

FL‐601 Rear Panel

③

④

IN

IN

IN

For test wiring warnings, please refer to page 35 in the operations manual.

OUT

②

IN

103

OPTIONAL EQUIPMENT APU UNIT ○ Basic Piping (2) Recommended piping circuit for work volumes up to 2L. (V Specifications) MASTER

No. Product Name Remarks Tank Volume 20L

① Air Tank Tank Volume 38L

② Standard Regulator ③ Pneumatic Regulator ④ Pressure Sensor SX-100D Included with APU

APU Control Cable

WORK

Adjust the pressure to 300～400kPa

Vacuum Pump ①Air Tank

Use the shortest piping with the largest possible diameter with the APU.

OUT

④

③

IN

Pressure Sensor Cable

FL‐601 Rear Panel

Source Pressure

OUT

IN

②

For test wiring warnings, please refer to page 35 in the operations manual.

104

OPTIONAL EQUIPMENT APU UNIT (3) Recommended piping circuit for work volumes of at least 2 L (UL, L. M. Specifications)

MASTER Note 1: Adjust the remote control dial regulator ③ pressure to be equal to a test pressure of +100kPa using the decompression

valve ②. NO. Product Name Remarks

Tank Volume 20L ① Air Tank

Tank Volume 38L ② Precision Regulator ③ Remote Control Dial Regulator ④ Standard Regulator ⑤ Pneumatic Regulator ⑥ Pressure Sensor SX-100D Included with APU ⑦ 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

①Air Tank

Source Pressure

Rear Panel

OUT

IN

Warning 1

Be sure to use the shortest piping possible for the APU

⑤ IN

⑦

⑥

Front Panel

OUT

OUT

②

OUT

④

IN

For test wiring warnings, please refer to page 35 in the operations manual

IN ③

105

OPTIONAL EQUIPMENT APU UNIT (4) Recommended piping circuit for work volumes of at least 2L. (V Specifications) MASTER

No Product Name Remarks Tank Volume 20 L

① Air Tank Tank Volume 38L ② Precision Regulator ③ Pneumatic Regulator ④ Pressure Sensor Included with APU ⑤ Charge Bypass Unit ⑥ Filter

①Air Tank

Vacuum Pump

IN

OUT

Source Pressure

②

IN OUT

Adjust pressure to 300～400kPa

Use as the shortest piping with the largest possible diameter with the APU.

Front Panel

Pressure Sensor Cable

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 perform this adjustment.

④

⑤

③

WARNING

For test wiring warnings, please refer to page 35 in the operations manual

⑥

106

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 Put the tester in RDY (ready) status.⇒ Display the initial screen. ② Press the [SET] key and input the password if it is required to modify settings. ③ Press the [ENT] key and find the “OUTDATA” input screen using the cursor. ④ Select “OUTDATA” using the cursor and set “4” as its numerical value. ⑤ Press the [ENT] key and the [STOP] key to return to the initial screen. ■ Printer setting ① Flip the printer [POWER] switch OFF and confirm that the POWER lamp has gone out. ② While holding the printer [FEED] switch down, flip the printer [POWER] switch to ON. ⇒Keep holding the [FEED] switch down until the settings information is printed.

Setting for use BL-80RS[VX.XX] XXXX/XX/XX SANEI ELECTRIC INC. ********************************* Data input = Serial International char = England Print mode = Graphic Character set = 24Dot ANK Gothic type Select switch = Available Baud rate = 19200bps Bit length = 8 bit Parity = Non Data control = SBUSY Paper selection = Normal paper Upright/inverted = Upright printing Auto Power Off = Invalidity Graphic speed mode = Low speed Shr=117 temp=029 Vp=740 Push FEED button => END Push SEL button => Setting mode

（Setting1）Setting conditions for International Characters （Setting2）Space Setting for Letters and Lines （Setting3）24-dot、Gothic type characters （Setting4）Whether the SELECT switch is

necessary or not （Setting5）Baud Rate （Setting6）Data 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

③ 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 set to ”Japan”. Change to "England”. Setting 2: When you received the unit from your supplier, it was set to ”9600bps”. Change to "19200bps”.

④ When the settings in section (3) have been completed, switch the power off to confirm. ■ Change procedure

(1) If the [SELECT] key is pressed continuously following the above procedure, the printer is shifted to function setting mode and the following message is printed:

Ｉｎｔｅｒｎａｔｉｏｎａｌ ｃｈａｒ =Ｊａｐａｎ

Ｉｎｔｅｒｎａｔｉｏｎａｌ ｃｈａｒ =U.S.A

Ｉｎｔｅｒｎａｔｉｏｎａｌ ｃｈａｒ =Germany

Ｉｎｔｅｒｎａｔｉｏｎａｌ ｃｈａｒ =England

(2) Each time the [SELECT] key is pressed, the selected character set is printed. (3) Each time the [FEED] key is pressed, the selected mode is printed.

Pｒｉｎｔ mode =Ｇｒａｐｈｉｃ

Character set =24Dot ANK Gothic ｔｙｐｅ

Select ｓｗｉｃｈ =Ａｖａｉｌａｂｌｅ

Baud ｒａｔｅ =9600ｂｐｓ

(4) Each time the [FEED] key is pressed, the selected mode is printed. Baud ｒａｔｅ =19200ｂｐｓ

(5) Each time the [FEED] key is pressed, the selected mode is printed. Parity =None

Data ｃｏｎｔｒｏｌ =SBUSY

Paper ｓｅｌｅｃｔｉｏｎ =Normal ｐａｐｅｒ

Upright/ｉｎｖｅｒｔｅｄ =Upright printing

Auto Power Off =Ｉｎｖａｌｉｄ

Graphic speed mode =Low speed

shr=117 temp=029 Vp=740

(6) When you have completed these settings, a “test print” is output and the setting procedure has been completed.

Data Keep, Setting mode ＥＮＤ

Japanese characters may be used.

ＴＥＳＴ ＰＲＩＮＴ

* Refer to the attached BL-80RSⅡ printer operation manual for details on the printer settings.

111

SUPPLEMENT

112

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. With Masterless testing, the differential pressure (noise) that is generated even in the absence of a leak is negated by using Fitting testing. Ordinary testing methods will not yield the same result. However, a problem arises from the fact that the collected master data changes over time and the data will eventually not correspond correctly. Due to this, it became necessary to perform a second fitting test. Fitting testing uses wave analysis to separate the leak component (proportional to time) from the rest of the input data. To accomplish this, and resist environmental fluctuations, we generate this fit to the ideal. Since there are data decomposition and operating capacity limitations with the FL-601, extended time becomes available through fitting testing. The work characteristics and other vital information can be collected beforehand, making ordinary testing operations easier and less daunting. Q2: Fitting testing uses detected differential pressure tendencies to conduct wave analysis. Is it possible for the differential pressure to stray off pattern?

A2: Some differential pressure waves are off pattern. With differential pressure air leak testers, since the work is enclosed with compressed air, insulated compression causes heat to be generated internally. By insulating the charge pressure valve and creating a hermetically sealed environment, the heat generated will eventually radiate into the environment. This hermetic seal changes the internal temperature, creating a pressure change. This is the detected differential pressure change (noise). This change in differential pressure alters the work’s heat 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 derived from work construction. (5) The work heating up due to pre processing influences. (6) Fluctuations in clamping equipment (7) Vibration from different processes being conducted side by side.

Changes in (1) and (2) are values from the heat radiation curve and compression heat and will not cause problems with the fitting pattern. However, sudden changes will offset the test value. With (3)～(7) it is not possible to attain a proper test value without fitting. However, this noise is common with all differential pressure leak

testers. For these problems, as with past testing procedures, it is necessary to make improvements in labor, facilities and processes. When fitting cannot be conducted appropriately due to the aforementioned problems, we have prepared models that adapt the data. For more information, please refer to the basic principle section in this manual.

Countermeasures

Problem Countermeasure 1 The O ring within the work moves Use the Turbo function. Apply high pressure in the beginning and test only after the O ring has

moved completely.

2

Work changes/deforms shape Use the Turbo function. Apply high pressure in the beginning and test only after the deformation settles. (If the deformation time is consistent, it is possible to obtain the deformation component through fitting testing)

3 The clamping seal shifts. Press down on the seal, be sure to mount it against metal and clamp it down firmly.

(If it is not possible to have the aforementioned clamping construction, prepare an APU regulator for each cylinder to remove interference and stabilize the clamp pressure.)

4 Vibrations generated from other procedures

Change the process sequence. If there is a vibration effect on the work during the leak test (especially during the detection process) do not proceed with the vibration-generating process until the leak test is complete.

113

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. 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 pressure to stabilize, start the DET process and the leak test.

Other than when there is movement influenced by the valve, evaluate the data from the DET process. If it is possible to attain the differential pressure curve, the DET process can be shortened.

114

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.

With the Masterless leak tester, the differential pressure generated from non-leak sources is stored as “Master Data.” By subtracting the differential pressure from the “Master Data” during testing, we can obtain accurate test results that only consider the leak (For more information and details please refer to principles on pages 20~21.) Tests that include reading the “Master Data” are called fitting tests. At this point it becomes necessary to measure the differential pressure generated from non-leak sources, therefore it would be ideal to have a work that does not leak. Unfortunately, maintaining a leakless master is very difficult. Please perform the following procedure to obtain the “Master Data” from a work in your production line.

Differential pressure generated from non-leak sources 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 pressure changes resulting only from leaks. The pressure drop that we must measure is insignificant compared to the test pressure. For this reason, the change can be considered to be proportional to time. The change in differential pressure (following stabilization) resulting from a leak only is seen as being proportional to these constituents. Once the differential pressure is subtracted from the differential data obtained during the detection phase, we can obtain leakless data or “Master Data”.

However, if the leak rate is significantly large, the other error constituents will increase as well. Therefore, it would be advantageous to use data from a known good work (a small leak may be acceptable.)

Stable domain

Fitting Detection Process

111

SUPPLEMENT

112

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. With Masterless testing, the differential pressure (noise) that is generated even in the absence of a leak is negated by using Fitting testing. Ordinary testing methods will not yield the same result. However, a problem arises from the fact that the collected master data changes over time and the data will eventually not correspond correctly. Due to this, it became necessary to perform a second fitting test. Fitting testing uses wave analysis to separate the leak component (proportional to time) from the rest of the input data. To accomplish this, and resist environmental fluctuations, we generate this fit to the ideal. Since there are data decomposition and operating capacity limitations with the FL-601, extended time becomes available through fitting testing. The work characteristics and other vital information can be collected beforehand, making ordinary testing operations easier and less daunting. Q2: Fitting testing uses detected differential pressure tendencies to conduct wave analysis. Is it possible for the differential pressure to stray off pattern?

A2: Some differential pressure waves are off pattern. With differential pressure air leak testers, since the work is enclosed with compressed air, insulated compression causes heat to be generated internally. By insulating the charge pressure valve and creating a hermetically sealed environment, the heat generated will eventually radiate into the environment. This hermetic seal changes the internal temperature, creating a pressure change. This is the detected differential pressure change (noise). This change in differential pressure alters the work’s heat 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 derived from work construction. (5) The work heating up due to pre processing influences. (6) Fluctuations in clamping equipment (7) Vibration from different processes being conducted side by side.

Changes in (1) and (2) are values from the heat radiation curve and compression heat and will not cause problems with the fitting pattern. However, sudden changes will offset the test value. With (3)～(7) it is not possible to attain a proper test value without fitting. However, this noise is common with all differential pressure leak

testers. For these problems, as with past testing procedures, it is necessary to make improvements in labor, facilities and processes. When fitting cannot be conducted appropriately due to the aforementioned problems, we have prepared models that adapt the data. For more information, please refer to the basic principle section in this manual.

Countermeasures

Problem Countermeasure 1 The O ring within the work moves Use the Turbo function. Apply high pressure in the beginning and test only after the O ring has

moved completely.

2

Work changes/deforms shape Use the Turbo function. Apply high pressure in the beginning and test only after the deformation settles. (If the deformation time is consistent, it is possible to obtain the deformation component through fitting testing)

3 The clamping seal shifts. Press down on the seal, be sure to mount it against metal and clamp it down firmly.

(If it is not possible to have the aforementioned clamping construction, prepare an APU regulator for each cylinder to remove interference and stabilize the clamp pressure.)

4 Vibrations generated from other procedures

Change the process sequence. If there is a vibration effect on the work during the leak test (especially during the detection process) do not proceed with the vibration-generating process until the leak test is complete.

113

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. 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 pressure to stabilize, start the DET process and the leak test.

Other than when there is movement influenced by the valve, evaluate the data from the DET process. If it is possible to attain the differential pressure curve, the DET process can be shortened.

114

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.

With the Masterless leak tester, the differential pressure generated from non-leak sources is stored as “Master Data.” By subtracting the differential pressure from the “Master Data” during testing, we can obtain accurate test results that only consider the leak (For more information and details please refer to principles on pages 20~21.) Tests that include reading the “Master Data” are called fitting tests. At this point it becomes necessary to measure the differential pressure generated from non-leak sources, therefore it would be ideal to have a work that does not leak. Unfortunately, maintaining a leakless master is very difficult. Please perform the following procedure to obtain the “Master Data” from a work in your production line.

Differential pressure generated from non-leak sources 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 pressure changes resulting only from leaks. The pressure drop that we must measure is insignificant compared to the test pressure. For this reason, the change can be considered to be proportional to time. The change in differential pressure (following stabilization) resulting from a leak only is seen as being proportional to these constituents. Once the differential pressure is subtracted from the differential data obtained during the detection phase, we can obtain leakless data or “Master Data”.

However, if the leak rate is significantly large, the other error constituents will increase as well. Therefore, it would be advantageous to use data from a known good work (a small leak may be acceptable.)

Stable domain

Fitting Detection Process

115

SUPPLEMENT Pneumatic Circuit Diagram

■ ＦＬ－６０１ＵＬ，Ｌ、Ｍ、Ｈ１Pneumatic Circuit Diagram

116

SUPPLEMENT Pneumatic Circuit Diagram

Masterless leak tester ＦＬ－６０１Ｖ－□

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.

117

SUPPLEMENT Pneumatic Circuit Diagram

Exhaust Bypass Unit ＥＢＵ－６００□

A.P SUP Pilot Pressure Supply Port

AIR IN Pressure Port

SV4 Pilot Pressure Operation Valve

APV 2 ( Exhaust Valve )

F1 Filtered Nipple

BV1 AIR OUT Bowl Valve

.

TEST P Test Pressure

Port

EBU - 600V

A.P SUP PilotPressure Supply Port

SV4 Pilot PressureOperation Valve

APV 2 (Exhaust Valve)

F1 Filtered Nipple

AIR IN Pressure SupplyPort

EXH Exhaust Port

EBU-600C

B V 1

Air Out Ball Valve

118

SUPPLEMENT Pneumatic Circuit Diagram

Charge Bypass Unit ＣＢＵ－６００Ｃ

Exhaust Valve

119

SUPPLEMENT External Dimensions

■ Air Leak Tester FL-601 External Diagram

Mounting bracket dimension

Body mounting bracket

Dimension with rubber pad

120

SUPPLEMENT External Dimensions Exhaust Bypass Unit ＥＢＵ－６００□

Charge Bypass Unit ＣＢＵ－６００□

(External dimensions below are only for the CBU-600□)

142.5

Rc1/8

PRODUCT WARRANTTY 1. 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. 2. When the product is relocated from the original location at the time of purchase, please contact

your nearest FUKUDA agent for service. 3. Additional costs may apply even during this warranty period in the following situations:

(A) Destruction, malfunctions and other damages caused by misuse of the product, or when any inappropriate modifications are made.

(B) Destruction, malfunctions and other damages caused by accidents during transport and/or relocations.

(C) Destruction, malfunctions and other damages caused by earthquake, fire, flood, thunder and 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 warranty will not be reissued.

保 証 書

Warranty 機 種

Model

製 造 番 号 Serial Number

保 証 期 間 Warranty period

御購入日より１年間

One year from the date of purchase

御 購 入 日 Purchased date

お 客 様 Customer

会 社 名： Company Name ご住所: Address 電話番号： - - Phone Number：

This warranty card assure you of the repair at free based on the period shown on this warranty card and conditions are fulfilled. This does not mean to restrict your legal right by this warranty card. If you have questions on the repair after the warranty period, please make inquiries to the trading company or a business office of Fukuda.

検査合格印

http://www.fukuda-jp.com

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

101-ho,Da-dong,564-12,Gajoa-1dong,Seo-gu,

Incheon KOREA

TEL: (82)-32-584-8464 FAX: (82)-32-584-8465

Representative in Taiwan: LI AN INDUSTRY MEASUREMENT CORP.

No.270 Ming Teh 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 in Thailand: CHAVANAN CORPORATION LIMITED

156 Soi Thonglor Sukhumvit 55 Road Klongton Nua

Vadhana Bangkok, 10110 Thailand

TEL:(66)-2-392-4692/714-9088 FAX: (66)-2-381-1832

Representative in Germany: ADZ NAGANO GMEH

Bergener Ring 43 D-01458 Ottendorf-Okrilla Germany

TEL: (49)35205-59-6930 FAX: (49)35205-59-6959