Fujikura FSM40S Service Manual LEVEL 2

KSP75-0086-51-02 (3)

Fujikura Proprietary DocumentNo part of this document may be transferred to any third party

without prior written consent from Fujikura Ltd.

ARC FUSION SPLICER

LEVEL 2

MAINTENANCE MANUAL

FSM–40S

Table of Contents

§ 1. Introduction....................................................................................................4§ 2. Notes to users..................................................................................................5

§ 2.1. Warning and Cautions for Maintenance......................................................5§ 2.2. Abbreviations ...............................................................................................9§ 2.3. General Overview ........................................................................................9

§ 2.3.1. Composition of FSM-40S .....................................................................................................9§ 2.3.2. Basics and Preparations.......................................................................................................10§ 2.3.3. Cleaning and checking before adjustment ..........................................................................11

§ 2.4. Accessing Secret Menu’s and Secret Key Functions ..................................12§ 2.4.1. “Secret” Menu.....................................................................................................................12§ 2.4.2. Password..............................................................................................................................14§ 2.4.3. Total Initialization of all data (Emergency only) ................................................................14

§ 3. Mechanical Assembly................................................................................ 15§ 3.1. Focus/Camera Assembly ............................................................................15

§ 3.1.1. Camera Assembly................................................................................................................15§ 3.2. Electrode Unit Assembly ............................................................................17§ 3.3. Z-Axis Unit Assembly.................................................................................19

§ 3.3.1. Z-Axis Unit Assembly.........................................................................................................19§ 3.3.1.1 Sheath Clamp Top........................................................................................................19§ 3.3.1.2 Fiber Clamp Arm.........................................................................................................20

§ 3.3.2. Setting Clamp Top...............................................................................................................21§ 4. Mechanical Adjustment ............................................................................ 22

§ 4.1. Installing Focus Unit ..................................................................................22§ 4.2. Installing Z-Unit .........................................................................................25§ 4.3. Installing Tube Heater................................................................................26§ 4.4. Installing Wind Protector...........................................................................27§ 4.5. Installing Power Unit Dock to Base-Frame ................................................28§ 4.6. Adjusting the Set-Plate Position to the V-groove .......................................29§ 4.7. Adjusting Z-Clamp Unit Height.................................................................29§ 4.8. Adjustment Fiber Clamp Position .............................................................30§ 4.9. Adjusting Display Image............................................................................31

§ 4.9.1. Rough Adjusting Display Image .........................................................................................31§ 4.9.2. Adjusting Camera Inclination.............................................................................................32§ 4.9.3. Image Alignment.................................................................................................................34§ 4.9.4. Wind Protector Mirror Adjustment .....................................................................................36

§ 4.10. Adjustment of XY Unit.............................................................................37§ 4.10.1. Confirmation of XY adjustment condition........................................................................37§ 4.10.2. Confirmation of Swing-arm Travel...................................................................................39

§ 4.11. Adjustment of Focus Motor LS-dog’s Position.........................................40§ 4.12. Adjustment of Focus-Mechanical-Stopper’s Position ..............................41§ 4.13. Confirmation of Z Motor End Play..........................................................42

§ 4.14. Install the Discharge Circuit ....................................................................43§ 4.15. Installing Monitor ....................................................................................44§ 4.16. Installing Connector Box..........................................................................45§ 4.17. Installing Panel.........................................................................................46§ 4.18. Tube Heater Adjustment ..........................................................................47

§ 4.18.1. Adjust Tube Heater Temperature ......................................................................................47§ 4.19. Splice Test.................................................................................................51

§ 4.19.1. Estimate Check..................................................................................................................51§ 4.19.2. Stuff Check........................................................................................................................52§ 4.19.3. Arc Calibration..................................................................................................................52

§ 5. Electrical ...................................................................................................... 53§ 5.1. PCB Connection.........................................................................................53

§ 6. How to: ......................................................................................................... 54§ 6.1. Replace PCB ..............................................................................................54

§ 6.1.1. Preparations before Replacement........................................................................................54§ 6.1.2. Removal of PCB..................................................................................................................54§ 6.1.3. Installation of PCB..............................................................................................................55§ 6.1.4. Adjusting Voltage Indicator for 40S....................................................................................56

§ 6.2. Software Upgrade ......................................................................................57§ 6.2.1. Software Upgrade with Programming Chip Device ...........................................................57§ 6.2.2. Software Upgrade with RS-232C cable ..............................................................................58

§ 6.2.2.1 Install of PCUG software.............................................................................................58§ 6.2.2.2 Upgrading of software. ................................................................................................58

§ 6.2.3. Data Download Software with RS-232C............................................................................59§ 7. Trouble Shooting ........................................................................................ 61

§ 7.1. ERROR 01 Too Long Fiber........................................................................61§ 7.2. ERROR 01 Too Long Fiber........................................................................61§ 7.3. ERROR 03 Fiber too Dusty........................................................................61§ 7.4. ERROR 04 Motor Overrun........................................................................62§ 7.5. ERROR 05 Close Cover.............................................................................62§ 7.6. ERROR 06 Cover Opened Error...............................................................62§ 7.7. ERROR 07 Motor Trouble.........................................................................63§ 7.8. ERROR 08 Fiber Judge Error...................................................................63§ 7.9. ERROR 09 (ARC) Calibration Error........................................................63§ 7.10. ERROR 10 Fiber Separate Error.............................................................64§ 7.11. ERROR 11 Fiber Set Error......................................................................64§ 7.12. Splicer does not boot up ...........................................................................64§ 7.13. Heater Trouble .........................................................................................65

§ 8. Appendices................................................................................................... 66§ 8.1. The Check-Sheet for the Adjusting Display Image ....................................66§ 8.2. List of the necessary tools for FSM-40S adjustment ..................................67

§ 1. Introduction

This manual describes the mechanical assembly, adjustment, and maintenance of Fujikura’s FSM-40Sfusion splicer. When maintaining the FSM-40S, it is important to locate the exact problem and makethe necessary repairs properly. This manual will provide processes to repair the FSM-40S in a safe,concise, and easy to follow manner for a qualified technician.

§ 2. Notes to users

§ 2.1. Warning and Cautions for Maintenance

This maintenance manual also includes safety requirements.

• Read this manual carefully before performing any maintenance procedure to the splicer.• Keep this manual in a safe place.

Fujikura Ltd. accepts no responsibility for personal injury or physical loss including equipment damageresulting from improper use or modification.

This maintenance manual indicates warnings and cautions by using alert symbols. It is important to understandwhat it means.

WARNINGThere is a possibility of personal death or serious injury resulting from improper useby ignoring this indication.

CAUTIONThere is a possibility of personal injury or physical loss resulting from improper use byignoring this indication.

Symbol means “Pay Attention.”The left symbol indicates “Pay attention to explosion.”

Symbol means “Must not do.”The left symbol indicates “You must not disassemble.”

Symbol means “Must do.”The left symbol indicates “You must disconnect the AC power cord from the wall socketor the appliance inlet.”

Alert Symbol

Example of Alert Symbol

WARNING

The appliance inlet is used to disconnect the power cord when you disassemble the splicer.

Check to insert the all connector correctly before packaging.

Never maintain the splicer in an environment where flammable liquid or vapor exists. Extremelydangerous fire and explosion could result from the splicer’s electrical arc in such an environment.

Do not disassemble or modify AC adapter and battery pack. In particular, do not remove or bypassany electrical or mechanical device (e.g. a fuse or safety switch) incorporated into the design andmanufacturing of this equipment.

Check the connector to insert correctly before discharging.During arc discharge, the electrodes generate high voltage and high temperature, and it causespersonal injury. Do not touch the electrodes during the maintain (though arc discharge stops whenthe wind protector is opened). Turn the splicer power off, and disconnect the AC power cord (orremove the battery pack) when replacing the electrodes.This equipment is designed for splicing optical glass fiber for telecommunication. Do not attempt tosplice any materials other than the optical glass fibers.

Never use a canned type air cleaner to remove dust, or to clean the splicer. The electrical arc mayignite any remaining gas mixture.

Safety glass should always be worn during the fiber preparation and the splicing process. A glassfiber fragment can be extremely dangerous if it comes into contact with the eye, skin, or is ingested.

Use only specified power supply unit and proper AC power source.• Only the AC adapter / battery charger (ADC-07) or the battery pack (BTR-04) can be used for

supplying power to the splicer.• Proper AC power source to the ADC-07 is AC100-240V, 50-60Hz. Check the AC power source

before use. Improper AC power source out of the range can cause personal injury, emitting smokeor equipment damage.

• Abnormal high AC output voltage or frequency from an AC generator is a common fault.Measure the output AC voltage by a circuit tester before connecting the AC power cord.Improper high voltage or frequency from generator causes personal injury, emitting smoke orequipment damage.

Use only specified AC power cord. Do not put a heavy object on the power cord. Also, do not pull,heat up or modify the power cord. Using an improper cord or a damaged cord can result in a fire,emitting smoke, equipment damage or personal injury.

WARNING

Connect the AC power cord properly to the appliance inlet and wall socket. When inserting the ACplug, confirm no dust or dirt on terminals, and insert it to the end. Incomplete connection can cause afire, emitting smoke or personal injury.

Connect the AC adapter / battery charger to electrical ground when using it. It is possible to connectthrough a third pin of AC plug. No connection to electrical ground can cause personal injury.

Use only the specified battery charger (ADC-07) to recharge the battery pack (BTR-04) with abattery charger cord (DCC-08). Personal injury or equipment damage can result from using notspecified battery charger. Proper AC power source to the ADC-07 is AC100-240V, 50-60Hz. Checkthe AC power source before use. Improper AC power source can cause personal injury, emittingsmoke or equipment damage.

The appliance inlet is used to disconnect the power cord when the splicer is abnormal. Be sure toposition the splicer so that it is easy to disconnect the power cord.

Disconnect the AC power cord from the appliance inlet or the wall socket when the equipment emitssmoke or bad smell, or is noisy or heated up. Leaving the abnormal condition can cause a fire,personal injury or equipment damage.Disconnect the AC power cord from the appliance inlet or the wall socket when the equipment isdamaged (e.g. by dropping). It may cause personal injury or equipment damage.

Disconnect the AC power cord from the appliance inlet or the wall socket when liquid (e.g. water) oran object (e.g. screw) enters to inside the splicer. It can cause personal injury or equipment damage.

Do not touch the splicer, AC power cord and AC plug with a wet hand. It can cause personal injury.

Do not operate and maintain the splicer when it is wet with dew. It can cause personal injury orequipment damage.

Do not use the splicer in circumstance of extremely hot temperature. It may cause personal injury orequipment damage.

Do not throw the battery pack away into a fire. Or, do not heat it up. It can cause a dangerousexplosion.

Do not short-circuit both terminals of the battery pack and the AC adapter / battery charger. Largeelectrical current can cause personal injury, a fire or equipment damage.

CAUTION

Do not store the equipment in any area where extreme heat and humidity are present. It may causeequipment damage.

During / after heating the splice protector, do not touch the ceramic heater and the splice protector.The high temperature may cause personal injury.

Do not place the splicer at an unstable place. In a case of dropping the equipment, it can causepersonal injury or equipment damage.

Precise adjustment and alignment have been made to this splicer. Do not give a strong shock. Use acarrying case to transport and store the splicer. The carrying case will prevent damage and provideprotection from moisture, vibration and shock during storage and transportation.

Keep the splicer free from sand or dust. It degrades the splicing performance.

Replace the electrodes properly.• Only specified electrodes can be used.• Set the new electrodes to the correct position.• Replace the electrodes as a pair.Not following the above cautions can cause abnormal discharge. And, it can result in equipmentdamage or degrading the splicing quality.

Do not use any other chemical except alcohol to clean the objective lens, V-groove, mirror, LCDmonitor, body and so on. Doing so may cause blurring, discoloration or deterioration.

The splicer requires no lubrication. Oil may degrade the performance and damage the splicer.

Repair or re-adjustment should be performed by an authorized engineer, except the electrodesreplacement. Failure to repair the equipment can result in personal injury or equipment damage.Please contact a sales agency in your country.

§ 2.2. Abbreviations

Cap screw: Hexagon Socket Head Cap ScrewSet screw: Hexagon Socket Set ScrewWS2: Small Circular Washer of 2 mm in nominal diameterWF2 : Finished Circular Washer of 2 mm in nominal diameterPhillips-head screw: Cross Recessed Phillips-head ScrewCountersunk screw: Cross Recessed Counters ink head ScrewPan-head screw: Cross Recessed Pan-head ScrewT=20: Tightening Torque is 20kgf·cm. (1kgf·cm = 9.80N·cm)SLG: Screw Locking Glue

§ 2.3. General Overview

§ 2.3.1. Composition of FSM-40S

FSM-40S composes of the following unit.(1) XY unit (2) Heater unit(3) Focus unit (4) Base unit(5) Electrode unit (6) Battery unit(7) Z axis unit (8) Monitor unit(9) Wind Protector unit

§ 2.3.2. Basics and Preparations

Name of keys – Refer to Fig. 2.3.1.

MENU

EXIT ENT

ON

HELP ARC X/Y

RESET HEAT

SET

OFF/

�MENU� key � �� key �HELP� key �ARC� key

�ON/OFF� key

�X/Y� key

�EXIT� key �ENT� key �RESET� key �SET� key �HEAT� key

Fig.2.3.1

<ON/OFF> key • • • Turns power on and off. To turn off power, press and hold key untill the LEDcolor changes from green to red.<HELP> key • • • Displays [HELP] screen.<ARC> key • • • Executes re-arc discharge at end of splicing.<X/Y> key • • • Selects frame image display, X-direction enlarged, Y-direction enlarged or X-Ydirection composite image.<RESET> key • • • Return system to [READY] state from any state.<HEAT> key • • • States tube heater heat cycle<SET> key • • • Start splicing operation. This key is also used to cancel monitor power savingstate.<MENU> key • • • Open [Main Menu] screen. According to circumstances, changes manual drivemotor.<EXIT> key • • • Return system to previous menu screen.<ENT> key • • • Execute or select command or parameter on menu screen.< >< > key • • • Used to move cursor or change parameters. According to circumstances, drivesXY-motor or Focus-motor manually.< >< > key • • • Used to change pages. According to circumstances, drives Z-motor manually.

§ 2.3.3. Cleaning and checking before adjustment

Before adjustment, do the following work. Refer to “INSTRUCTION MANUAL for FSM-40S” forfurther information.

• Clean V-grooves• Clean Fiber Clamp Chips• Clean Wind Protector Mirrors

Secret Menu 1/5

+ENT:Select

Corner Check

EXIT:Exit

st

Camera PositionFocus & Electrode

Stuff CheckConfig Code DispConfig Code Input

:Change Page

Estimate Test

Secret Menu 2/5

+ENT:Select

Heater Adjustment

EXIT:Exit

st

Voltage Adjustment

:Change Page

Heat AD-250 80bit

Heat AD-100 230bit

AD-12V 152bit

Secret Menu 3/5

+ENT:Select

Splice Database Init

EXIT:Exit

st

Splice Mode Init.

Heater Mode Init.

Utility Init.

:Change Page

§ 2.4. Accessing Secret Menu’s and Secret Key Functions

§ 2.4.1. “Secret” Menu

At “READY”, press UP, DOWN and MENU at the same time. Secret Menu consists of 4 pages.Using Secret Menu, software version needs to be later than V01.09.

Page 1 of 5Corner Check – Background brightness indicator.Camera Position - Use when aligning camera mechanical position.Focus & Electrode – Use when adjusting focus and position ofelectrodes.Estimate Test – Estimation confirmation test.Stuff Check – Checks stuff amount. Specification = 30±5.Config Code Disp. - “Config Code” includes many calibrationparameters for the splicer. These “codes” have a relation to the

following: Serial Number, ICORE, Heater Calibration, Fiber Parameter, Voltage Adjust Parameter andothers.Config Code Input - This command should be used after replacing the CPU Board

Page 2 of 5Heater Adjustment – Use when calibrating heater unitHeat AD-250/100 – Result of Heater AdjustmentVoltage Adjustment – Use when calibrating voltage valueAD-12V – Result of Voltage Adjustment

Page 3 of 5Splice Database Init. - Initializes splice database area and thedatabase area to the condition when shipped . When database areais upgraded, perform this command.Splice Mode Init. - Initializes all arc parameters of all 100 splicemodes in both the user programmable area and the database area tothe condition when shipped from the factory. The splicer softwareon the ROM chip contains these initial parametersHeater Mode Init. - Initializes all heater parameters of all 40heater modes in both the user programmable area and the database

area to the condition when shipped from the factory. The splicer software on the ROM chip containsthese initial parameters.Utility Init. - Initializes all parameter of “Utility” including Configurations.

Secret Menu 5/5

+ENT:Select

Focus Home Adjustment

EXIT:Exit

st

FCS Home X 1500ms

:Change Page

FCS Home Y 1600ms

Page 4 of 5

Arc Count Input - Edits Arc CountTotal Arc Count Input - Edits Total Arc CountTrue AP1, AP2, AP3, and Gap Center - Result of “ARCCALIBRATION”

Page 5 of 5

Focus Home Adjustment – Use when calibrating “Focus HomePosition”FCS Home X, Y – Result of “Focus Home Adjustment”.Input Port Status. – Shows status of all Input Port and A/DConverters. Note - Only RESET switch is available to exit thismenu.

7 6 5 4 3 2 1 0S0 MENU UP DOWN LEFT RIGHT ENT EXITS1 HELP SET ARC X/Y L-FoXR L-FoXF L-XR L-XFS2 L-ZRR L-ZRF L-ZLR L-ZLF L-FoYF L-FoYR L-YR L-YF

IN2 COVER L-TEMP H-Temp3 H-Temp2 H-Temp1 HEAT RESETIN4 Magnet2 Magnet1AD Voltage Pressure Temp Humid Heater3 Heater2 Heater1

(MENU UP DOWN..etc ) is Key Pad.Slanting Font (L-????) is Limit Switch. For example, L-ZRF is limit of ZR motor, Forward direction.COVER is window protector cover magnet sensor.L-TEMP: if heater temp is lower than finish temp setting, ON.H-Temp 1: if heater temp is higher than heating temp setting, ON.H-Temp2 and 3 are not used.Magnet 1 and 2 are magnet sensors, which are used to judge power source type.Heater 2 and 3 are not used.

Secret Menu 4/5

+ENT:Select

Arc Count Input

EXIT:Exit

st

Total Arc Count InputTrue AP1

Gap Center

:Change Page

True AP2

True AP3

§ 2.4.2. Password

Factory password to enter “Configurations” is “ARUKIJUF”. Note - After entering “Secret Mode”,password is no longer required.

§ 2.4.3. Total Initialization of all data (Emergency only)

With splicer off, press “MENU”, “EXIT”, and “X/Y” at the same time and hold, then press the“ON/OFF” to turn the splicer on.

Note - All Parameters of All Splice Modes, All Heater Modes, Utility, and Secret are initialized toprogram set values.

§ 3. Mechanical Assembly

§ 3.1. Focus/Camera Assembly§ 3.1.1. Camera Assembly

1. Refer to Fig. 3.1.1 for steps 2 ~ 4.2. Attached Kyoutou-Mirror onto Kyoutou with cap screw (M2×6, T=2, SLG).3. Insert 0.3mm thick Lens-Liner between Lens and Kyoutou. Screw Lens in Kyoutou.4. Insert CCD-Adapter with CCD-Camera into Kyoutou, and attach with set screw (M3×3, T=2).

Note-Pay attention the direction of installation CCD-Adapter for X and Y positions (Refer to Fig.3.1.2).

CCD Camera Unit(S1330R-12)

Lens Shim (t=0.3)(S1330M-03-03)Don’t remove!

Objective LensDon’t remove!

Kyoutou(S1330M-03-01)

Kyoutou Mirror(S1330R-16)

Cap screw M2×6(T=2, SLG)

Set screw M3×3(T=2)

Not reverse

Fig. 3.1.1

Kyoutou Y Unit

AttentionConnector position

Kyoutou X Unit

Fig. 3.1.2

5. Refer to Fig. 3.1.3 for steps 5 ~ 6.6. Attach Focus Adjuster on Kyoutou Unit with cap screw (M3×10, T= temporary, WS3)7. Attach Focus Arm Joint Plate on Kyoutou with cap screw (M3×10, T= temporary, WS3)

Focus Adjuster(S1330M-03-12)

Focus Arm Joint Plate(S1330M-03-07)

Cap screw M3×10(WS3)

Cap screw M3×10(WS3)

Fig. 3.1.3

§ 3.2. Electrode Unit Assembly

Description

Refer to Fig. 3.2.1. The electrode unit consists of the electrode unit, electrode, and LED. Phillips-headscrew (M2×8, T=2) is used with the anode electrode holder and the cathode electrode holder to securethe electrodes. The chamfered electrode holder (holds V-groove LED) is located on the cathode side.

Nut M2

LED Holder(S1330M-01-10)

LED Holder

Cathode Electrode Holder(S1330R-05)

V-Groove LED Screw Stopper(S1330M-01-10)

Phillips-head screwM2×8 (T=2)

Electrode

Electrode Base(S1330M-01-01)

Nut M2

Anode Electrode Holder(S1330R-04)

Anode Electrodeleaf Spring

Cathode Electrodeleaf Spring

Electrode

LED (KR5004X)

Phillips head screwM2×4 (T=2, SLG)

Pan-head screwM2×8 (T=2)

Phillips head screwM2×4 (T=2, SLG)

Phillips-head screwM2×8 (T=2)

Pan head screwM2×8 (T=2)

LED (KR5004X)

Fig. 3.2.1

1. Refer to Fig. 3.2.2.2. Place LED into LED-Holder.3. Place LED-Holder onto electrode unit. Apply by pushing LED-Holder from diagonally bottom to

diagonally top.4. Attach with Pan-head screw (M2×8, T=2) and nut (M2).

Hanging

Pushing

Fig. 3.2.2

5. Install electrodes by applying light pressure to the back of electrode base (Refer to Fig. 3.2.3).6. Attach with Phillips-head screw (M2×8, T=2)

Pushing

Fig. 3.2.3

§ 3.3. Z-Axis Unit Assembly

§ 3.3.1. Z-Axis Unit Assembly

Z-Axis-Unit consists of two elements, Z-Clamp-Unit and Z-Motor-Unit.

§ 3.3.1.1 Sheath Clamp Top

1. Refer to Fig. 3.3.1.2. Insert Super-Shaft (h7-1518) through Sheath-Clamp� and Hinge�.3. Insert Fiber-Pusher-Spring� between Fiber-Pusher�and Sheath Clamp�.4. Press Fiber-Pusher �into Sheath Clamp �, install Magnet-Catcher (Front)� and Magnet-Catcher

(Rear)� with each two phillips-head screws (M2×4, T=3). Note – Front and rear Magnet Catcherare not interchangeable. Insure that Fiber-Pusher� moves smoothly after installation.

Phillips-head screw M2×4(T=3)

Magnet-Catcher(Front)�(S1330M-04-05)

Magnet-Catcher(Rear)�(S1330M-04-05)

Fiber-Pusher�(S1330R-24)

Hinge�

Sheath Clamp Spring�(S1330M-04-07)

Sheath Clamp�(S1330R-22)

Super-Shaft h7-1518

Fig. 3.3.1

§ 3.3.1.2 Fiber Clamp Arm

Note - Fiber-Clamp-Arm, Right side illustrated.

1. Refer to Fig. 3.3.2.2. Insert Clamp-Arm-Shaft� through Clamp-Arm (right)� and Clamp-Arm-Bracket�.3. Attach Clamp-Arm-Shaft� to Clamp-Arm (right) with set screw (M2×2 with flat type T=1.5). Note

- position axes pin chamfer to align with set screw (M2×2).4. Make Clamp-Arm (right)� parallel with base of Clamp-Arm-Bracket� by adjusting set screw

(M2×3 with flat type, SLG) (Refer to Fig. 3.3.3).

Clamp-Arm (right) �(S1330R-26)

Set screw M2×2 with flat type(T=1.5, SLG)

Clamp-Arm-shaft�

Clamp-Arm-Bracket �(S1330M-04-11)

Set screw M2×3 with flat point(for adjustment of Clamp-Arm parallel, SLG)

Clamp-Arm(left)uses this-side hole.

Fig. 3.3.2

Set parallel with set screw M2×3

Fig. 3.3.3

§ 3.3.2. Setting Clamp Top

1. Refer to Fig. 3.3.4 ~ Fig. 3.3.6.2. Loosely attach Sheath-Clamp-Top to Sheath-Clamp-Base Unit with cap screw (M2×6).3. Insert gauge block (t=0.2) between Sheath-Clamp-Top and Sheath-Clamp-Base Unit.4. Insert gauge block (t=0.25) between Sheath-Clamp-Top and Set plate A.5. Push Clamp-Top forward and tighten cap screw (M2×6, T=3, SLG).

Block gauge(t=0.2)

Pushing toHinge side

Fig. 3.3.4

Fig. 3.3.5 Fig. 3.3.6

6. Refer to Fig. 3.3.7.7. Loosely attach Sheath-Clamp Arm Unit to Sheath-Clamp-Base Unit.8. Apply pressure by pressing Sheath-Clamp forward and tighten cap screw (M2×6, WS2, SLG).

Pushing

Fig. 3.3.7

Block gauge(t = 0 . 2 5 ) P u s h i n g

Block gauge(t=0.25)

Block gauge(t=0.2)

§ 4. Mechanical Adjustment

§ 4.1. Installing Focus Unit

Note – XY-Block has been removed from Base Frame for illustration. To reduce the chance of damageto objective lens the Kyoutou installation would normally occur after the XY-block has already beeninstalled into the Base Frame.

1. Refer to Fig. 4.1.1. Loosely attach Kyoutou to Focus-Arm with Cap screw (M3×8 or 10).

Cap screw M3×8

Fig. 4.1.1

2. Apply force by pushing Focus Arms against Focus Arm Joint Plate from right and left (Refer to Fig.4.1.2). While maintaining outside force on Focus Arms also apply force to top of Focus arm andbottom of Focus arm Joint Plate (Refer to Fig. 4.1.3). Tighten Cap screws (M3×10, WS3, T=12)using illustrated toque sequence.

PushingPushing

Fig. 4.1.2

Pus

hing1

4

3

2

No spaceNo space

Pus

hing

Fig. 4.1.3

3. Refer to Fig. 4.1.4 for steps 4 ~ 6.4. Place Focus-Arm-Swing-Bearing into side holes (2 each) of Focus-arm.5. Apply pressure by lightly pressing Focus-Arm-Swing-Bearing against XY-block. Note – Chamfer

of Focus-Arm-Bearing should align with set screw (M4×6).6. Tighten set-screw (M4×6, T=15, flat type) located on Focus-arm.

***Attention***Chamfer surface of Focus-Arm-Bearing Holder should only be used one time per side. Do not recycleFocus-Arm-Bearing Holders chamfer surface, they are designed to indent when the set screw isinstalled.

Fix Kyoutou each side.Set screw M4×6with flat type

Pay attention to pushing surface.

No space

Direction of to insert set screw.

Fig. 4.1.4

7. Refer to Fig. 4.1.5. Attach Focus Arms to Focus Arm Joint Plate with cap screw (M3×10, T=12,WS3) using illustrated torque sequence.

Push

ing

1 2

No space

Push

ing

Fig. 4.1.5

8. Place 1.5mm Block Gauge between Kyoutou Unit and Focus adjuster plate (Refer to Fig. 4.1.6).9. Apply force by pushing top of Kyoutou Unit and bottom of Focus adjuster plate (Refer to Fig.

4.1.9).

Block gauge(t=1.5)

Fig. 4.1.6

10. Refer to Fig. 4.1.7. Attach Kyoutou Unit to Focus Arm adjuster with Cap screw (M3×10, T=12)using illustrated toque sequence.

1 2

Pushing

Fig. 4.1.7

§ 4.2. Installing Z-Unit

1. Refer to Fig. 4.2.1 for steps 2~3.2. Loosely Attached Z-Motor Unit to Base Frame with Cap screw M3×103. Apply pressure by pushing Z-Motor forward. Tighten Cap screw (M3×10, T=10, WS3, SLG).

Fig. 4.2.1

4. Refer to Fig. 4.2.2. Place Liner (t=0.7) between Z-Unit and Frame-Base. Note – A small amount ofSilicon-Grease may be applied to Liners to help maintain their position during installation.

5. Refer to Fig. 4.2.3. Apply pressure by Pushing Z-unit against Frame-Base center and back.6. Tighten Cap screw (M3×10, T=10, WS3).

Liner(t=0.7)(S1330M-04-18)

Cap screw M3×10(T=10,WS3)

Pushing

Fig. 4.2.2 Fig. 4.2.3

Pushing

§ 4.3. Installing Tube Heater

1. Refer to Fig. 4.3.1 for steps 2 ~ 3.2. Attach Fan to Frame-Base with Pan screw (M2.6×14, T=1, SLG).3. Wind the wire of the fan around the shaft of the base frame twice and insert this wire into the hole.4. Insert Heater unit wiring into the same hole as the fan wire.5. Attach Heater Unit to Frame-Base with Cap screw (M2×14,T=4, WS2, SLG)6. Connect heater to PCB terminal CN29.

Phillips-head screw M2.6×14 (T=1, WS2.6, SLG)

Heater fan Base frame

Wind the wire for fan around this pin twice.

Front side

Cap screw M2×14(T=4, WS2, SLG)

Pan-head screw M2.6×14(T=1, WS2.6, SLG)

Pushing

Fig. 4.3.1 Fig. 4.3.2

§ 4.4. Installing Wind Protector

1. Refer to Fig. 4.4.12. Attach Wind Protector and WP-Washer to Frame-Base with Cap screw (M2×4, T=3, SLG).

WP-Washer

Cap screw M2×4(T=3,SLG)Wind Protector shaft

Fig. 4.4.1

§ 4.5. Installing Power Unit Dock to Base-Frame

1. Refer to Fig. 4.5.12. Attach Power Unit Dock to Base-Frame with Cap screw (M3×6, T=7).3. Attach the 2 GND wires with Cap screw (M3×6, T=10, WS3)

Cap screw M3×6 (T=7)(S1330R-37)

Fix the 2 GND wire.Cap screw M3×6(T=10, WS3)

Fig. 4.5.1

Warning!There is a Lithium coin battery on the main PCB. The battery surface isexposed with the positive terminal facing up. A short circuit of the coin batterycan easily happen if;

- A screw falls off between the battery and the post. - A shield plate edge on the PCB falls off between the battery and the post. - A free wire terminal contacts the battery.

A short circuit may cause battery failure, calendar malfunction, or a damagedcalendar IC.

Be careful not to short circuit battery. A rubbercap is available from Fujikura that should beinstalled during any maintenance procedure.The rubber cap may be left permanently inplace after repair.

CoinBatteryPost

§ 4.6. Adjusting the Set-Plate Position to the V-groove

1. Refer to Fig. 4.6.1 for steps 2 ~ 7.2. Place special tool (φ2.0mm short electrode: STOOL4080) into the V-groove.3. Adjust the set plate position by positioning the center of set plate slit to the tip of the electrode.4. Apply pressure by lightly pushing set plate toward sheath clamp base.5. Attach set plate with Cap screw (M2×6, WS2, T= temporary).6. Remove only one screw and apply screw- locking-glue (Three-Bond) to the thread of the screw,

apply pressure by lightly pushing set plate toward sheath clamp base. Tighten Cap screw (M2×6,T=1, WS2, SLG). Repeat process for second Cap screw. Note - Remove excess screw-locking-glueon the set plate.

7. Confirm the set plate position.

Fix these screws one by one

Adjusting direction

Arrange the center position

φ2

Pushing

Pushing

Fig. 4.6.1

§ 4.7. Adjusting Z-Clamp Unit Height

Note - Use shim (No. 40SM-4180).

1. Refer to section 4.2, steps 4 ~ 6 for shim installation.2. Set the 250µm UV coating fiber into V-grooves. Note - Cleave length: 16mm3. Refer to Fig. 4.7.1. Adjust the Z clamp height with shims so that 80% of the fiber is contacting the

bottom of the V-groove. Note – In Fig. 4.7.1, sheath clamp would be located to the left of V-groove.

Full attachingOptical fiber

OKHigh LowFlat

80% attaching

Fig. 4.7.1

§ 4.8. Adjustment Fiber Clamp Position

1. Refer to Fig. 4.8.1 for steps 2 ~ 5.2. Adjust the Fiber Clamp by positioning the Fiber Clamp over the center of the V-groove.3. Attach Fiber clamp with Cap screw (M2×6, T= temporary, WS2).4. Remove only one screw and apply screw- locking-glue to the thread of the screw. Tighten Cap

screw (M2×6, T=3, SLG). Repeat process for second Cap screw.5. Confirm Fiber Clamp position.

Put it temporary, after adjusting position.

Align the center of them.

Fiber-Clamp

Fiber clamp arm bracket

V-Groove Two cap screws(M2×6, T=3, WS2, SLG)Adjust the both sides.

Fig. 4.8.1

§ 4.9. Adjusting Display Image

§ 4.9.1. Rough Adjusting Display Image

1. Adjust that display image looks like Fig. 4.9.1 (Refer to Section 4.9.3).

XR

1. Fiber position Is almost center.2. The edge of both X and Y axes fiber can see.

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

ZL

XL

YLYR

Electrode center lineFiber position center line of X

Fiber position center line of Y

Fig. 4.9.1

§ 4.9.2. Adjusting Camera Inclination

1. Refer to section 2.4.1 (page 1 of 4), execute “Camera Position” command in [SECERT MENU].2. Refer to Fig. 4.9.2. Use left sheath clamp, set the 250um UV coating fiber into V-grooves. Note -

Cleave length: 16mm3. Drive fiber past electrode using the ZL motor manually. Note - Don’t overrun ZL-Motor.

ZL side Drive ahead manually.

Move fiber farther than the center of Electrode-Base.

Fig. 4.9.2

4. Refer to section 3.1.1 to review Camera components.5. Refer to section 4.1.1.6. Refer to Fig. 4.9.3. Loosen set screw (M3×3, flat type) which attaches CCD-Camera Unit.

Set screw(M3×10, T=2)

Fig. 4.9.3

7. Refer to Fig. 4.9.4.8. Rotate the “X” CCD-Camera Unit until the difference “XL “ and “XR” is lees than 1 line.9. Refer to Fig. 4.9.3. Tighten set screw (M3×3, T=2, flat type) which attaches “X” CCD-Camera

Unit.10. Use right sheath clamp, set the 250µm UV coating fiber into V-grooves. Note – Cleave length:

16mm.11. Drive fiber past electrode using the ZR motor manually. Note – Don’t overrun ZL-Motor.12. Rotate the “Y” CCD-Camera Unit until the difference “YL “ and “YR” is lees than 1 line.13. Refer to Fig. 4.9.3. Tighten set screw (M3×3, T=2, flat type) which attaches “Y” CCD-Camera

Unit.

XRZL motor moving

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

ZL

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

ZR

ZR motor moving

XL

YL YR

Fig. 4.9.4

§ 4.9.3. Image Alignment

1. Refer to Fig. 4.9.5.2. Install special tool (26mm electrode) into rear (anode side). Note - The tip should not to touch the

fiber.3. Refer to section 3.1.1,. Install special tool (cap screw and a spring No.1053) into center of Focus

Adjuster. Gently rotate screw clockwise until it touches Kyoutou, then rotate the screwcounterclockwise ½ turn.

4. Prepare and load two 250µm fibers into splicer.5. Refer to section 2.4.1 (page 1 of 4), execute “Camera Position” command in [Secret Menu].

Fig. 4.9.5

6. Refer to Fig. 4.9.6.7. Loosen vertical position Cap screws (M3×10, WS3).8. Install 1.5mm block gauge between Kyoutou unit and Focus Adjuster.9. Apply pressure by pressing Kyoutou unit onto Focus Adjuster. Tighten Cap screw (M3×10, T =

temporary) “1” first and cap screw (M3×10, T = temporary) “2” second.10. Check X-axis and Y-axis positions. Specification X=280 ± 10 line, Y=200 ± 10 line. Note –

Target X=285, Y=195.11. If out of specification, adjust Block Gauge thickness. Repeat steps 9 ~ 10 until the specification is

achieved.12. Tighten Cap screw (M3×10, T=12) “1” first and Cap screw (M3×10, T=12) “2” second.13. Refer to Fig. 4.9.7 for steps 14 ~ 21.14. Switch fiber view to “X large” view by pressing [X/Y] key.15. Enable focus “X” motor. Adjust the white band to one-third of fiber diameter.16. Switch fiber view to “Y large” view by pressing [X/Y] key.17. Enable focus “Y” motor. Adjust the white band to one-third of fiber diameter.18. Loosen horizontal position Cap screws (M3×10, WS3)19. Electrode cursor should be set at line 376.20. Adjust right side fiber end-face in the “Y” view by moving the Focus-Adjuster. Tighten cap screw

(M3×10, T=12) “1” first and Cap screw (M3×10, T=12) “2” second. Specification Y=376 ± 10 line.Note – Target=366-376 line

21. Adjust right side fiber end-face in the “X” view by moving the Focus-Adjuster. Tighten Cap screw(M3×10, T=12) “1” first and Cap screw (M3x10, T=12) “2” second. Specification (Y-X) ± 10 line.Note – Target = (Y-X) = 0 ~10 line.

Block gauge

Vertical position screws

Fig. 4.9.6

Focus-Adjuster

Horisontal position screws

A

B

Fig. 4.9.7

22. Recheck fiber vertical position in Y view.23. Recheck gap center position in Y view.24. Recheck gap center position in X view.25. Recheck fiber vertical position in X view.26. Remove all special tools and Block Gauges.

§ 4.9.4. Wind Protector Mirror Adjustment

1. Refer to Fig. 4.9.8.2. Adjust Wind protector angle by turning set screw B (M2×3).3. Refer to Fig. 4.9.9. Using Focus motor, adjust fiber image (both X and Y-axis) so that the outside

black bands are equal in width.4. After adjustment, install Set screw A (M2×2, SLG)

Wind-Protector-Cover(S1330M-01-14)

Wind-Protector-Mirror(S1330R-03)

Setting screw A M2×2(SLG)

Setting screw B M2×3

Super-Shaft h7-1522

Spring No.1043

Cap screw M2×4(T=3, SLG)

Wind-Protector-Shaft(S1330M-01-11)

Wind-Protector(S1330R-02)

Cap screw M2×6(T=3,WF2)

Magnet

Plate

Fig. 4.9.8

Fig. 4.9.9

READY

X

Mak

e ab

out s

ame

wid

th.

§ 4.10. Adjustment of XY Unit

§ 4.10.1. Confirmation of XY adjustment condition

1. Refer to section 4.9.2. Confirm the CCD camera inclination.2. Refer to Fig. 4.10.1. Confirm the parallel position of X and Y axes.3. Execute “Camera Position” command in [Secret Menu].4. Manually align “X” and “Y” axes motors until the difference between left and right fiber position

is less than ±1.5 line.

XR

(XL-XR) <= ±1.5 line(YL-YR) <= ±1.5 line

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

ZL

XL

YLYR

Fig. 4.10.1

5. Use left sheath clamp, set the 250µm UV coating fiber into V-grooves. Note – Cleave length:16mm.

6. Drive fiber past electrode using the ZL motor manually. Note – Don’t overrun ZL-Motor.7. Record values (ZL-XL), (ZL-XR), (ZL-YL), (ZL-YR). Refer to Fig. 4.10.2.8. Use right sheath clamp, set the 250µm UV coating fiber into V-grooves. Note – Cleave length:

16mm.9. Drive fiber past electrode using the ZR motor manually. Note – Don’t overrun ZR-Motor.10. Record values (ZR-XL), (ZR-XR), (ZR-YL), (ZR-YR). Refer to Fig. 4.10.2.

ZL-XRZL motor moving

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

ZL

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

ZR

ZR motor movingZL-XL

ZR-YL ZR-YR

You calculate shown below.1) A = (ZL-XL) – (ZL-XR) on ZL fiber2) B = (ZL-YL) – (ZL-YR) on ZL fiber3) C = (ZR-XL) – (ZR-XR) on ZR fiber4) D = (ZR-YL) – (ZR-YR) on ZR fiber

ZR-XL

ZL-YL ZL-YR

ZR-XR

Fig. 4.10.2

11. Calculate A, B, C and D from formula in Fig. 4.10.2.12. Confirm the difference (A-C) and (B-D) are less than 1.5 line.

ZL ZR Difference StandardX A C (A-C) (A-C)<= 1.5 lineY B D (B-D) (B-D)<= 1.5line

§ 4.10.2. Confirmation of Swing-arm Travel

1. Prepare and load two 250µm fibers into splicer.2. Refer to Fig. 4.10.3. Execute “Camera Position” command in [Secret Menu] and push “SET” key.

Note: X and Y motors automatically move to there outer limits at which time they are measured.3. Record the “U” and “D” values in both axes.4. Specification for “X” or “Y” movable range: both “U” and “D” values > 30 µm.

Camera Position

X

Y

182.7

278.5

374.2

94.6

190.2

285.9

97.2

193.08

299.2

94.1

190.0

285.8

Camera Position

X

Y

182.7

278.5

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

U: 38.5D: 43.8

U: 42.8D: 45.2

U: Top limit distance [µm]D: Bottom limit distance [µm]

Fig. 4.10.3

§ 4.11. Adjustment of Focus Motor LS-dog’s Position

1. Prepare 250µm fiber with 30mm strip section and load into both V-grooves.2. Refer to “Secret” Menu, execute “Focus & Electrode” command in [Secret Menu].3. Refer to Fig. 4.11.1 for steps 4 ~ 6.4. Pushing “SET” key, automatically adjust focal point to produce sharp fiber core image. 5. Focus Motor movable range Specification is > ¾ rotation ether clockwise or counterclockwise

from sharp fiber core image focal point.6. If out of specification adjust gap (standard - 1.5mm block gauge = “A”) between Motor-gear and

LS-dog. Attach with set screw (M3×3, T=2, flat type).

X

376

Focus & ElectrodeSet screw M3×3 withflat type (T=2)Turn in the front.

More than 3/4 rotation

More than 3/4 rotation“A”

Auto focusing

Fig. 4.11.1

7. After adjusting of the Sensor-dog, Execute the “Focus Home Adjustment“ command in [SecretMenu].

§ 4.12. Adjustment of Focus-Mechanical-Stopper’s Position

1. Prepare 250µm fiber with 30mm strip section and load into both V-grooves.2. Using Focus Motor, manually adjust focal point to produce sharp fiber core image.3. Refer to Fig. 4.13.1.4. Measure gap “g” from Focus-Arm-A to Focus-Arm-B. Note – Measure with Block Gauges.5. Calculate Block Gauge thickness. Formula - (Block Gauge thickness = ”g”-1mm).6. Loosen the set-screw (M4×6) for Focus-Arm-Stopper.7. Place Block Gauge between Focus-Arm-A and Focus-Arm-B, apply pressure by pressing Focus-

Arm-B against Focus-Arm-A.8. Apply pressure by pushing Focus-Mechanical-Stopper up. Attach set-screw (M4×6, T=10, W point

type, SLG) to Focus-mechanical-Stopper.

Fix the state of pressing Focus-Stopper

against Focus-Arm-A.Focus-mechanical -Stopper

Focus-Arm-BFocus-Arm-A

Focus-Arm-A Focus-Arm-B

Measure the gap "g" from Focus-Arm-A to Focus-Arm-B.

Insert "t" milimaters thick gauge between Focus-Arm-A and Focus-Arm-B.And press Focus-Arm-B against this gauge.

SetScrew M4×6 with W point(T=10, SLG)

Fig. 4.13.1

Note - New XY-block has the rubber bushing to resist shock created by stopper pin impact. In this case,change the block gauge thickness (g-0.8) mm.

§ 4.13. Confirmation of Z Motor End Play

1. Refer to Fig. 4.13.12. Press [RESET] key.3. Prepare and load fiber. Position end-face of fiber very close to electrode. Fiber should appear on

monitor when the wind protector is closed.

Camera Position

X

Y

176.9

198.7

219.3

257.5

277.9

300.1

177.0

198.8

219.4

258.0

278.4

300.6

Monitor Display

Fig. 4.13.1

4. Refer to Fig. 4.13.2.5. While observing fiber image on monitor move Z-Motor forward by pressing key pad command.6. Fiber on monitor should move forward before Z-motor Micrometer Gear rotate ½ turn.7. If out of specification, refer to Fig. 4.13.2 to adjust gap between Carbide plate and Micrometer.

0.1~ 0.4mm

Carbide plateMarking

Set screw M3×3with flat type (T=2)

3.2mm(Standard)

Half rotation

Fig. 4.13.2

§ 4.14. Install the Discharge Circuit

1. Connect discharge circuit wiring to PCB connector CN24.2. Refer to section 3.2. Insert the discharge wires (anode and cathode) into the space between the

Mechanical base and the Base frame.3. Refer to Fig. 4.14.1. Insert the discharge wires into the electrode holders and tighten set screw

(M2×2, T=1.5).4. Attach discharge circuit to left side of Frame-Base with cap screw (M3×6, T=5, WS3, SLG).

Insert the discharge wire into the holes

Set screw M2×2, T=1.5

Fig. 4.14.1

§ 4.15. Installing Monitor

1. Refer to Fig. 4.15.1. Attach the LCD monitor to the monitor frame with countersink screws (M3×6,T=6). Note – Route monitor cable through hook for monitor code.

2. Monitor cable length from Monitor Bracket to end of Monitor connector (J14) should be 90mm.

Confirm this length.

90mm

Monitor Frame

Countersink screw M3×6 (T=6)

Monitor Cord

LCD Monitor(Back view)

Pan-head screw M3×4 (T=6)

Hook forMonitor Cord

Fig. 4.15.1

3. Refer to Fig. 4.15.2. Attach Monitor-Unit to Base Frame with Pan-head screw M3×14 (T=10, WF3outside diameter φ8, SLG).

Pan-head screw M3×14(T=10, WF3-diameter φ8, SLG)

(S1330R-28）

Fig. 4.15.2

§ 4.16. Installing Connector Box

1. Refer to Fig. 4.16.1, Fig. 4.16.2. Attach the Connector Box to Base Frame with Countersink screw(M2×6, T=3). Note – The CCD and Monitor cables should pass through the connector box hook thetwo FPCs of the keypad as Illustrated.

Right side - back view Top view

Pillar

FPC of Key Pad

Hook2

Note: The monitor cord should go through the hook of connector box.Note: The CCD camera cord should go through the hook of connector panel with monitorcable.

Connector Box

(1) Insert CCDcamera cable (Y)in Hook2.

(2) Insert Monitorcable in Hook2.

Hook3

Hook1Hook2

(3) Set CCD camera cable (X)and Connector box cablesin front of Hook 1.

(4) Attach the Connectorbox to Base frame.

Video out

CCD (Y)

CCD (X)

C-Box

ZR

(5) Insert CCD cameracable (X) in Hook3.

(6) Insert ZR cablein Hook3.

Fig. 4.16.1

Countersink screw M2×6(T=3, steel)

(S1330R-36)

Fig. 4.16.2

§ 4.17. Installing Panel

Set Front Cover and Rear Cover to Base Frame with Pan-head screw (M3×6, T=7). Set CameraCover to Rear Cover with Pan-head screw (M3×6, T=7).

Pan-head screw M3×6 (T=7)

Pan-head screw M3×6 (T=7)for Camera Cover

(S1330M-07-07)

(S1330M-07-08)

Fig. 4.17.1

Note: There is no need to remove the screw that attaches the Camera Cover.

§ 4.18. Tube Heater Adjustment

§ 4.18.1. Adjust Tube Heater Temperature

1. Prepare the temperature sensor for the heater adjustment.

• Method 1 - Thermo spot sensor (non-touch sensor).

Refer to Fig. 4.18.1 and Fig. 4.18.2. Set the thermo spot sensor on the splicer.

Thermo spot sensor*Tool for fixing the thermo spot sensor.Note: This unit can only use for 40S.

Splicer

Set the tool for fixing the thermo spot sensor on the corner

Thermo spot sensor*

(display part)

Fig. 4.18.1

Push

PushPush the tool for fixing the thermospot sensor on the corner

Base frame The tool for fixing the thermo spot sensor

Fig. 4.18.2

Set the infrared ray by the spot sensor on the center of the radiator

Fig. 4.18.3

Note1: Sensor type is as follows: Japan Sensor Co. Ltd. Thermo Spot Sensor TMZ51-500-5E3-2Note2: You must set the radiation ratio value before the heater adjustment as follow.

1. Push the “MODE” key and “Left” key at once.2. Push the “Up” or “Down” key to change the far right variable.3. Push the “Left” key to shift the cursor left. Press “Up” or “Down” to change the value of that

variable.4. Set the radiation ratio value at 0.930, push the “ENT” key.5. Push the “MENU” key 6 more times to complete the operation.

Note3: The tool for fixing the thermo spot sensor can be constant 50mm distance between the sensorand the radiator plate. This distance is this thermo spot sensor specification.Note4: Use thermo sensor only on the new type tube heater (e.g.FSM-16R and 30R).

• Method 2 - Thermo couple sensor. Fig. 4.18.4 illustrates how to use thermo couple sensor on theheat emission plate.

Heat Sinker(Shin-etsu Chemical Co. Ltd. Oil Compound KS-609

Thermocouple

Radiator plate

Center of radiator plate

Fig. 4.18.4

2. Refer to section 2.4.1. Execute “Heater Adjustment” in [Secret Menu] Page 3 of 5.

WARNING - Refer to Fig. 4.18.5. Immediately Push the “Down” key after pressing “ENT” key in step4, and set the [A/D 250] to 80 bit. Failure to do so will result in tube heater damaged due tooverheating.

Note: Initialized [A/D 250] value is set at 36 bit with program 01.03 or earlier version.

Adjust Temparature 250 deg

A/D 250 deg = 80 bit

Fig. 4.18.5

3. Wait 1 minute.4. Refer to Fig. 4.18.6. Adjust A/D bit value up or down while checking temperature sensor output.

Adjustment should be complete in less than 30 seconds. Specification = maximum heattemperature 248 ~ 250ºC.

5. Press “ENT” key.

Heat Time

HeatTemp erature

Heat temp. adjustment must be done in this period.

60 seconds 30 sec.

Max. temperature is between 248 and 250ºC.

Adjusting point for cool finish temperaturemust be between 100 and 105ºC.

Note: It is only one chance to check it. When thetemperature is out of specification, a re-adjustmentfor AD100 is required. And, execute the programfrom the first step.

Fig. 4.18.6

6. Refer to Fig. 4.18.7. Adjust “100ºC” A/D bit value up or down while checking temperature sensoroutput. Specification = temperature 100 ~ 105ºC. Note – Reading for adjustment should be takenduring the first decline from the high temperature point (refer to Fig. 4.18.6).

Note – A/D must be > 50 bit after adjustment. If not, refer to section 7.13 “Heater Trouble” to repair.


A/D 250 deg = 80 bit

Wait 59 sec.


A/D 100 deg = 220 bit

Fig. 4.18.7

§ 4.19. Splice Test

§ 4.19.1. Estimate Check

1. Enter the “Main Menu”.2. Set the splice mode to “Standard SM” Auto.3. Prepare and load two 250µm SM fibers into splicer.4. Refer to section 2.4.1. Execute the “Estimate Test” in “Secret Menu”.5. Refer to Fig. 4.19.1. The left fiber moves forward and the estimation loss is calculated automatically.

Estimation Specification: <= 0.02dB.6. To re-estimate, push the “ENT” key.

Estimate Test

X

Y

0.234

0.229 LOSS=0.00dB

BGB=101 99LED =166 167

OF:0.02

ECC-X:–0.06 –0.02 –0.04 Y: –0.19 –0.28 0.09 XY: 0.20 0.28 0.10

0.231

0.231

5:SM 1:60mm

CS:0.012X:C Y:C

MF:0.000CORE CLAD

X: –0.16 –0.02Y: 0.20 0.28

Fig. 4.19.1

§ 4.19.2. Stuff Check

1. Prepare and load two 250µm SM fibers into splicer.2. Refer to section 2.4.1. Execute “Stuff Check” in the [Secret Menu]3. The result of stuff check is displayed on the monitor. Specification: 30±5 µm.4. If this value is no good, adjust the stuff speed by pushing “Up” or “Down” cursor key.5. Repeat steps 1 ~ 3.

§ 4.19.3. Arc Calibration

1. Refer to the instruction manual.2. Execute “Arc Calibration” mode in the main menu.3. If “Test again” appears on the monitor after executing arc calibration mode, repeat until “Test

again” message does not appear.4. If “Arc Calibration” is attempted 10 times with poor results. Execute “Replace Electrode” mode

without changing the electrodes.5. Repeat “Arc Calibration”.

§ 5. Electrical§ 5.1. PCB Connection

§ 6. How to:

§ 6.1. Replace PCB

§ 6.1.1. Preparations before Replacement

1. Refer to section 2.4.1. Select “Config Code” in [secret menu].2. Record “Config Code” codes (3 each). Each code has 15 characters. Characters used for the

configuration codes are “ABCDEFGHIJKLMNOPQRSTUVWXYZ” and “234567”.3. Turn the splicer power off and remove Power Supply

§ 6.1.2. Removal of PCB

1. Refer to section 5. Remove all connectors from Main PCB. Note – Remove screw that holds blackcathode cable to Frame-Base.

2. Refer to section 4.6. Remove Power Unit Dock from Frame-Base3. Refer to Fig. 6.1.1. Remove corner screws from shield board.4. Refer to Fig. 6.1.2. Remove 2 screws and 4 posts from main PCB.

Shield board

Release 4 screws

Release 4 posts

Release 2 screws

Fig. 6.1.1 Fig. 6.1.2

5. Refer to Fig. 6.1.3. Detach power supply cord from main PCB. Connectors of power supply arereverse side of PCB.

Left side view of PCB

Cathode: Black Anode: Red

Fig. 6.1.3

§ 6.1.3. Installation of PCB

6. Refer to Fig. 6.1.4, Fig. 6.1.5. Attach New PCB in reversed order of replacement procedure steps 1~5. Note - Confirm that cables and connectors are not pinched between the post and screw. Thismay be view through the peephole as illustrated.

Left side view of PCB

Battery Frame

Peephole of wiring corfirm

Fig. 6.1.4

Cap screw (M3×6, T=5)

Shield Plate

Main P.C.B.

Spacer (M3, WS3, SLG)SLG paints only screw head.

Cap screw (M3×6, WS3, SLG)SLG paints only screw head.

Fig. 8.2.5

7. Install Program software.8. Turn splicer ON, “Initializing... Please wait” message is displayed on the monitor, All parameters

are cleared.9. Refer to section 2.4.1. Select “Config Code Input” in [secret menu].10. Input configuration codes recorded in Step 2 of section 8.2.1. Note - If you enter an incorrect code

it will be displayed in a “RED” color.11. Refer to section 8.2.4. Adjust voltage indicator.12. Refer to section 4.21.1. Adjust tube heater temperature.

§ 6.1.4. Adjusting Voltage Indicator for 40S

To operate the battery indicator correctly, it is necessary to adjust the sensor value of splicer.

Components Required for Testing• Ohmmeter• Fully Charge ADC-07 AC Adapter

Procedure

1. Confirm software version is > 01.06.2. Measure voltage of ADC-07 with ohmmeter and record measured voltage.3. Insert ADC-07 AC adapter into the power unit dock until it clicks into place.4. Refer to 2.4.1. Turn on the splicer and select the “Voltage Adjustment” in the [Secret Menu]5. Refer to Fig. 6.1.5. Adjust “Input Voltage” to match recorded measured voltage by pressing <s> or

<t> key and input output AC voltage6. Press <ENT> key.

Fig. 6.1.5

Note: The splicer automatically adjusts the value of voltage sensor. Adjusted value appears on thescreen.

§ 6.2. Software Upgrade

§ 6.2.1. Software Upgrade with Programming Chip Device

Components Required for Upgrade

• New version ROM• ROM Download PCB• ROM Download PCB extension cable

Procedure

1. Turn the splicer power off. Disconnect the power source from the splicer.2. Refer to section 4.17. Remove cover panels.3. Connect the ROM Download Extension Cable between CPU Board and ROM Download PCB.4. Install the New ROM into the Download PCB. Caution: Install ROM correctly.5. Connect power source to splicer.6. Push the “ON” key. The ROM download Menu will appear.7. Select “OK”. Download is initiated. Wait until download is completed.8. Confirm the software version by power on menu or Maintenance Information.

Fig. 6.2.1

§ 6.2.2. Software Upgrade with RS-232C cable

§ 6.2.2.1 Install of PCUG software

Before using PCUG, install as follows:1) Click “SETUP.EXE”2) Select folder to install. Default is “C:¥Program Files¥SY012 ROM Upgrade”. Do not change

the folder, except for special reason.3) Click “Computer Mark ICON”.4) Automatically installed.5) After install, making “Short Cut of PCUG” to the desktop of PC is convenience in the case

of upgrading.<NOTICE> PCUG software can be executed Windows® 95/98.

§ 6.2.2.2 Upgrading of software.

1) Close all windows applications. Other applications (especially, E-Mail applilications ) haspossibility to prevent communication between splicer and PC. Just in case, turn the screensaver of PC to OFF.

2) Connect splicer to PC using RS232C cross cable. Please refer to section 8.3.3.3) PCUG program (SY012 Upgrade) start from “Windows Start Menu”. Icon of windows menu

is blue circle.4) Select COM port “COM1” or “COM2”.5) Select ROM data file.6) ROM data file extract automatically. Please wait 1 or 2 minutes. Wait time is decided by the

performance of PC.7) Confirm the “Model Name” and “ROM Version” shown in the right side of the window. For

example, Model Name is “FSM-40S”, Version Name is “01.10”.8) Confirm that splicer power is off or not. If power is on, turn the power off and click “OK”.9) Turn the splicer power on. Then 4 buttons are shown, and select baud rate 38400 for the first

time. Baud rate of splicer is automatically set. If buttons are not shown, confirm theconnection between PC and splicer and try again.

10) Confirm the previous software version, and click “OK”.11) Wait until upgrading.

Wait time is about 5 minutes. (In the case of 38400 bps.)10 minutes. (In the case of 19200 bps.)13 minutes. (In the case of 14400 bps.)20 minutes. (In the case of 9600 bps.)

12) If upgrade failure, error message is shown on the window. In this case, try again and selectlower baud rate at the step 7. Some devices installed to PC have the possibility of preventingthe communications between PC and splicer.

13) After finishing upgrade, confirm the value of check sum shown on the right down corner ofwindow. The value of check sum is announced by KOKAI-M with the file of “SoftwareVersion History of FSM-40S”.

14) In the case of upgrading other splicer, click “Y”. On the other hand, in the case of finishing,click “N”.

§ 6.2.3. Data Download Software with RS-232C

1. Computer Requirements

• PC/AT Compatible• Operating System – Microsoft Windows® NT, Windows® 98/95• Program – Microsoft EXCEL® 97/2000

2. RS232 cable requirements

• End 1 = D-Sub 9pin Female• End 2 = D-Sub 9 pin Female• Cable Length = <3 meters

Note: RS232 cables have multiple configurations, checked new cable for continuity based on the aboveschematic.

3. How to install VBMan

• Copy “40S-PC E03” ZIP file to PC directory (example – C:¥programs¥40Sdownload• Un-zip contents of file into same PC directory• Double click “setuo03.bat” file to install VBMan

Pin No.

D-Sub 9pin

1

Shield

23

4

56

7

8

9

Pin No.

D-Sub 9pin

1

Shield

23

4

56

7

8

9

Note: The above procedure installs VBMan which is the control software for RS232 (COM) port. Ifyour PC has other RS232 software installed, VBMan may not be able to configure the COM port. Insuch a case, UN-install software or use another PC.

4. To setup Microsoft® EXCEL “40S-PC E03” Program

• Connect RS232 cable to PC COM port and FSM-40S• Turn splicer ON• Open “40S-PC E03.xls” file• Set baud rate for splicer and program to the same rate (fastest baud rate = 19200)• Open My computer ¥ control panel ¥ ports folder to excess COM port 1 configuration. Confirm the

following settings:

Baud Rate = 19200Data bits = 8Parity = noneStop bits = 1Flow control = none

Note: The EXCEL program automatically configures the COM port.

Confirm communication between PC and Splicer

§ 7. Trouble Shooting

When trouble occurs, a customer is required to record error message with "Error Code." That codeincludes information to solve the trouble.

§ 7.1. ERROR 01 Too Long Fiber

01-01 Left fiber is too long01-02 Right fiber is too long01-03 Both left and right fibers are too long.

Reason1: Improper loadingReason2: Micro-dust

§ 7.2. ERROR 02 Too Dark

02-01 X image brightness is not enough ( not zero )02-02 X image brightness is not enough ( not zero )

Reason1: Improper loadingReason2: Micro-dustReason2: Mechanical adjustment (mirror or kyoutou).Reason3: LED or wiring damaged.

02-11 X image brightness is zero02-12 Y image brightness is zero

Reason1: CCD camera is damagedReason2: CPU Board is damagedReason3: LED connector is out of placeReason4: LED wire is damagedReason5: LED is damaged

§ 7.3. ERROR 03 Fiber too Dusty

03-01 Image processor cannot find fiber on the X image03-02 Image processor cannot find fiber on the Y image

Reason1: Micro-dustReason2: cleaning arc weak (especially true for carbon coated fiber)Reason3: Wrong fiber mode

§ 7.4. ERROR 04 Motor Overrun

04-01 ZL Motor forward04-02 ZL Motor backward04-11 ZR Motor forward04-12 ZR Motor backward04-21 X Motor forward04-22 X Motor backward04-31 Y Motor forward04-32 Y Motor backward04-41 Focus X Motor forward04-42 Focus X Motor backward04-51 Focus Y Motor forward04-52 Focus Y Motor backward

Reason1: Limit switch is damagedReason2: Main PCB is damaged

To diagnose error: Press [RESET] and [ENT] at the same time. Splicer performs a reset motionwithout resetting the motor position. This operation is SECRET, don’t show to customer. Execute“Input Port Status” command on the secret menu and check the status of error port. Check theconnector terminal using a circuit tester. GND level is ON. By the above procedures, it is possible tojudge if the limit switch or the Main PCB caused the problem.

§ 7.5. ERROR 05 Close Cover

Reason: Cover is opened

§ 7.6. ERROR 06 Cover Opened Error

Reason1: Connector terminal damaged or not connectedReason2: Cover magnet missing or position wrongReason3: Main PCB is damaged

Note: If cover is opened when [SET] is pressed, ERROR-05 will appear. On the other hand, if thecover is opened during the image processing, ERROR06 will appear.

To diagnose error: Execute “Input Port Status” command on the secret menu and check the status oferror port. Check the connector terminal using a circuit tester. GND level is ON. By the aboveprocedures, it is possible to judge if the limit switch or the Main PCB caused the problem.

§ 7.7. ERROR 07 Motor Trouble

04-01 ZL Motor04-02 ZR Motor04-03 X Motor04-04 Y Motor04-05 Focus X04-06 Focus Y

Reason1: Connector terminal damaged or not connectedReason2: Limit switch is damagedReason3: Mechanical adjustmentReason4: Motor is damaged

Note: Error appears when the Motor’s LS dog does not strike the limit switch in the predetermineduration of time. Standard time is less than 10 seconds for the Z motors, 30 seconds for the XY motors,and 5 seconds for the focus motors.

To diagnose error: Execute “Input Port Status” command on the secret menu and check the status oferror port. Check the connector terminal using a circuit tester. If the port and terminal are OK, there isa possibility that the motor is damaged. Check the motor moving time from forward limit to backwardlimit.

§ 7.8. ERROR 08 Fiber Judge Error

Reason: Left fiber type and right fiber types are different

Note: Fiber type is judged only to SM. DS, or MM when using AUTO MODE.

§ 7.9. ERROR 09 (ARC) Calibration Error

Reason1: Worn electrodesReason2: Electrode mechanical adjustment

§ 7.10. ERROR 10 Fiber Separate Error

Reason1: Arc Power is too strong.Reason2: Connector terminal damaged or not connected

Note: This error message appears when there is no fiber at the designated slice point position afterdischarge.

To diagnose error: Check the AD converter value using “Sensor Value” in “Utility Menu”. Example-if pressure sensor is broken or connector J07 is not connected, CPU judges pressure to be very lowduring arc compensation mode. As a result, Arc Power will be set to strong for normal operation.

§ 7.11. ERROR 11 Fiber Set Error

11-01 Error on Left Fiber11-02 Error on Right Fiber

Reason1: Improper fiber loading.Reason2: Mechanical adjustment (XY swingarm)Reason2: Mechanical adjustment (CCD camera position)

§ 7.12. Splicer does not boot up

Check the following:

1. Check PCB connections and Keypad.2. Locate the two LEDs at the right/front side of PCB.3. LED1 is 5V line and LED2 is 12V line. They should be illuminated. If LED’s are illuminated

proceed to step 9.4. If both of LED1 and LED2 are not illuminated, check the voltage between CN27 and CN23. If this

voltage is not 12V, the power supply may be damaged and should be replaced.5. If LED2 is not illuminated check the fuses. If fuse is broken, replace fuses.6. Check voltage between 12V (example - No3 pin of CN01) and GND.7. If no voltage, check for possible short circuit (loose screw, etc.). Replace PCB if short circuit

cannot be found.8. If LED1 is not illuminated, check voltage between 5V (example - No3 pin of CN14) and GND.9. If no voltage, check for possible short circuit (loose screw, etc.). Replace PCB if short circuit

cannot be found.10. If splicer parameters (including secret parameters) are set incorrectly, there is a possibility the CPU

is “OK”, but will not progress to “READY” state. In this case, the LCD monitor is on.11. Boot up pressing [MENU] [EXIT] [XY] while tuning the splicer on. All parameters are cleared and

initialized. If machine still does not boot up replace the PCB.

§ 7.13. Heater Trouble

Heater Error occurs when temperature of heater does not increase to “Heater Temp of Heater ModeMenu” after heating cycle has started.

Notification of alarm: LED [HEAT] key will flash on and off and buzzer sounds in rhythm with flash.Turn off by pressing [HEAT] key.

Reason1: Connector terminal (CN29) damaged or not connectedReason2: Thermister of heater damagedReason3: Heater PCB damaged.Reason4: Broken lead between heater element and PCBReason5: Strong wind (rare case)

Check the following:

1. Disconnect connector (H03) from PCB.2. Measure resistance value of heater element (Pins 1,2 of H03). Typical resistance value is 6 to 7

ohms. Check for broken lead or replace heater element if necessary.3. With tube heater cool, measure resistance of termister (Pins 3,4 of H03). Typical resistance value is

400k ohm at a temperature is 25ºC and 300k ohm at 30degrees. Check for broken lead or replaceheater element if necessary.

4. Measure voltage between pins No1 and No2 of CN29 after pressing [HEAT] key. Typical voltage is12V. Check power supply output or replace main PCB if necessary.

§ 8. Appendices§ 8.1. The Check-Sheet for the Adjusting Display Image

Ser. No. DATE: Name:No Items check

1 Clean the V-grooves and the fiber clamps2 Confirm the dust on the monitor3 Adjust to cross the center of X and Y axes4 Confirm the parallel position of X and Y axes ZL ZR difference

-1.5<=(ZL-ZR)<=+1.5 Xboth X and Y axes Y

5 Turn the power off.6 Remove the covers (both front and back sides). Pan head M3×67 Remove the monitor. Pan head M3×14 with big washer8 Remove the Connector Box. Countersink M2×6 (steel)9 Remove the LED cover.

10 Remove the Discharge Power Supply. Cap M3×6 with small washer11 Remove the Electrode. Phillips-head M2×812 Remove the 4 focus bearing holders. Set screw M4×613 Re-attach the focus arms joint plate (Cap M3×8)14 Attach the focus bearing holders (4 pc.) Set M4×6, 150N-cm

Notice: It cannot use that the surface of the focus bearing holder to have used once.15 Attach the battery cover of the main P.C.B.16 Turn the splicer power on.17 Version up the latest ROM. ROM Ver.18 Adjust the display position

Note: The display position must adjust after you confirm the center of X and Y fibers adjust.The target value of adjustment of fiber position: X = 285line, Y = 195 lineThe target value of adjustment of electrode position: 366~ Y ~376line, 0 ~ (Y-X) ~10line

19 Shock Test20 The final checking other display position.

1. CCD camera parallel position L R difference-1.0line <= (X-Y) <= +1.0line X-ZL

Y-ZR2. CCD camera position to the Y electrode posit ion 366line <= Y <= 386line3. The fiber position of X and Y axes L R

270 <= X <= 290line X-ZL190 <= Y <= 210line Y-ZR

4. The difference of the edge of X and Y fibers X Y difference-10 <= (Y-X) <= +10line

21 Turn the splicer power off.22 Attach the Electrodes Pan-head M2×8, 20N-cm23 Attach the Discharge Power Supply cap M3×6 with small washer, 50N-cm24 Attach the LED Cover.25 Attach the Monitor. pan head M3×14 with big washer, 100N-cm, SLG26 Attach the Connector Box Countersink M2×6(steel), 30N·cm27 Attach the cover of the back side and front one Pan-head M3×6, 70N·cm28 Turn the splicer power on. ---> Next splice check.

§ 8.2. List of the necessary tools for FSM-40S adjustment

Item No. Description Design No. Q’tyPer Unit

STOOL 4040 Heater Adjustment Device S8612M-05-ASSY 1STOOL 4050 Wind Protector Protection Device S8612M-06-ASSY 1STOOL 4060 Z Unit Standby Device S8612M-07-ASSY 1STOOL 4080 Z-axis Centering Device S8612M-09-ASSY 1STOOL 4100 Display Adjustment Device Cap Screw M3×18

Spring No.105320

STOOL 4110 Monitor Extensional Code S1330R-38 1STOOL 4120 Thermo Spot Sensor TMZ51-500-5E3-2 1STOOL 4130 Electrode Position Adjustment Device #1 (length 26mm) S8612M-08-ASSY#1 1STOOL 4201 Nipper HOZAN N-9-125 1STOOL 4202 Parallel hand reamer φ4.02 1STOOL 3010 Torque Wrench Driver 5~60N•cm (0.5~6kgf·cm) N6LTDK 1STOOL 3012 Torque Wrench Driver 40~300N•cm (4~30kgf·cm) N30LTDK 1STOOL 3051 Tip portion of Torque Wrench Driver Standard Phillips Type No.1 +BIT-SB-No.1 1STOOL 3052 Tip portion of Torque Wrench Driver Standard Phillips Type No.2 +BIT-SB-No.2 1STOOL 3053 Tip portion of Torque Wrench Driver Standard Cabinet Type 0.4mm -BIT-SB-0.4mm 1STOOL 3054 Tip portion of Torque Wrench Driver Standard Cabinet Type 1.0mm -BIT-SB-1.0mm 1STOOL 3056 Tip portion of Torque Wrench Driver Standard Allen Type 1.5H HEX-SB-1.5H 1STOOL 3057 Tip portion of Torque Wrench Driver Standard Allen Type 2.0H HEX-SB-2.0H 1STOOL 3058 Tip portion of Torque Wrench Driver Standard Allen Type 2.5H HEX-SB-2.5H 1STOOL 3060 Tip portion of Torque Wrench Driver Standard Box Type 5.5H Box-SB-5.5H 1STOOL 3065 Tip portion of Torque Wrench Driver Standard Box Type 3/4"H MitoloyType206HB

Type Square 6.31

STOOL 3066 Tip portion Adapter of Torque Wrench Driver (Used Allen Type0.89H)

S8620M-03-10 #1 1

Fujikura FSM40S Service Manual LEVEL 2

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Transcript of Fujikura FSM40S Service Manual LEVEL 2