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MAINTENANCE MANUAL
FSM40S
LEVEL 2
Fujikura Proprietary Document
No part of this document may be transferred to any third party
without prior written consent from Fujikura Ltd.
Page 2
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
Page 3
5. Electrical ...................................................................................................... 53
5.1. PCB Connection.........................................................................................53
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
Page 4
1. Introduction
This manual describes the mechanical assembly, adjustment, and maintenance of Fujikuras FSM-40S
fusion splicer. When maintaining the FSM-40S, it is important to locate the exact problem and make
the 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.
Page 5
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 damage
resulting from improper use or modification.
Alert Symbol
This maintenance manual indicates warnings and cautions by using alert symbols. It is important to understand
what it means.
WARNING
There is a possibility of personal death or serious injury resulting from improper use
by ignoring this indication.
CAUTION
There is a possibility of personal injury or physical loss resulting from improper use by
ignoring this indication.
Page 6
WARNING
The appliance inlet is used to disconnect the power cord when you disassemble the splicer.
Never maintain the splicer in an environment where flammable liquid or vapor exists. Extremely
dangerous fire and explosion could result from the splicers electrical arc in such an environment.
Do not disassemble or modify AC adapter and battery pack. In particular, do not remove or bypass
any electrical or mechanical device (e.g. a fuse or safety switch) incorporated into the design and
manufacturing of this equipment.
Check the connector to insert correctly before discharging.
During arc discharge, the electrodes generate high voltage and high temperature, and it causes
personal injury. Do not touch the electrodes during the maintain (though arc discharge stops when
the wind protector is opened). Turn the splicer power off, and disconnect the AC power cord (or
remove the battery pack) when replacing the electrodes.
This equipment is designed for splicing optical glass fiber for telecommunication. Do not attempt to
splice 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 may
ignite any remaining gas mixture.
Safety glass should always be worn during the fiber preparation and the splicing process. A glass
fiber 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 smoke
or 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 or
equipment 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.
Page 7
WARNING
Connect the AC power cord properly to the appliance inlet and wall socket. When inserting the AC
plug, confirm no dust or dirt on terminals, and insert it to the end. Incomplete connection can cause a
fire, emitting smoke or personal injury.
Connect the AC adapter / battery charger to electrical ground when using it. It is possible to connect
through 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 a
battery charger cord (DCC-08). Personal injury or equipment damage can result from using not
specified battery charger. Proper AC power source to the ADC-07 is AC100-240V, 50-60Hz. Check
the AC power source before use. Improper AC power source can cause personal injury, emitting
smoke or equipment damage.
The appliance inlet is used to disconnect the power cord when the splicer is abnormal. Be sure to
position 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 emits
smoke 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 is
damaged (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) or
an 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 or
equipment damage.
Do not use the splicer in circumstance of extremely hot temperature. It may cause personal injury or
equipment damage.
Do not throw the battery pack away into a fire. Or, do not heat it up. It can cause a dangerous
explosion.
Do not short-circuit both terminals of the battery pack and the AC adapter / battery charger. Large
electrical current can cause personal injury, a fire or equipment damage.
Page 8
CAUTION
Do not store the equipment in any area where extreme heat and humidity are present. It may cause
equipment 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 cause
personal injury or equipment damage.
Precise adjustment and alignment have been made to this splicer. Do not give a strong shock. Use a
carrying case to transport and store the splicer. The carrying case will prevent damage and provide
protection from moisture, vibration and shock during storage and transportation.
Keep the splicer free from sand or dust. It degrades the splicing performance.
The splicer requires no lubrication. Oil may degrade the performance and damage the splicer.
Page 9
2.2. Abbreviations
Cap screw:
Set screw:
WS2:
WF2:
Phillips-head screw:
Countersunk screw:
Pan-head screw:
T=20:
SLG:
Page 10
key
ON/OFF key
HELP key ARC key
X/Y key
ON
/OFF
MENU
HELP
ARC
RESET
EXIT
EXIT key
X/Y
HEAT
SET
ENT
ENT key
<ON/OFF> key Turns power on and off. To turn off power, press and hold key untill the LED
color 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-Y
direction 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 saving
state.
<MENU> key Open [Main Menu] screen. According to circumstances, changes manual drive
motor.
<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, drives
XY-motor or Focus-motor manually.
< >< > key Used to change pages. According to circumstances, drives Z-motor manually.
Page 11
Page 12
1/5
Page 2 of 5
Secret Menu
2/5
Heater Adjustment
Heat AD-250
80bit
Heat AD-100
230bit
Voltage Adjustment
AD-12V
152bit
st+ENT:Select
:Change Page
EXIT:Exit
Page 3 of 5
Splice Database Init. - Initializes splice database area and the
database area to the condition when shipped . When database area
Splice Database Init
is upgraded, perform this command.
Splice Mode Init.
Splice Mode Init. - Initializes all arc parameters of all 100 splice
Heater Mode Init.
modes in both the user programmable area and the database area to
Utility Init.
the condition when shipped from the factory. The splicer software
st+ENT:Select
on the ROM chip contains these initial parameters
:Change Page
Heater Mode Init. - Initializes all heater parameters of all 40
EXIT:Exit
heater 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 contains
these initial parameters.
Utility Init. - Initializes all parameter of Utility including Configurations.
Secret Menu
3/5
Page 13
Page 4 of 5
Secret Menu
4/5
st+ENT:Select
:Change Page
EXIT:Exit
Page 5 of 5
Secret Menu
5/5
1500ms
FCS Home Y
1600ms
st +ENT:Select
:Change Page
EXIT:Exit
7
S0
S1
S2
IN2
IN4
AD
HELP
L-ZRR
MENU
UP
DOWN LEFT
L-FoXR
SET
ARC
X/Y
L-ZRF
L-ZLR
L-ZLF
L-FoYF
COVER L-TEMP H-Temp3 H-Temp2
Voltage Pressure
Temp
Humid
RIGHT
L-FoXF
L-FoYR
H-Temp1
ENT
L-XR
L-YR
HEAT
Magnet2
Heater2
Heater3
0
EXIT
L-XF
L-YF
RESET
Magnet1
Heater1
Page 14
2.4.2. Password
Factory password to enter Configurations is ARUKIJUF. Note - After entering Secret Mode,
password is no longer required.
Page 15
3. Mechanical Assembly
3.1. Focus/Camera Assembly
3.1.1. Camera Assembly
1.
2.
3.
4.
Objective Lens
Dont remove!
Set screw M33
(T=2)
Dont remove!
Kyoutou Mirror
(S1330R-16)
Kyoutou
(S1330M-03-01)
Not reverse
Cap screw M2 6
(T=2, SLG)
Fig. 3.1.1
Kyoutou Y Unit
Kyoutou X Unit
Attention
Connector position
Fig. 3.1.2
Page 16
5. Refer to Fig. 3.1.3 for steps 5 ~ 6.
6. Attach Focus Adjuster on Kyoutou Unit with cap screw (M310, T= temporary, WS3)
7. Attach Focus Arm Joint Plate on Kyoutou with cap screw (M310, T= temporary, WS3)
Focus Adjuster
(S1330M-03-12)
Focus Arm Joint Plate
(S1330M-03-07)
Fig. 3.1.3
Page 17
Anode Electrode
leaf Spring
Phillips-head screw
M28 (T=2)
Phillips head screw
M24 (T=2, SLG)
Pan-head screw
M28 (T=2)
Screw Stopper
(S1330M-01-10)
Cathode Electrode
leaf Spring
LED Holder
LED (KR5004X)
Electrode
Nut M2
LED Holder
(S1330M-01-10)
Electrode Base
(S1330M-01-01)
Nut M2
LED (KR5004X)
Fig. 3.2.1
Page 18
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 (M28, T=2) and nut (M2).
Pushing
Hanging
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 (M28, T=2)
Pushing
Fig. 3.2.3
Page 19
3.3.1.1
1.
2.
3.
4.
Magnet-Catcher(Front)
(S1330M-04-05)
Hinge
Magnet-Catcher(Rear)
(S1330M-04-05)
Fiber-Pusher
(S1330R-24)
Sheath Clamp Spring
(S1330M-04-07)
Sheath Clamp
(S1330R-22)
Super-Shaft h7-1518
Fig. 3.3.1
Page 20
3.3.1.2
Clamp-Arm(left)
uses this-side hole.
Clamp-Arm-Bracket
(S1330M-04-11)
Set screw M23 with flat point
(for adjustment of Clamp-Arm parallel, SLG)
Fig. 3.3.2
Page 21
Pushing
Block gauge
(t=0.25)
Block gauge
(t=0.2)
Pushing to
Hinge side
Block gauge
(t=0.2)
Fig. 3.3.4
Fig. 3.3.5
Fig. 3.3.6
Pushing
Fig. 3.3.7
Page 22
4. Mechanical Adjustment
4.1. Installing Focus Unit
Note XY-Block has been removed from Base Frame for illustration. To reduce the chance of damage
to objective lens the Kyoutou installation would normally occur after the XY-block has already been
installed into the Base Frame.
1. Refer to Fig. 4.1.1. Loosely attach Kyoutou to Focus-Arm with Cap screw (M38 or 10).
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 and
bottom of Focus arm Joint Plate (Refer to Fig. 4.1.3). Tighten Cap screws (M310, WS3, T=12)
using illustrated toque sequence.
Pushing
Pushing
Fig. 4.1.3
Pushing
No space
Pushing
Fig. 4.1.2
No space
Page 23
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 (M46).
6. Tighten set-screw (M46, 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 recycle
Focus-Arm-Bearing Holders chamfer surface, they are designed to indent when the set screw is
installed.
Fix Kyoutou each side.
No space
Fig. 4.1.4
7. Refer to Fig. 4.1.5. Attach Focus Arms to Focus Arm Joint Plate with cap screw (M310, T=12,
WS3) using illustrated torque sequence.
Pushing
Pushing
No space
Fig. 4.1.5
Page 24
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 (M310, T=12)
using illustrated toque sequence.
Pushing
Fig. 4.1.7
Page 25
Pushing
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 of
Silicon-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 (M310, T=10, WS3).
Pushing
Fig. 4.2.2
Fig. 4.2.3
Page 26
Heater fan
Pushing
Base frame
Front side
Fig. 4.3.1
Fig. 4.3.2
Page 27
WP-Washer
Fig. 4.4.1
Page 28
(S1330R-37)
Fig. 4.5.1
Warning!
There is a Lithium coin battery on the main PCB. The battery surface is
exposed with the positive terminal facing up. A short circuit of the coin battery
can 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 damaged
calendar IC.
Be careful not to short circuit battery. A rubber
cap is available from Fujikura that should be
installed during any maintenance procedure.
The rubber cap may be left permanently in
place after repair.
Post
Coin
Batter
y
Page 29
Pushing
Fig. 4.6.1
High
Flat
Fig. 4.7.1
Low
80% attaching
OK
Page 30
V-Groove
Fig. 4.8.1
Page 31
Camera Position
XL
176.9
177.0
198.7
198.8
219.3
257.5
YR
X
Y
ZL
XR
219.4
258.0
277.9
278.4
300.1
300.6
Fig. 4.9.1
YL
Page 32
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 (M33, flat type) which attaches CCD-Camera Unit.
Set screw
(M310, T=2)
Fig. 4.9.3
Page 33
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 (M33, T=2, flat type) which attaches X CCD-Camera
Unit.
10. Use right sheath clamp, set the 250m UV coating fiber into V-grooves. Note Cleave length:
16mm.
11. Drive fiber past electrode using the ZR motor manually. Note Dont 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 (M33, T=2, flat type) which attaches Y CCD-Camera
Unit.
ZL motor moving
ZR motor moving
XR
Camera Position
XL
Camera Position
176.9
177.0
176.9
177.0
198.7
198.8
198.7
198.8
219.4
219.3
258.0
257.5
277.9
278.4
277.9
278.4
300.1
300.6
300.1
300.6
219.3
257.5
X
Y
ZL
YL
Fig. 4.9.4
X
Y
219.4
ZR
258.0
YR
Page 34
Fig. 4.9.5
6.
7.
8.
9.
Page 35
21. Adjust right side fiber end-face in the X view by moving the Focus-Adjuster. Tighten Cap screw
(M310, 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
Fig. 4.9.6
Focus-Adjuster
B
Horisontal position screws
Fig. 4.9.7
Page 36
Wind-Protector-Mirror
(S1330R-03)
Wind-Protector
(S1330R-02)
Super-Shaft h7-1522
Spring No.1043
Plate
Magnet
Wind-Protector-Shaft
(S1330M-01-11)
Cap screw M26
(T=3,WF2)
Make about same width.
READY
Fig. 4.9.8
Fig. 4.9.9
Page 37
XL
YR
176.9
177.0
198.7
198.8
219.3
257.5
ZL
XR
219.4
258.0
277.9
278.4
300.1
300.6
Fig. 4.10.1
YL
Page 38
5.
Use left sheath clamp, set the 250m UV coating fiber into V-grooves. Note Cleave length:
16mm.
6. Drive fiber past electrode using the ZL motor manually. Note Dont 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 250m UV coating fiber into V-grooves. Note Cleave length:
16mm.
9. Drive fiber past electrode using the ZR motor manually. Note Dont overrun ZR-Motor.
10. Record values (ZR-XL), (ZR-XR), (ZR-YL), (ZR-YR). Refer to Fig. 4.10.2.
ZL motor moving
ZL-XL
ZL-XR
ZR motor moving
ZR-XL
Camera Position
ZR-XR
Camera Position
176.9
177.0
176.9
177.0
198.7
198.8
198.7
198.8
219.4
219.3
258.0
257.5
277.9
278.4
277.9
278.4
300.1
300.6
300.1
300.6
219.3
257.5
X
Y
ZL
ZL-YL
ZL-YR
X
Y
258.0
ZR-YL
ZR-YR
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.
X
Y
ZL
A
B
ZR
C
D
Difference
(A-C)
(B-D)
219.4
ZR
Standard
(A-C)<= 1.5 line
(B-D)<= 1.5line
Page 39
97.2
278.5
193.0
8
299.2
374.2
94.6
X
Y
94.1
190.2
190.0
285.9
285.8
Camera Position
182.7
U: 42.8
D: 45.2
278.5
219.3
257.5
277.9
300.1
177.0
198.8
219.4
258.0
U: 38.5
D: 43.8
278.4
300.6
Fig. 4.10.3
Page 40
Prepare 250m fiber with 30mm strip section and load into both V-groove s.
Refer to Secret Menu, execute Focus & Electrode command in [Secret Menu].
Refer to Fig. 4.11.1 for steps 4 ~ 6.
Pushing SET key, automatically adjust focal point to produce sharp fiber core image.
Focus Motor movable range Specification is > 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 (M33, T=2, flat type).
Auto focusing
More than
3/4 rotation
376
More than
3/4 rotation
Fig. 4.11.1
7. After adjusting of the Sensor-dog, Execute the Focus Home Adjustment command in [Secret
Menu].
Page 41
Prepare 250m fiber with 30mm strip section and load into both V-groove s.
Using Focus Motor, manually adjust focal point to produce sharp fiber core image.
Refer to Fig. 4.13.1.
Measure gap g from Focus-Arm-A to Focus-Arm-B. Note Measure with Block Gauges.
Calculate Block Gauge thickness. Formula - (Block Gauge thickness = g-1mm).
Loosen the set-screw (M46) for Focus-Arm-Stopper.
Place Block Gauge between Focus-Arm-A and Focus-Arm-B, apply pressure by pressing FocusArm-B against Focus-Arm-A.
8. Apply pressure by pushing Focus-Mechanical-Stopper up. Attach set-screw (M46, T=10, W point
type, SLG) to Focus- mechanical-Stopper.
Measure the gap "g" from Focus-Arm-A to Focus-Arm-B.
Focus-Arm-A
Focus-Arm-B
Focus-Arm-B
Focus-Arm-A
Fix the state of pressing Focus-Stopper
against Focus-Arm-A.
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.
Page 42
177.0
198.7
198.8
219.3
257.5
219.4
258.0
277.9
278.4
300.1
300.6
Fig. 4.13.1
4.
5.
6.
7.
Carbide plate
Half rotation
0.1~ 0.4mm
3.2mm(Standard)
Fig. 4.13.2
Page 43
Page 44
Refer to Fig. 4.15.1. Attach the LCD monitor to the monitor frame with countersink screws (M36,
T=6). Note Route monitor cable through hook for monitor code.
Monitor cable length from Monitor Bracket to end of Monitor connector (J14) should be 90mm.
Countersink screw M36 (T=6)
Confirm this length.
Monitor Frame
Hook for
Monitor Cord
90mm
LCD Monitor
(Back view)
Monitor Cord
Pan-head screw M34 (T=6)
Fig. 4.15.1
3.
Refer to Fig. 4.15.2. Attach Monitor-Unit to Base Frame with Pan-head screw M314 (T=10, WF3
outside diameter 8, SLG).
Pan-head screw M314
(T=10, WF3-diameter 8, SLG)
(S1330R-28
Fig. 4.15.2
Page 45
Pillar
Hook1
Hook2
Video out
CCD (Y)
CCD (X)
Connector Box
C-Box
ZR
Hook3
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 monitor
cable.
Fig. 4.16.1
Countersink screw M26
(T=3, steel)
(S1330R-36)
Fig. 4.16.2
Page 46
(S1330M-07-08)
Pan-head screw M36 (T=7)
(S1330M-07-07)
Fig. 4.17.1
Note: There is no need to remove the screw that attaches the Camera Cover.
Page 47
Splicer
Set the tool for fixing the thermo spot sensor on the corner
Fig. 4.18.1
Base frame
Pus h
Push the tool for fixing the thermo
spot sensor on the corner
Push
Fig. 4.18.2
Page 48
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 TMZ51-500-5E3-2
Note2: 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 sensor
and 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 the
heat emission plate.
Center of radiator plate
Thermocouple
Radiator plate
Heat Sinker
(Shin-etsu Chemical Co. Ltd. Oil Compound KS-609
Fig. 4.18.4
Page 49
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 step
4, and set the [A/D 250] to 80 bit. Failure to do so will result in tube heater damaged due to
overheating.
Note: Initialized [A/D 250] value is set at 36 bit with program 01.03 or earlier version.
Fig. 4.18.5
Page 50
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 heat
temperature 248 ~ 250C.
5. Press ENT key.
Heat
Temp erature
60 seconds
30 sec.
Heat Time
Fig. 4.18.6
6. Refer to Fig. 4.18.7. Adjust 100C A/D bit value up or down while checking temperature sensor
output. Specification = temperature 100 ~ 105C. Note Reading for adjustment should be taken
during 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.
Wait 59 sec.
Adjust Temparature 250 deg
A/D 250 deg = 80 bit
Fig. 4.18.7
Page 51
X 0.234
Y 0.229
OF:0.02
0.231
LOSS=0.00dB
CORE CLAD
X: 0.16 0.02
Y: 0.20 0.28
5:SM
0.231
CS:0.012
X:C Y:C
MF:0.000
1:60mm
Fig. 4.19.1
Page 52
Page 53
5. Electrical
5.1. PCB Connection
Page 54
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
Release 4 screws
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 are
reverse side of PCB.
Left side view of PCB
Anode: Red
Cathode: Black
Fig. 6.1.3
Page 55
Battery Frame
Fig. 6.1.4
Cap screw (M36, T=5)
Main P.C.B.
Shield Plate
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.
Page 56
Procedure
1.
2.
3.
4.
5.
Fig. 6.1.5
Note: The splicer automatically adjusts the value of voltage sensor. Adjusted value appears on the
screen.
Page 57
Procedure
1.
2.
3.
4.
5.
6.
7.
8.
Turn the splicer power off. Disconnect the power source from the splicer.
Refer to section 4.17. Remove cover panels.
Connect the ROM Download Extension Cable between CPU Board and ROM Download PCB.
Install the New ROM into the Download PCB. Caution: Install ROM correctly.
Connect power source to splicer.
Push the ON key. The ROM download Menu will appear.
Select OK. Download is initiated. Wait until download is completed.
Confirm the software version by power on menu or Maintenance Information.
Fig. 6.2.1
Page 58
Upgrading of software.
1) Close all windows applications. Other applications (especially, E-Mail applilications ) has
possibility to prevent communication between splicer and PC. Just in case, turn the screen
saver 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 the
connection 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 select
lower baud rate at the step 7. Some devices installed to PC have the possibility of preventing
the communications between PC and splicer.
13) After finishing upgrade, confirm the value of check sum shown on the right down corner of
window. The value of check sum is announced by KOKAI-M with the file of Software
Version 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.
Page 59
Computer Requirements
PC/AT Compatible
Operating System Microsoft Windows NT, Windows 98/95
Program Microsoft EXCEL 97/2000
2.
D-Sub 9pin
D-Sub 9pin
Pin No.
Pin No.
2
3
2
3
5
6
5
6
Shield
Shield
Note: RS232 cables have multiple configurations, checked new cable for continuity based on the above
schematic.
3.
Page 60
Note: The above procedure installs VBMan which is the control software for RS232 (COM) port. If
your PC has other RS232 software installed, VBMan may not be able to configure the COM port. In
such a case, UN-install software or use another PC.
4.
Page 61
7. Trouble Shooting
When trouble occurs, a customer is required to record error message with "Error Code." That code
includes information to solve the trouble.
Page 62
ZL Motor forward
ZL Motor backward
ZR Motor forward
ZR Motor backward
X Motor forward
X Motor backward
Y Motor forward
Y Motor backward
Focus X Motor forward
Focus X Motor backward
Focus Y Motor forward
Focus Y Motor backward
Reason1: Limit switch is damaged
Reason2: Main PCB is damaged
To diagnose error: Press [RESET] and [ENT] at the same time. Splicer performs a reset motion
without resetting the motor position. This operation is SECRET, dont show to customer. Execute
Input Port Status command on the secret menu and check the status of error port. Check the
connector terminal using a circuit tester. GND level is ON. By the above procedures, it is possible to
judge if the limit switch or the Main PCB caused the problem.
Note: If cover is opened when [SET] is pressed, ERROR-05 will appear. On the other hand, if the
cover 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 of
error port. Check the connector terminal using a circuit tester. GND level is ON. By the above
procedures, it is possible to judge if the limit switch or the Main PCB caused the problem.
Page 63
ZL Motor
ZR Motor
X Motor
Y Motor
Focus X
Focus Y
Reason1: Connector terminal damaged or not connected
Reason2: Limit switch is damaged
Reason3: Mechanical adjustment
Reason4: Motor is damaged
Note: Error appears when the Motors LS dog does not strike the limit switch in the predetermine
duration 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 of
error port. Check the connector terminal using a circuit tester. If the port and terminal are OK, there is
a possibility that the motor is damaged. Check the motor moving time from forward limit to backward
limit.
Page 64
Page 65
Page 66
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 clamps
2 Confirm the dust on the monitor
3 Adjust to cross the center of X and Y axes
4 Confirm the parallel position of X and Y axes
ZL
ZR
difference
-1.5<=(ZL-ZR)<=+1.5 X
both X and Y axes Y
5 Turn the power off.
6 Remove the covers (both front and back sides).
Pan head M36
7 Remove the monitor.
Pan head M314 with big washer
8 Remove the Connector Box.
Countersink M26 (steel)
9 Remove the LED cover.
10 Remove the Discharge Power Supply.
Cap M36 with small washer
11 Remove the Electrode.
Phillips-head M28
12 Remove the 4 focus bearing holders.
Set screw M46
13 Re-attach the focus arms joint plate
(Cap M38)
14 Attach the focus bearing holders (4 pc.)
Set M46, 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 line
The target value of adjustment of electrode position:
366~ Y ~376line, 0 ~ (Y-X) ~10line
19 Shock Test
20 The final checking other display position.
1. CCD camera parallel position
L
R
difference
-1.0line <= (X-Y) <= +1.0line X-ZL
Y-ZR
2. CCD camera position to the Y electrode posit ion
366line <= Y <= 386line
3. The fiber position of X and Y axes
L
R
270 <= X <= 290line
X-ZL
190 <= 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 M28, 20N-cm
23 Attach the Discharge Power Supply
cap M36 with small washer, 50N-cm
24 Attach the LED Cover.
25 Attach the Monitor.
pan head M314 with big washer, 100N-cm, SLG
26 Attach the Connector Box
Countersink M26(steel), 30Ncm
27 Attach the cover of the back side and front one
Pan-head M36, 70Ncm
28 Turn the splicer power on. ---> Next splice check.
Page 67
4040
4050
4060
4080
4100
STOOL 4110
STOOL 4120
STOOL 4130
STOOL 4201
STOOL 4202
STOOL 3010
STOOL 3012
STOOL 3051
STOOL 3052
STOOL 3053
STOOL 3054
STOOL 3056
STOOL 3057
STOOL 3058
STOOL 3060
STOOL 3065
STOOL 3066
Description
Heater Adjustment Device
Wind Protector Protection Device
Z Unit Standby Device
Z-axis Centering Device
Display Adjustment Device
Design No.
S8612M-05-ASSY
S8612M-06-ASSY
S8612M-07-ASSY
S8612M-09-ASSY
Cap Screw M318
Spring No.1053
Monitor Extensional Code
S1330R-38
Thermo Spot Sensor
TMZ51-500-5E3-2
Electrode Position Adjustment Device #1 (length 26mm)
S8612M-08-ASSY# 1
Nipper
HOZAN N-9-125
Parallel hand reamer
4.02
Torque Wrench Driver 5~60Ncm (0.5~6kgfcm)
N6LTDK
Torque Wrench Driver 40~300Ncm (4~30kgfcm)
N30LTDK
Tip portion of Torque Wrench Driver Standard Phillips Type No.1
+BIT-SB-No.1
Tip portion of Torque Wrench Driver Standard Phillips Type No.2
+BIT-SB-No.2
Tip portion of Torque Wrench Driver Standard Cabinet Type 0.4mm
-BIT-SB-0.4mm
Tip portion of Torque Wrench Driver Standard Cabinet Type 1.0mm
-BIT-SB-1.0mm
Tip portion of Torque Wrench Driver Standard Allen Type 1.5H
HEX-SB-1.5H
Tip portion of Torque Wrench Driver Standard Allen Type 2.0H
HEX-SB-2.0H
Tip portion of Torque Wrench Driver Standard Allen Type 2.5H
HEX-SB-2.5H
Tip portion of Torque Wrench Driver Standard Box Type 5.5H
Box-SB-5.5H
Tip portion of Torque Wrench Driver Standard Box Type 3/4"H
MitoloyType206HB
Type Square 6.3
Tip portion Adapter of Torque Wrench Driver (Used Allen Type
S8620M-03-10 #1
0.89H)
Qty
Per Unit
1
1
1
1
20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1