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KSP75-0086-51-02 (3)

MAINTENANCE MANUAL

ARC FUSION SPLICER

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

2.4. Accessing Secret Menus 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-dogs Position.........................................40


4.12. Adjustment of Focus-Mechanical-Stoppers Position ..............................41
4.13. Confirmation of Z Motor End Play..........................................................42

Page 3

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

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.

Example of Alert Symbol


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 socket
or the appliance inlet.

Page 6

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. 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.

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 equipment
damage or degrading the splicing quality.
Do not use any other chemical except alcohol to clean the objective lens, V-groove, mirror, LCD
monitor, 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 electrodes


replacement. Failure to repair the equipment can result in personal injury or equipment damage.
Please contact a sales agency in your country.

Page 9

2.2. Abbreviations
Cap screw:
Set screw:
WS2:
WF2:
Phillips-head screw:
Countersunk screw:
Pan-head screw:
T=20:
SLG:

Hexagon Socket Head Cap Screw


Hexagon Socket Set Screw
Small Circular Washer of 2 mm in nominal diameter
Finished Circular Washer of 2 mm in nominal diameter
Cross Recessed Phillips-head Screw
Cross Recessed Counters ink head Screw
Cross Recessed Pan-head Screw
Tightening Torque is 20kgfcm. (1kgfcm = 9.80Ncm)
Screw Locking Glue

2.3. General Overview


2.3.1. Composition of FSM-40S
FSM-40S composes of the following unit.
(1) XY unit
(3) Focus unit
(5) Electrode unit
(7) Z axis unit
(9) Wind Protector unit

(2) Heater unit


(4) Base unit
(6) Battery unit
(8) Monitor unit

Page 10

2.3.2. Basics and Preparations


Name of keys Refer to Fig. 2.3.1.
MENU key

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

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 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

2.3.3. Cleaning and checking before adjustment


Before adjustment, do the following work. Refer to INSTRUCTION MANUAL for FSM-40S for
further information.
Clean V-grooves
Clean Fiber Clamp Chips
Clean Wind Protector Mirrors

Page 12

2.4. Accessing Secret Menus 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 5
Corner Check Background brightness indicator.
Corner Check
Camera Position - Use when aligning camera mechanical position.
Camera Position
Focus & Electrode Use when adjusting focus and position of
Focus & Electrode
Estimate Test
electrodes.
Stuff Check
Estimate Test Estimation confirmation test.
Config Code Disp
Config Code Input
Stuff Check Checks stuff amount. Specification = 305.
st+ENT:Select
Config Code Disp. - Config Code includes many calibration
:Change Page
EXIT:Exit
parameters for the splicer. These codes have a relation to the
following: Serial Number, ICORE, Heater Calibration, Fiber Parameter, Voltage Adjust Parameter and
others.
Config Code Input - This command should be used after replacing the CPU Board
Secret Menu

1/5

Page 2 of 5
Secret Menu

2/5

Heater Adjustment
Heat AD-250

80bit

Heat AD-100

230bit

Heater Adjustment Use when calibrating heater unit


Heat AD-250/100 Result of Heater Adjustment
Voltage Adjustment Use when calibrating voltage value
AD-12V Result of Voltage Adjustment

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

Arc Count Input - Edits Arc Count


Total Arc Count Input - Edits Total Arc Count
True AP1, AP2, AP3, and Gap Center - Result of ARC
CALIBRATION

Arc Count Input


Total Arc Count Input
True AP1
True AP2
True AP3
Gap Center

st+ENT:Select
:Change Page
EXIT:Exit

Page 5 of 5
Secret Menu

5/5

Focus Home Adjustment


FCS Home X

1500ms

FCS Home Y

1600ms

st +ENT:Select
:Change Page
EXIT:Exit

7
S0
S1
S2

IN2
IN4
AD

HELP
L-ZRR

Focus Home Adjustment Use when calibrating Focus Home


Position
FCS Home X, Y Result of Focus Home Adjustment.
Input Port Status. Shows status of all Input Port and A/D
Converters. Note - Only RESET switch is available to exit this
menu.

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

(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.

Page 14

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 to
program set values.

Page 15

3. Mechanical Assembly
3.1. Focus/Camera Assembly
3.1.1. Camera Assembly
1.
2.
3.
4.

Refer to Fig. 3.1.1 for steps 2 ~ 4.


Attached Kyoutou-Mirror onto Kyoutou with cap screw (M26, T=2, SLG).
Insert 0.3mm thick Lens-Liner between Lens and Kyoutou. Screw Lens in Kyoutou.
Insert CCD-Adapter with CCD-Camera into Kyoutou, and attach with set screw (M33, 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)

Objective Lens

Dont remove!
Set screw M33
(T=2)

Lens Shim (t=0.3)


(S1330M-03-03)

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)

Cap screw M310


(WS3)

Cap screw M310


(WS3)

Focus Adjuster
(S1330M-03-12)
Focus Arm Joint Plate
(S1330M-03-07)
Fig. 3.1.3

Page 17

3.2. Electrode Unit Assembly


Description
Refer to Fig. 3.2.1. The electrode unit consists of the electrode unit, electrode, and LED. Phillips-head
screw (M28, T=2) is used with the anode electrode holder and the cathode electrode holder to secure
the electrodes. The chamfered electrode holder (holds V-groove LED) is located on the cathode side.
Anode Electrode Holder
(S1330R-04)
Phillips-head screw
M28 (T=2)

Anode Electrode
leaf Spring

Phillips-head screw
M28 (T=2)
Phillips head screw
M24 (T=2, SLG)

Cathode Electrode Holder


(S1330R-05)
Electrode
V-Groove LED

Pan-head screw
M28 (T=2)

Screw Stopper
(S1330M-01-10)

Cathode Electrode
leaf Spring

LED Holder

Phillips head screw


M24 (T=2, SLG)
Pan head screw
M28 (T=2)

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. 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

1.
2.
3.
4.

Sheath Clamp Top

Refer to Fig. 3.3.1.


Insert Super-Shaft (h7-1518) through Sheath- Clamp and Hinge.
Insert Fiber-Pusher-Spring between Fiber-Pusherand Sheath Clamp.
Press Fiber-Pusher into Sheath Clamp , install Magnet-Catcher (Front) and Magnet-Catcher
(Rear) with each two phillips-head screws (M24, T=3). Note Front and rear Magnet Catcher
are not interchangeable. Insure that Fiber-Pusher moves smoothly after installation.
Phillips-head screw M24
(T=3)

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

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 (M22 with flat type T=1.5). Note
- position axes pin chamfer to align with set screw (M22).
4. Make Clamp-Arm (right) parallel with base of Clamp-Arm-Bracket by adjusting set screw
(M23 with flat type, SLG) (Refer to Fig. 3.3.3).
Clamp-Arm (right)
(S1330R-26)

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

Set screw M22 with flat type


(T=1.5, SLG)
Clamp-Arm-shaft

Clamp-Arm-Bracket
(S1330M-04-11)
Set screw M23 with flat point
(for adjustment of Clamp-Arm parallel, SLG)

Fig. 3.3.2

Set parallel with set screw M23


Fig. 3.3.3

Page 21

3.3.2. Setting Clamp Top


1.
2.
3.
4.
5.

Refer to Fig. 3.3.4 ~ Fig. 3.3.6.


Loosely attach Sheath-Clamp-Top to Sheath-Clamp-Base Unit with cap screw (M26).
Insert gauge block (t=0.2) between Sheath- Clamp-Top and Sheath-Clamp-Base Unit.
Insert gauge block (t=0.25) between Sheath- Clamp-Top and Set plate A.
Push Clamp-Top forward and tighten cap screw (M26, T=3, SLG).
Block gauge
(t = 0 . 2 5 )

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

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 (M26, WS2, SLG).

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).

Cap screw M38

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.

Set screw M46


with flat type

No space

Pay attention to pushing surface.

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 (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

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 M310
3. Apply pressure by pushing Z-Motor forward. Tighten Cap screw (M310, T=10, WS3, SLG).

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).

Cap screw M310


(T=10,WS3)
Liner(t=0.7)
(S1330M-04-18)

Pushing

Fig. 4.2.2

Fig. 4.2.3

Page 26

4.3. Installing Tube Heater


1.
2.
3.
4.
5.
6.

Refer to Fig. 4.3.1 for steps 2 ~ 3.


Attach Fan to Frame-Base with Pan screw (M2.614, T=1, SLG).
Wind the wire of the fan around the shaft of the base frame twice and insert this wire into the hole.
Insert Heater unit wiring into the same hole as the fan wire.
Attach Heater Unit to Frame-Base with Cap screw (M214,T=4, WS2, SLG)
Connect heater to PCB terminal CN29.
Phillips-head screw M2.614
(T=1, WS2.6, SLG)

Cap screw M214


(T=4, WS2, SLG)

Heater fan

Pushing

Base frame

Pan-head screw M2.614

Wind the wire for fan around this pin twice.

(T=1, WS2.6, SLG)

Front side

Fig. 4.3.1

Fig. 4.3.2

Page 27

4.4. Installing Wind Protector


1. Refer to Fig. 4.4.1
2. Attach Wind Protector and WP-Washer to Frame-Base with Cap screw (M24, T=3, SLG).

Wind Protector shaft

Cap screw M24


(T=3,SLG)

WP-Washer

Fig. 4.4.1

Page 28

4.5. Installing Power Unit Dock to Base-Frame


1. Refer to Fig. 4.5.1
2. Attach Power Unit Dock to Base-Frame with Cap screw (M36, T=7).
3. Attach the 2 GND wires with Cap screw (M36, T=10, WS3)
Fix the 2 GND wire.
Cap screw M36
(T=10, WS3)

Cap screw M36 (T=7)

(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

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


1.
2.
3.
4.
5.
6.

Refer to Fig. 4.6.1 for steps 2 ~ 7.


Place special tool (2.0mm short electrode: STOOL4080) into the V-groove.
Adjust the set plate position by positioning the center of set plate slit to the tip of the electrode.
Apply pressure by lightly pushing set plate toward sheath clamp base.
Attach set plate with Cap screw (M26, WS2, T= temporary).
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 (M26,
T=1, WS2, SLG). Repeat process for second Cap screw. Note - Remove excess screw-locking-glue
on the set plate.
7. Confirm the set plate position.
Adjusting direction
Pushing
2

Pushing

Arrange the center position

Fix these screws one by one

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 250m UV coating fiber into V-grooves. Note - Cleave length: 16mm
3. 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 Vgroove.
Optical fiber
Full attaching

High

Flat

Fig. 4.7.1

Low

80% attaching

OK

Page 30

4.8. Adjustment Fiber Clamp Position


1.
2.
3.
4.

Refer to Fig. 4.8.1 for steps 2 ~ 5.


Adjust the Fiber Clamp by positioning the Fiber Clamp over the center of the V-groove.
Attach Fiber clamp with Cap screw (M26, T= temporary, WS2).
Remove only one screw and apply screw- locking-glue to the thread of the screw. Tighten Cap
screw (M26, 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
Two cap screws
(M26, T=3, WS2, SLG)
Adjust the both sides.

V-Groove

Fiber clamp arm bracket

Fig. 4.8.1

Page 31

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).
Electrode center line

Fiber position center line of X

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

Fiber position center line of Y


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

Fig. 4.9.1

YL

Page 32

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: 16mm
3. Drive fiber past electrode using the ZL motor manually. Note - Dont 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 (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

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 screw
counterclockwise turn.
4. Prepare and load two 250m 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.
7.
8.
9.

Refer to Fig. 4.9.6.


Loosen vertical position Cap screws (M310, WS3).
Install 1.5mm block gauge between Kyoutou unit and Focus Adjuster.
Apply pressure by pressing Kyoutou unit onto Focus Adjuster. Tighten Cap screw (M310, T =
temporary) 1 first and cap screw (M310, 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 (M310, T=12) 1 first and Cap screw (M310, 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 (M310, 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
(M310, T=12) 1 first and Cap screw (M310, T=12) 2 second. Specification Y=376 10 line.
Note Target=366-376 line

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

Vertical position screws

Fig. 4.9.6

Focus-Adjuster

B
Horisontal position screws

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.

Page 36

4.9.4. Wind Protector Mirror Adjustment


1. Refer to Fig. 4.9.8.
2. Adjust Wind protector angle by turning set screw B (M23).
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 (M22, SLG)
Wind-Protector-Cover
(S1330M-01-14)

Setting screw A M22


(SLG)
Setting screw B M23

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

Cap screw M24


(T=3, SLG)

Fig. 4.9.8

Fig. 4.9.9

Page 37

4.10. Adjustment of XY Unit


4.10.1. Confirmation of XY adjustment condition
1.
2.
3.
4.

Refer to section 4.9.2. Confirm the CCD camera inclination.


Refer to Fig. 4.10.1. Confirm the parallel position of X and Y axes.
Execute Camera Position command in [Secret Menu].
Manually align X and Y axes motors until the difference between left and right fiber position
is less than 1.5 line.
Camera Position

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

(XL-XR) <= 1.5 line


(YL-YR) <= 1.5 line

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

You calculate shown below.


1) A = (ZL-XL) (ZL-XR) on ZL fiber
2) B = (ZL-YL) (ZL-YR) on ZL fiber
3) C = (ZR-XL) (ZR-XR) on ZR fiber
4) D = (ZR-YL) (ZR-YR) on ZR fiber

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

4.10.2. Confirmation of Swing-arm Travel


1. Prepare and load two 250m 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 m.
Camera Position
182.7

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

U: Top limit distance [m]


D: Bottom limit distance [m]

Page 40

4.11. Adjustment of Focus Motor LS-dogs Position


1.
2.
3.
4.
5.

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).

Focus & Electrode

Set screw M33 with


flat type (T=2)
Turn in the front.

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

4.12. Adjustment of Focus-Mechanical-Stoppers Position


1.
2.
3.
4.
5.
6.
7.

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

Insert "t" milimaters thick gauge between Focus-Arm-A and Focus-Arm-B.


And press Focus-Arm-B against this gauge.

Focus-Arm-B

Focus-Arm-A
Fix the state of pressing Focus-Stopper
against Focus-Arm-A.

SetScrew M46 with W point


(T=10, SLG)
Focus-mechanical -Stopper

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

4.13. Confirmation of Z Motor End Play


1. Refer to Fig. 4.13.1
2. 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.
Monitor Display
Camera Position
176.9

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.

Refer to Fig. 4.13.2.


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

Carbide plate

Set screw M33


with flat type (T=2)
Marking

Half rotation

0.1~ 0.4mm

3.2mm(Standard)
Fig. 4.13.2

Page 43

4.14. Install the Discharge Circuit


1.
2.
3.
4.

Connect discharge circuit wiring to PCB connector CN24.


Refer to section 3.2. Insert the discharge wires (anode and cathode) into the space between the
Mechanical base and the Base frame.
Refer to Fig. 4.14.1. Insert the discharge wires into the electrode holders and tighten set screw
(M22, T=1.5).
Attach discharge circuit to left side of Frame-Base with cap screw (M36, T=5, WS3, SLG).

Set screw M22, T=1.5

Insert the discharge wire into the holes


Fig. 4.14.1

Page 44

4.15. Installing Monitor


1.
2.

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

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
(M26, T=3). Note The CCD and Monitor cables should pass through the connector box hook the
two FPCs of the keypad as Illustrated.
Top view
Right side - back view
FPC of Key Pad
Hook2

(2) Insert Monitor


cable in Hook2.

Pillar

(1) Insert CCD


camera cable (Y)
in Hook2.

Hook1
Hook2
Video out

(4) Attach the Connector


box to Base frame.

CCD (Y)

(6) Insert ZR cable


in Hook3.

CCD (X)

Connector Box

C-Box

(3) Set CCD camera cable (X)


and Connector box cables
in front of Hook 1.

ZR

Hook3

(5) Insert CCD camera


cable (X) in 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

4.17. Installing Panel


Set Front Cover and Rear Cover to Base Frame with Pan-head screw (M36, T=7). Set Camera
Cover to Rear Cover with Pan-head screw (M36, T=7).
Pan-head screw M36 (T=7)
for Camera Cover

(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

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

Thermo spot sensor*

Thermo spot sensor*


(display part)

Splicer

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

Fig. 4.18.1

The tool for fixing the thermo spot sensor

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.

Adjust Temparature 250 deg


A/D 250 deg = 80 bit

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.

Max. temperature is between 248 and 250C.

Heat
Temp erature

Adjusting point for cool finish temperature


must be between 100 and 105C.

Note: It is only one chance to check it. When the


temperature is out of specification, a re-adjustment
for AD100 is required. And, execute the program
from the first step.

60 seconds

30 sec.

Heat Time

Heat temp. adjustment must be done in this period.

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

Adjust Temparature 100 deg


A/D 100 deg = 220 bit

Fig. 4.18.7

Page 51

4.19. Splice Test


4.19.1. Estimate Check
1.
2.
3.
4.
5.

Enter the Main Menu.


Set the splice mode to Standard SM Auto.
Prepare and load two 250m SM fibers into splicer.
Refer to section 2.4.1. Execute the Estimate Test in Secret Menu.
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 BGB=101 99


LED =166 167

X 0.234
Y 0.229

ECC-X:0.06 0.02 0.04


Y: 0.19 0.28 0.09
XY: 0.20 0.28 0.10

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

4.19.2. Stuff Check


1.
2.
3.
4.
5.

Prepare and load two 250m SM fibers into splicer.


Refer to section 2.4.1. Execute Stuff Check in the [Secret Menu]
The result of stuff check is displayed on the monitor. Specification: 305 m.
If this value is no good, adjust the stuff speed by pushing Up or Down cursor key.
Repeat steps 1 ~ 3.

4.19.3. Arc Calibration


1.
2.
3.
4.
5.

Refer to the instruction manual.


Execute Arc Calibration mode in the main menu.
If Test again appears on the monitor after executing arc calibration mode, repeat until Test
again message does not appear.
If Arc Calibration is attempted 10 times with poor results. Execute Replace Electrode mode
without changing the electrodes.
Repeat Arc Calibration.

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

6.1.2. Removal of PCB


1. Refer to section 5. Remove all connectors from Main PCB. Note Remove screw that holds black
cathode cable to Frame-Base.
2. Refer to section 4.6. Remove Power Unit Dock from Frame-Base
3. 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 posts

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

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. This
may be view through the peephole as illustrated.
Left side view of PCB

Battery Frame

Peephole of wiring corfirm

Fig. 6.1.4
Cap screw (M36, T=5)

Main P.C.B.

Shield Plate

Spacer (M3, WS3, SLG)


SLG paints only screw head.

Cap screw (M36, 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.

Page 56

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.
2.
3.
4.
5.

Confirm software version is > 01.06.


Measure voltage of ADC-07 with ohmmeter and record measured voltage.
Insert ADC-07 AC adapter into the power unit dock until it clicks into place.
Refer to 2.4.1. Turn on the splicer and select the Voltage Adjustment in the [Secret Menu]
Refer to Fig. 6.1.5. Adjust Input Voltage to match recorded measured voltage by pressing <s> or
<t> key and input output AC voltage
6. Press <ENT> key.

Fig. 6.1.5
Note: The splicer automatically adjusts the value of voltage sensor. Adjusted value appears on the
screen.

Page 57

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.
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

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 FilesSY012 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 ) 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

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

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.

How to install VBMan

Copy 40S-PC E03 ZIP file to PC directory (example C:programs40Sdownload


Un-zip contents of file into same PC directory
Double click setuo03.bat file to install VBMan

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.

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 = 19200
Data bits = 8
Parity = none
Stop bits = 1
Flow control = none

Note: The EXCEL program automatically configures the COM port.


Confirm communication between PC and Splicer

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.

7.1. ERROR 01 Too Long Fiber


01-01 Left fiber is too long
01-02 Right fiber is too long
01-03 Both left and right fibers are too long.
Reason1: Improper loading
Reason2: 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 loading
Reason2: Micro-dust
Reason2: Mechanical adjustment (mirror or kyo utou).
Reason3: LED or wiring damaged.
02-11 X image brightness is zero
02-12 Y image brightness is zero
Reason1: CCD camera is damaged
Reason2: CPU Board is damaged
Reason3: LED connector is out of place
Reason4: LED wire is damaged
Reason5: LED is damaged

7.3. ERROR 03 Fiber too Dusty


03-01 Image processor cannot find fiber on the X image
03-02 Image processor cannot find fiber on the Y image
Reason1: Micro-dust
Reason2: cleaning arc weak (especially true for carbon coated fiber)
Reason3: Wrong fiber mode

Page 62

7.4. ERROR 04 Motor Overrun


04-01
04-02
04-11
04-12
04-21
04-22
04-31
04-32
04-41
04-42
04-51
04-52

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.

7.5. ERROR 05 Close Cover


Reason: Cover is opened

7.6. ERROR 06 Cover Opened Error


Reason1: Connector terminal damaged or not connected
Reason2: Cover magnet missing or position wrong
Reason3: Main PCB is damaged

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

7.7. ERROR 07 Motor Trouble


04-01
04-02
04-03
04-04
04-05
04-06

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.

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 electrodes
Reason2: Electrode mechanical adjustment

Page 64

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 after
discharge.
To diagnose error: Check the AD converter value using Sensor Value in Utility Menu. Exampleif pressure sensor is broken or connector J07 is not connected, CPU judges pressure to be very low
during 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 Fiber
11-02 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 LEDs 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.

Page 65

7.13. Heater Trouble


Heater Error occurs when temperature of heater does not increase to Heater Temp of Heater Mode
Menu 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 connected
Reason2: Thermister of heater damaged
Reason3: Heater PCB damaged.
Reason4: Broken lead between heater element and PCB
Reason5: 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 25C and 300k ohm at 30degrees. Check for broken lead or replace
heater element if necessary.
4. Measure voltage between pins No1 and No2 of CN29 after pressing [HEAT] key. Typical voltage is
12V. Check power supply output or replace main PCB if necessary.

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

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


Item No.
STOOL
STOOL
STOOL
STOOL
STOOL

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