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MAINTENANCE MANUAL
FSM–40S
LEVEL 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 Menu’s and Secret Key Functions ..................................12
§ 2.4.1. “Secret” Menu.....................................................................................................................12
§ 2.4.2. Password..............................................................................................................................14
§ 2.4.3. Total Initialization of all data (Emergency only) ................................................................14
§ 3. Mechanical Assembly ................................................................................ 15
§ 3.1. Focus/Camera Assembly ............................................................................15
§ 3.1.1. Camera Assembly................................................................................................................15
§ 3.2. Electrode Unit Assembly ............................................................................17
§ 3.3. Z-Axis Unit Assembly.................................................................................19
§ 3.3.1. Z-Axis Unit Assembly.........................................................................................................19
§ 3.3.1.1 Sheath Clamp Top........................................................................................................19
§ 3.3.1.2 Fiber Clamp Arm.........................................................................................................20
§ 3.3.2. Setting Clamp Top...............................................................................................................21
§ 4. Mechanical Adjustment ............................................................................ 22
§ 4.1. Installing Focus Unit ..................................................................................22
§ 4.2. Installing Z-Unit.........................................................................................25
§ 4.3. Installing Tube Heater................................................................................26
§ 4.4. Installing Wind Protector...........................................................................27
§ 4.5. Installing Power Unit Dock to Base-Frame ................................................28
§ 4.6. Adjusting the Set-Plate Position to the V-groove .......................................29
§ 4.7. Adjusting Z-Clamp Unit Height.................................................................29
§ 4.8. Adjustment Fiber Clamp Position .............................................................30
§ 4.9. Adjusting Display Image............................................................................31
§ 4.9.1. Rough Adjusting Display Image .........................................................................................31
§ 4.9.2. Adjusting Camera Inclination.............................................................................................32
§ 4.9.3. Image Alignment.................................................................................................................34
§ 4.9.4. Wind Protector Mirror Adjustment .....................................................................................36
§ 4.10. Adjustment of XY Unit.............................................................................37
§ 4.10.1. Confirmation of XY adjustment condition........................................................................37
§ 4.10.2. Confirmation of Swing-arm Travel...................................................................................39
§ 4.11. Adjustment of Focus Motor LS-dog’s Position.........................................40
§ 4.12. Adjustment of Focus-Mechanical-Stopper’s Position ..............................41
§ 4.13. Confirmation of Z Motor End Play..........................................................42
Page 3
§ 1. Introduction
This manual describes the mechanical assembly, adjustment, and maintenance of Fujikura’s 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.
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 splicer’s 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.
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.
§ 2.2. Abbreviations
Cap screw: Hexagon Socket Head Cap Screw
Set screw: Hexagon Socket Set Screw
WS2: Small Circular Washer of 2 mm in nominal diameter
WF2: Finished Circular Washer of 2 mm in nominal diameter
Phillips-head screw: Cross Recessed Phillips-head Screw
Countersunk screw: Cross Recessed Counters ink head Screw
Pan-head screw: Cross Recessed Pan-head Screw
T=20: Tightening Torque is 20kgf·cm. (1kgf·cm = 9.80N·cm)
SLG: Screw Locking Glue
MENU ON
/OFF
HELP ARC X/Y
RESET HEAT
†EXIT‡ key †ENT‡ key †RESET‡ key †SET‡ key †HEAT‡ key
Fig.2.3.1
<ON/OFF> key • • • Turns power on and off. To turn off power, press and hold key untill the 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
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
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
Secret Menu 1/5 Corner Check – Background brightness indicator.
Corner Check Camera Position - Use when aligning camera mechanical position.
Camera Position
Focus & Electrode
Focus & Electrode – Use when adjusting focus and position of
Estimate Test electrodes.
Stuff Check
Config Code Disp
Estimate Test – Estimation confirmation test.
Config Code Input Stuff Check – Checks stuff amount. Specification = 30±5.
st+ENT:Select
:Change Page Config Code Disp. - “Config Code” includes many calibration
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
Page 2 of 5
Heater Adjustment – Use when calibrating heater unit
Secret Menu 2/5
Heat AD-250/100 – Result of Heater Adjustment
Heater Adjustment
Heat AD-250 80bit Voltage Adjustment – Use when calibrating voltage value
Heat AD-100 230bit AD-12V – Result of Voltage Adjustment
Voltage Adjustment
AD-12V 152bit
st+ENT:Select
:Change Page
EXIT:Exit
Page 3 of 5
Secret Menu 3/5
Splice Database Init. - Initializes splice database area and the
Splice Database Init
database area to the condition when shipped . When database area
Splice Mode Init.
is upgraded, perform this command.
Heater Mode Init.
Splice Mode Init. - Initializes all arc parameters of all 100 splice
Utility Init.
modes in both the user programmable area and the database area to
the condition when shipped from the factory. The splicer software
st+ENT:Select on the ROM chip contains these initial parameters
:Change Page
EXIT:Exit Heater Mode Init. - Initializes all heater parameters of all 40
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.
Page 13
Page 4 of 5
Secret Menu 4/5
Page 5 of 5
Secret Menu 5/5
Focus Home Adjustment Focus Home Adjustment – Use when calibrating “Focus Home
FCS Home X 1500ms Position”
FCS Home Y 1600ms
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
st +ENT:Select
:Change Page
menu.
EXIT:Exit
7 6 5 4 3 2 1 0
S0 MENU UP DOWN LEFT RIGHT ENT EXIT
S1 HELP SET ARC X/Y L-FoXR L-FoXF L-XR L-XF
S2 L-ZRR L-ZRF L-ZLR L-ZLF L-FoYF L-FoYR L-YR L-YF
IN2 COVER L-TEMP H-Temp3 H-Temp2 H-Temp1 HEAT RESET
IN4 Magnet2 Magnet1
AD Voltage Pressure Temp Humid Heater3 Heater2 Heater1
§ 2.4.2. Password
Factory password to enter “Configurations” is “ARUKIJUF”. Note - After entering “Secret Mode”,
password is no longer required.
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. Refer to Fig. 3.1.1 for steps 2 ~ 4.
2. Attached Kyoutou-Mirror onto Kyoutou with cap screw (M2×6, T=2, SLG).
3. Insert 0.3mm thick Lens-Liner between Lens and Kyoutou. Screw Lens in Kyoutou.
4. Insert CCD-Adapter with CCD-Camera into Kyoutou, and attach with set screw (M3×3, T=2).
Note-Pay attention the direction of installation CCD-Adapter for X and Y positions (Refer to Fig.
3.1.2).
Not reverse
Fig. 3.1.1
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 (M3×10, T= temporary, WS3)
7. Attach Focus Arm Joint Plate on Kyoutou with cap screw (M3×10, T= temporary, WS3)
Focus Adjuster
(S1330M-03-12)
Fig. 3.1.3
Page 17
Refer to Fig. 3.2.1. The electrode unit consists of the electrode unit, electrode, and LED. Phillips-head
screw (M2×8, 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.
Nut M2
LED Holder
(S1330M-01-10) Electrode Base
(S1330M-01-01)
Nut M2
LED (KR5004X)
Fig. 3.2.1
Page 18
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 (M2×8, T=2)
Pushing
Fig. 3.2.3
Page 19
Magnet-Catcher(Front)„
(S1330M-04-05)
Magnet-Catcher(Rear)…
Hinge ‚
(S1330M-04-05)
Fiber-Pusherƒ
(S1330R-24)
Sheath Clamp Spring†
(S1330M-04-07)
Sheath Clamp•
(S1330R-22)
Super-Shaft h7-1518
Fig. 3.3.1
Page 20
Clamp-Arm (right) •
(S1330R-26)
Clamp-Arm-Bracket ‚
(S1330M-04-11)
Fig. 3.3.2
Pushing to
Hinge side
Block gauge
Fig. 3.3.4 (t=0.2)
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 (M3×8 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 (M3×10, WS3, T=12)
using illustrated toque sequence.
Pushing Pushing
Fig. 4.1.2
No space No space
Pushing
Pushing
3 1
4 2
Fig. 4.1.3
Page 23
***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 M4×6
with flat type
No space
Fig. 4.1.4
7. Refer to Fig. 4.1.5. Attach Focus Arms to Focus Arm Joint Plate with cap screw (M3×10, T=12,
WS3) using illustrated torque sequence.
No space
Pushing
Pushing
1 2
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 (M3×10, T=12)
using illustrated toque sequence.
Pushing
1 2
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 (M3×10, T=10, WS3).
Liner(t=0.7)
(S1330M-04-18)
Pushing
Pushing
Heater fan Base frame
Pan-head screw M2.6×14
(T=1, WS2.6, SLG)
Wind the wire for fan around this pin twice.
Front side
Fig. 4.3.1 Fig. 4.3.2
Page 27
WP-Washer
Fig. 4.4.1
Page 28
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;
Pushing
φ2
Fig. 4.6.1
Fig. 4.7.1
Page 30
Fiber-Clamp
Fig. 4.8.1
Page 31
1. Adjust that display image looks like Fig. 4.9.1 (Refer to Section 4.9.3).
Camera Position
XL 176.9 177.0 XR
198.7 198.8
219.3 X 219.4
ZL
Y 258.0
257.5
277.9 278.4
YR 300.1 300.6 YL
Fig. 4.9.1
Page 32
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 - Don’t overrun ZL-Motor.
Fig. 4.9.2
Set screw
(M3×10, T=2)
Fig. 4.9.3
Page 33
YL YR
Fig. 4.9.4
Page 34
Fig. 4.9.5
21. Adjust right side fiber end-face in the “X” view by moving the Focus-Adjuster. Tighten Cap screw
(M3×10, T=12) “1” first and Cap screw (M3x10, T=12) “2” second. Specification (Y-X) ± 10 line.
Note – Target = (Y-X) = 0 ~10 line.
Block gauge
Fig. 4.9.6
Focus-Adjuster
Fig. 4.9.7
Wind-Protector-Cover
(S1330M-01-14)
Wind-Protector-Mirror
Super-Shaft h7-1522
(S1330R-03)
Wind-Protector Spring No.1043
(S1330R-02) Plate
Magnet
Wind-Protector-Shaft
(S1330M-01-11)
Cap screw M2×6
(T=3,WF2)
Cap screw M2×4 READY
(T=3, SLG)
Make about same width.
X
Fig. 4.9.8
Fig. 4.9.9
Page 37
Camera Position
XL 176.9 177.0 XR
198.7 198.8
219.3 X 219.4
ZL
257.5 Y 258.0
277.9 278.4
YR 300.1 300.6 YL
Fig. 4.10.1
Page 38
5. Use left sheath clamp, set the 250µm UV coating fiber into V-grooves. Note – Cleave length:
16mm.
6. Drive fiber past electrode using the ZL motor manually. Note – Don’t overrun ZL-Motor.
7. Record values (ZL-XL), (ZL-XR), (ZL-YL), (ZL-YR). Refer to Fig. 4.10.2.
8. Use right sheath clamp, set the 250µm UV coating fiber into V-grooves. Note – Cleave length:
16mm.
9. Drive fiber past electrode using the ZR motor manually. Note – Don’t overrun ZR-Motor.
10. Record values (ZR-XL), (ZR-XR), (ZR-YL), (ZR-YR). Refer to Fig. 4.10.2.
Fig. 4.10.2
ZL ZR Difference Standard
X A C (A-C) (A-C)<= 1.5 line
Y B D (B-D) (B-D)<= 1.5line
Page 39
Camera Position
182.7 97.2
278.5 193.0
8
374.2 X 299.2
Y
94.6 94.1
190.2 190.0
285.9 285.8
Camera Position
Fig. 4.10.3
Page 40
More than
3/4 rotation
More than
376
“A” 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
Focus-Arm-A Focus-Arm-B
Focus-Arm-A Focus-Arm-B
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
Monitor Display
Camera Position
176.9 177.0
198.7 198.8
219.3 X 219.4
Y 258.0
257.5
277.9 278.4
300.1 300.6
Fig. 4.13.1
Half rotation
Fig. 4.14.1
Page 44
Monitor Frame
Hook for
Monitor Cord LCD Monitor
(Back view)
Fig. 4.15.1
3. Refer to Fig. 4.15.2. Attach Monitor-Unit to Base Frame with Pan-head screw M3×14 (T=10, WF3
outside diameter φ8, SLG).
(S1330R-28)
Fig. 4.15.2
Page 45
Video out
(4) Attach the Connector
CCD (Y) box to Base frame.
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
(S1330R-36)
Fig. 4.16.2
Page 46
(S1330M-07-08)
(S1330M-07-07)
Fig. 4.17.1
Note: There is no need to remove the screw that attaches the Camera Cover.
Page 47
Refer to Fig. 4.18.1 and Fig. 4.18.2. Set the thermo spot sensor on the splicer.
Set the tool for fixing the thermo spot sensor on the corner
Fig. 4.18.1
Base frame The tool for fixing the thermo spot sensor
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.
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.
Radiator plate
Heat Sinker
(Shin-etsu Chemical Co. Ltd. Oil Compound KS-609
Fig. 4.18.4
Page 49
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 ~ 250ºC.
5. Press “ENT” key.
Fig. 4.18.6
6. Refer to Fig. 4.18.7. Adjust “100ºC” A/D bit value up or down while checking temperature sensor
output. Specification = temperature 100 ~ 105ºC. 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
Fig. 4.18.7
Page 51
5:SM 1:60mm
Fig. 4.19.1
Page 52
§ 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 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
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
Fig. 6.1.3
Page 55
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
Fig. 6.1.4
Shield Plate
Fig. 8.2.5
To operate the battery indicator correctly, it is necessary to adjust the sensor value of splicer.
Procedure
Fig. 6.1.5
Note: The splicer automatically adjusts the value of voltage sensor. Adjusted value appears on the
screen.
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Procedure
1. Turn the splicer power off. Disconnect the power source from the splicer.
2. Refer to section 4.17. Remove cover panels.
3. Connect the ROM Download Extension Cable between CPU Board and ROM Download PCB.
4. Install the New ROM into the Download PCB. Caution: Install ROM correctly.
5. Connect power source to splicer.
6. Push the “ON” key. The ROM download Menu will appear.
7. Select “OK”. Download is initiated. Wait until download is completed.
8. Confirm the software version by power on menu or Maintenance Information.
Fig. 6.2.1
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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”.
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1. Computer Requirements
• PC/AT Compatible
• Operating System – Microsoft Windows® NT, Windows® 98/95
• Program – Microsoft EXCEL® 97/2000
Note: RS232 cables have multiple configurations, checked new cable for continuity based on the above
schematic.
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.
§ 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.
Reason1: Micro-dust
Reason2: cleaning arc weak (especially true for carbon coated fiber)
Reason3: Wrong fiber mode
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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, don’t 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.
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Note: Error appears when the Motor’s 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.
Note: Fiber type is judged only to SM. DS, or MM when using AUTO MODE.
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”. Example-
if 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.
Notification of alarm: LED [HEAT] key will flash on and off and buzzer sounds in rhythm with flash.
Turn off by pressing [HEAT] key.
§ 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 M3×6
7 Remove the monitor. Pan head M3×14 with big washer
8 Remove the Connector Box. Countersink M2×6 (steel)
9 Remove the LED cover.
10 Remove the Discharge Power Supply. Cap M3×6 with small washer
11 Remove the Electrode. Phillips-head M2×8
12 Remove the 4 focus bearing holders. Set screw M4×6
13 Re-attach the focus arms joint plate (Cap M3×8)
14 Attach the focus bearing holders (4 pc.) Set M4×6, 150N-cm
Notice: It cannot use that the surface of the focus bearing holder to have used once.
15 Attach the battery cover of the main P.C.B.
16 Turn the splicer power on.
17 Version up the latest ROM. ROM Ver.
18 Adjust the display position
Note: The display position must adjust after you confirm the center of X and Y fibers adjust.
The target value of adjustment of fiber position: X = 285line, Y = 195 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 M2×8, 20N-cm
23 Attach the Discharge Power Supply cap M3×6 with small washer, 50N-cm
24 Attach the LED Cover.
25 Attach the Monitor. pan head M3×14 with big washer, 100N-cm, SLG
26 Attach the Connector Box Countersink M2×6(steel), 30N·cm
27 Attach the cover of the back side and front one Pan-head M3×6, 70N·cm
28 Turn the splicer power on. ---> Next splice check.
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