Fujikura FSM–40S Maintenance Manual
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Fujikura FSM–40S Maintenance Manual

Fujikura FSM–40S Maintenance Manual

Arc fusion splicer
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KSP75-0086-51-02 (3)
MAINTENANCE MANUAL
ARC FUSION SPLICER
FSM–40S
LEVEL 2
Fujikura Proprietary Document
No part of this document may be transferred to any third party
without prior written consent from Fujikura Ltd.

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  • Page 1 KSP75-0086-51-02 (3) MAINTENANCE MANUAL ARC FUSION SPLICER FSM–40S 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

    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 §...
  • Page 3 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 §...

  • Page 4: Introduction

    Page 4 § 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,...

  • Page 5: Notes To Users

    • 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.
  • Page 6 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 splicer’s electrical arc in such an environment.
  • Page 7 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.
  • Page 8 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.

  • Page 9: Abbreviations

    Page 9 § 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...

  • Page 10: Basics And Preparations

    Page 10 § 2.3.2. Basics and Preparations Name of keys – Refer to Fig. 2.3.1. †ON/OFF‡ key †MENU‡ key † ‡† ‡† ‡† ‡ key †HELP‡ key †ARC‡ key †X/Y‡ key MENU HELP RESET HEAT EXIT †EXIT‡ key †ENT‡ key †RESET‡...

  • Page 11: Cleaning And Checking Before Adjustment

    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: Accessing Secret Menu's And Secret Key Functions

    Page 12 § 2.4. Accessing Secret Menu’s and Secret Key Functions § 2.4.1. “Secret” Menu At “READY”, press UP, DOWN and MENU at the same time. Secret Menu consists of 4 pages. Using Secret Menu, software version needs to be later than V01.09. Page 1 of 5 Corner Check –...
  • Page 13 Page 13 Page 4 of 5 Secret Menu Arc Count Input - Edits Arc Count Arc Count Input Total Arc Count Input - Edits Total Arc Count Total Arc Count Input True AP1 True AP1, AP2, AP3, and Gap Center - Result of “ARC True AP2 CALIBRATION”...

  • Page 14: Password

    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”...

  • Page 15: Mechanical Assembly

    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.
  • Page 16 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) Cap screw M3×10 (WS3) Cap screw M3×10...

  • Page 17: Electrode Unit Assembly

    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 (M2×8, T=2) is used with the anode electrode holder and the cathode electrode holder to secure the electrodes.
  • Page 18 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 (M2×8, T=2) and nut (M2). Pushing Hanging Fig.

  • Page 19: Z-Axis Unit Assembly

    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. Sheath Clamp Top § 3.3.1.1 1. Refer to Fig. 3.3.1. 2. Insert Super-Shaft (h7-1518) through Sheath- Clamp • and Hinge‚. 3.

  • Page 20: Fiber Clamp Arm

    Page 20 Fiber Clamp Arm § 3.3.1.2 Note - Fiber-Clamp-Arm, Right side illustrated. 1. Refer to Fig. 3.3.2. 2. Insert Clamp-Arm- Shaftƒ through Clamp-Arm (right)• and Clamp-Arm-Bracket‚. 3. Attach Clamp-Arm- Shaftƒ to Clamp-Arm (right) with set screw (M2×2 with flat type T=1.5). Note - position axes pin chamfer to align with set screw (M2×2).

  • Page 21: Setting Clamp Top

    Page 21 § 3.3.2. Setting Clamp Top 1. Refer to Fig. 3.3.4 ~ Fig. 3.3.6. 2. Loosely attach Sheath-Clamp-Top to Sheath-Clamp-Base Unit with cap screw (M2×6). 3. Insert gauge block (t=0.2) between Sheath- Clamp-Top and Sheath-Clamp-Base Unit. 4. Insert gauge block (t=0.25) between Sheath- Clamp-Top and Set plate A. 5.

  • Page 22: Mechanical Adjustment

    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.
  • Page 23 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 (M4×6). 6.
  • Page 24 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.

  • Page 25: Installing Z-Unit

    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 M3×10 3. Apply pressure by pushing Z-Motor forward. Tighten Cap screw (M3×10, T=10, WS3, SLG). Pushing Fig.

  • Page 26: Installing Tube Heater

    Page 26 § 4.3. Installing Tube Heater 1. Refer to Fig. 4.3.1 for steps 2 ~ 3. 2. Attach Fan to Frame-Base with Pan screw (M2.6×14, T=1, SLG). 3. Wind the wire of the fan around the shaft of the base frame twice and insert this wire into the hole. 4.

  • Page 27: Installing Wind Protector

    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 (M2×4, T=3, SLG). Cap screw M2×4 (T=3,SLG) Wind Protector shaft WP-Washer Fig. 4.4.1...

  • Page 28: Installing Power Unit Dock To Base-Frame

    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.

  • Page 29: Adjusting The Set-Plate Position To The V-Groove

    Page 29 § 4.6. Adjusting the Set-Plate Position to the V-groove 1. Refer to Fig. 4.6.1 for steps 2 ~ 7. 2. Place special tool (φ2.0mm short electrode: STOOL4080) into the V-groove. 3. Adjust the set plate position by positioning the center of set plate slit to the tip of the electrode. 4.

  • Page 30: Adjustment Fiber Clamp Position

    Page 30 § 4.8. Adjustment Fiber Clamp Position 1. Refer to Fig. 4.8.1 for steps 2 ~ 5. 2. Adjust the Fiber Clamp by positioning the Fiber Clamp over the center of the V-groove. 3. Attach Fiber clamp with Cap screw (M2×6, T= temporary, WS2). 4.

  • Page 31: Adjusting Display Image

    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 177.0 176.9 198.8 198.7 219.4 219.3...

  • Page 32: Adjusting Camera Inclination

    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.
  • Page 33 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 (M3×3, T=2, flat type) which attaches “X” CCD-Camera Unit.

  • Page 34: Image Alignment

    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.
  • Page 35 Page 35 21. Adjust right side fiber end-face in the “X” view by moving the Focus-Adjuster. Tighten Cap screw (M3×10, T=12) “1” first and Cap screw (M3x10, T=12) “2” second. Specification (Y-X) ± 10 line. Note – Target = (Y-X) = 0 ~10 line. Block gauge Vertical position screws Fig.

  • Page 36: Wind Protector Mirror Adjustment

    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 (M2×3). 3. Refer to Fig. 4.9.9. Using Focus motor, adjust fiber image (both X and Y-axis) so that the outside black bands are equal in width.

  • Page 37: Adjustment Of Xy Unit

    Page 37 § 4.10. Adjustment of XY Unit § 4.10.1. Confirmation of XY adjustment condition 1. Refer to section 4.9.2. Confirm the CCD camera inclination. 2. Refer to Fig. 4.10.1. Confirm the parallel position of X and Y axes. 3. Execute “Camera Position” command in [Secret Menu]. 4.
  • Page 38 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.

  • Page 39: Confirmation Of Swing-Arm Travel

    Page 39 § 4.10.2. Confirmation of Swing-arm Travel 1. Prepare and load two 250µm fibers into splicer. 2. Refer to Fig. 4.10.3. Execute “Camera Position” command in [Secret Menu] and push “SET” key. Note: X and Y motors automatically move to there outer limits at which time they are measured. 3.

  • Page 40: Adjustment Of Focus Motor Ls-Dog's Position

    Page 40 § 4.11. Adjustment of Focus Motor LS-dog’s Position 1. Prepare 250µm fiber with 30mm strip section and load into both V-groove s. 2. Refer to “Secret” Menu, execute “Focus & Electrode” command in [Secret Menu]. 3. Refer to Fig. 4.11.1 for steps 4 ~ 6. Pushing “SET”...

  • Page 41: Adjustment Of Focus-Mechanical-Stopper's Position

    Page 41 § 4.12. Adjustment of Focus-Mechanical-Stopper’s Position 1. Prepare 250µm fiber with 30mm strip section and load into both V-groove s. 2. Using Focus Motor, manually adjust focal point to produce sharp fiber core image. 3. Refer to Fig. 4.13.1. 4.

  • Page 42: Confirmation Of Z Motor End Play

    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 177.0...

  • Page 43: Install The Discharge Circuit

    Page 43 § 4.14. Install the Discharge Circuit 1. Connect discharge circuit wiring to PCB connector CN24. 2. Refer to section 3.2. Insert the discharge wires (anode and cathode) into the space between the Mechanical base and the Base frame. 3.

  • Page 44: Installing Monitor

    Page 44 § 4.15. Installing Monitor 1. Refer to Fig. 4.15.1. Attach the LCD monitor to the monitor frame with countersink screws (M3×6, T=6). Note – Route monitor cable through hook for monitor code. 2. Monitor cable length from Monitor Bracket to end of Monitor connector (J14) should be 90mm. Countersink screw M3×6 (T=6) Confirm this length.

  • Page 45: Installing Connector Box

    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 (M2×6, T=3). Note – The CCD and Monitor cables should pass through the connector box hook the two FPCs of the keypad as Illustrated.

  • Page 46: Installing Panel

    Page 46 § 4.17. Installing Panel Set Front Cover and Rear Cover to Base Frame with Pan-head screw (M3×6, T=7). Set Camera Cover to Rear Cover with Pan-head screw (M3×6, T=7). Pan-head screw M3×6 (T=7) for Camera Cover (S1330M-07-08) Pan-head screw M3×6 (T=7) (S1330M-07-07) Fig.

  • Page 47: Tube Heater Adjustment

    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.
  • Page 48 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.
  • Page 49 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.
  • Page 50 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.

  • Page 51: Splice Test

    Page 51 § 4.19. Splice Test § 4.19.1. Estimate Check 1. Enter the “Main Menu”. 2. Set the splice mode to “Standard SM” Auto. 3. Prepare and load two 250µm SM fibers into splicer. 4. Refer to section 2.4.1. Execute the “Estimate Test” in “Secret Menu”. 5.

  • Page 52: Stuff Check

    Page 52 § 4.19.2. Stuff Check 1. Prepare and load two 250µm SM fibers into splicer. 2. Refer to section 2.4.1. Execute “Stuff Check” in the [Secret Menu] 3. The result of stuff check is displayed on the monitor. Specification: 30±5 µm. 4.

  • Page 53: Electrical

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

  • Page 54: How To

    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”...

  • Page 55: Installation Of Pcb

    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.

  • Page 56: Adjusting Voltage Indicator For 40S

    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. Confirm software version is > 01.06. 2.

  • Page 57: Software Upgrade

    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. Turn the splicer power off. Disconnect the power source from the splicer. 2.

  • Page 58: Software Upgrade With Rs-232C Cable

    Page 58 § 6.2.2. Software Upgrade with RS-232C cable Install of PCUG software § 6.2.2.1 Before using PCUG, install as follows: 1) Click “SETUP.EXE” 2) Select folder to install. Default is “C:¥Program Files¥SY012 ROM Upgrade”. Do not change the folder, except for special reason. 3) Click “Computer Mark ICON”.

  • Page 59: Data Download Software With Rs-232C

    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 D-Sub 9pin D-Sub 9pin •...
  • Page 60 Page 60 Note: The above procedure installs VBMan which is the control software for RS232 (COM) port. If your PC has other RS232 software installed, VBMan may not be able to configure the COM port. In such a case, UN-install software or use another PC. 4.

  • Page 61: Trouble Shooting

    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.

  • Page 62: Error 04 Motor Overrun

    Page 62 § 7.4. ERROR 04 Motor Overrun 04-01 ZL Motor forward 04-02 ZL Motor backward 04-11 ZR Motor forward 04-12 ZR Motor backward 04-21 X Motor forward 04-22 X Motor backward 04-31 Y Motor forward 04-32 Y Motor backward 04-41 Focus X Motor forward 04-42 Focus X Motor backward 04-51 Focus Y Motor forward...

  • Page 63: Error 07 Motor Trouble

    Page 63 § 7.7. ERROR 07 Motor Trouble 04-01 ZL Motor 04-02 ZR Motor 04-03 X Motor 04-04 Y Motor 04-05 Focus X 04-06 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 Motor’s LS dog does not strike the limit switch in the predetermine duration of time.

  • Page 64: Error 10 Fiber Separate Error

    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”...

  • Page 65: Heater Trouble

    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.

  • Page 66: Appendices

    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 difference -1.5<=(ZL-ZR)<=+1.5 X...

  • Page 67: List Of The Necessary Tools For Fsm-40S Adjustment

    Page 67 § 8.2. List of the necessary tools for FSM-40S adjustment Item No. Description Design No. Q’ty Per Unit STOOL 4040 Heater Adjustment Device S8612M-05-ASSY STOOL 4050 Wind Protector Protection Device S8612M-06-ASSY STOOL 4060 Z Unit Standby Device S8612M-07-ASSY STOOL 4080 Z-axis Centering Device S8612M-09-ASSY STOOL 4100 Display Adjustment Device...

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