Service Manual

Chart Projector CCP-7000

1
 1. GENERAL

1-1 How to use the manual

Use this manual in accordance with the following flowchart at the time of initial inspection or when inspection,
adjustment or repair are needed to correct problems:

Manual
Operation sequence
Reference Page

Occurrence of
Initial Inspection
a problem

OK
Inspection Inspection/adjustment P. 8

NO

Identifying the location of problem

Disassembly/reassembly P. 10
Locating the cause of problem
Troubleshooting P. 30

Disassembly/reassembly P. 10
Implementation of repair
Assembly adjusting procedure P. 10

Inspection Inspection/adjustment procedures P. 8

NO
Normal

YES

End

2
 2. PRODUCT OUTLINE

2-1 Optical system (Layout Drawing)

2-1-1 Position of Chart Projector

The single tube projector must be installed at the same distance from
the screen as the patient.

[Fig. 3 Installation without mirrors]

Install chart projector at desired position within 2.5~8m (8~26 feet).

Set the projection angle of chart processor based on Screen.
Project 0.05(20/400, 6/120) “C” chart onto the screen.
Adjust it for a bright clear image using the focusing wheel.

2-1-2 How to obtain correct Letter Size and focus (Zooming Type only)

Install chart projector at desired position of 2.5~8m (8~26 feet)

Measure the distance from patient to screen
Refer to the test scale shown in the Appendix A

3
 Have someone hold the test scale at the screen
Project the 20/400(6/120, 0.05) alphabet “C”
Adjust the position of the projector forward or backward and turn the focusing
wheel until “C” is brought in sharp focus within the respective distance scale

2-2 Electrical Construction Diagram

CDR-3100 OP
SERIAL PORT
(OPTION)

1
2
3

1
2
1
2
3

1
2
1 1 1 1
Tx Rx GND Tx Rx

2 Vcc 3
2 2 2 2
CHART PI MOTOR
V0 4 3 3 Vcc 3 3
ASSY 1 GND 5 ASSY(CHART)
4 4 VOUT 4 4
5 5 GND DC12V 5 5
DC12V 6 6
1 1
Mask 2 Vcc 3
2 2 1 1
PI ASSY V0 4 3 3 Vcc 2 2
1 GND 5
4 4 VOUT
CONTROL PCB ASSY 3 3 MOTOR
ASSY(M)
5 5 GND 4 4
DC12V 5 5
DC12V 6 6

AC AC AC AC AC AC
6V 6V 18V 18V 6V 6V
1
2

1
2
1
2
1
2

1
2
1
2

SWITCH INLET
AC AC AC AC
6V 6V 18V 18V 1 RED 220V/AC
1 220V/AC
FUSE
BROWN 110V/AC 110V/AC
TRANSFORMER 2 2
FUSE
0V 0V/AC
3 3
FG
4 110/220V LAMP
INPUT 6V 30W

[Fig. 4 E1]

4
2-3 Basic Principle

2-3-1 Visual angle

※ Optometric standards

The circular symbol corresponding to a visual acuity of 1.0, has a notch

forming a visual angle of 1’ when viewed from a distance of 5 m.

General Chart:

5m

C 1'

[Fig. 4 E2]

5
 2-4 PCB layout drawing

2-4-1 CONTROL PCB

PILOT
LAMP
U1

D4 D5

J1

J7

J5

J3
J12 J11

J2 J10 J9

< Fig E3 >

J1: To connect TRANSFORMER(18V/AC) ASSY(2pins)

J2: To communicate RS-232(3pins)
J3: To communicate CAN(2pins)
J5: To connect CHART PI ASSY(5pins)
J7: To connect MASK PI ASSY(5pins)
J9: To connect MOTOR(CHART) ASSY(6pins)
J10: To connect MOTOR(MASK) ASSY(6pins)
J11: To connect TRANSFORMER(6V/AC 5A RED LINE)
J12: To connect LAMP(6V, 30W Halogen)

6
3. REPAIR WORK
3-1 Inspection/adjustment procedures

3-1-1 Inspection items

① If the pilot lamp(green) lights when the power is turned on

② If the halogen lamp lights about 10 seconds after the power is turned on
③ If the entire chart is uniformly bright
④ If the remote control pilot lamp(orange) remains light when the CCP controller is in operation
⑤ If the CCP controller enables correct chart selection
⑥ Positional relationship between chart and mask
⑦ Auto shut-off function (Halogen lamp goes out after a some 10 minutes’ pause in operation.)

3-1-2 Inspection criteria

z Positional relationship between chart and mask

1. When a vertical line mask is used:

No right and left parts of the chart must be visible (when viewed from the correct position).
(Chart symbols must virtually align with the center of the mask.)

No adjoining parts of the

chart must be visible.

C 0.2
C

0.3

C
0.4

< Fig E4 >

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 2. When a horizontal line mask is used:
No upper and lower parts of the chart must be visible (when viewed from the correct position).
(Chart symbols must virtually align with the center of the mask.)

3. When a single isolation mask is used:

Only a single symbol must be visible with any other part of the chart staying invisible (when viewed from the
correct position).
(Chart symbol must virtually align with the center of the mask.)

4. When a red & green mask is used:

Boundary between the red and green parts of the mask must look straight with no tilt (when viewed from the
correct position).

3-2 Disassembly/Reassembly Producedures

3-2-1 NAME OF ILLUSTRATED PARTS

NO. NAME OF PART

1 STAND ASS’Y & BODY ASS’Y disassembly and assembly

2 BODY COVER(U) ASS’Y & FRONT COVER ASS’Y disassembly and assembly

3 PCB ASS’Y & POWER SOCKET ASS’Y disassembly and assembly

4 MECHA ASS’Y & BODY COVER(L) ASS’Y disassembly and assembly

5 MECHA ASS’Y disassembly and assembly

6 STAND ASS’Y disassembly and assembly

7 BODY COVER(L) ASS’Y & BUTTON ASS’Y disassembly and assembly

8 BODY COVER(U) ASS’Y disassembly and assembly

9 POWER SOCKET ASS’Y disassembly and assembly

10 MAIN PLATE ASS’Y disassembly and assembly

11 CHART ASS’Y disassembly and assembly

12 MASK ASS’Y disassembly and assembly

8
3-2-2 Parts Exchange

Exchange Parts Exchange Method

Sequence

#1 STAND ASS’Y 1. Disassembly

& ① To untie 1pcs of SCREW(2)
BODY ASS’Y through six angles wrench and
Disassembly and assembly disconnect STAND ASS’Y(3)

2. Assembly
① On the contrary to above sentence #1

9
Exchange Parts Exchange Method
Sequence

#2 BODY COVER(U) ASS’Y 1. Disassembly

& ② To untie 2pcs of SCREW(2)
FRONT COVER ASS’Y through six angles wrench and

Disassembly and assembly disconnect BODY COVER-U(1)

③ To untie 2pcs SCREW(5) and 1pcs of
SCREW(6) through + driver and
disconnect FRONT COVER ASS’Y(4)
2. Assembly

① On the contrary to above sentence #1

10
Exchange Parts Exchange Method
Sequence

#3 PCB ASS’Y 1. Disassembly

& ① To untie 4pcs of SCREW(2) through

POWER SOCKET ASS’Y + driver and disconnect PCB ASS’Y(1)

Disassembly and assembly ② To disconnect all connectors on the

PCB ASS’Y(1)

③ To untie 4pcs of SCREW(4) through + driver and

disconnect POWER SOCKET ASS’Y(3)

2. Assembly

① On the contrary to above sentence #1

② When assembling, be careful against

CABLE misconnecting.

11
Exchange Parts Exchange Method
Sequence

#4 MECHA ASS’Y 1. Disassembly

& ① To untie 4pcs of SCREW(2) through

BODY COVER(L) ASS’Y + driver and disconnect MECHA ASS’Y(1)

Disassembly and assembly 2. Assembly

① On the contrary to above sentence #1

12
Exchange Parts Exchange Method
Sequence

#5 MECHA ASS’Y 1. Disassembly

Disassembly and ① To untie 1pcs of SCREW(1) and 2pcs of SCREW(2)

assembly through + driver and disconnect MAIN PLATE ASS’Y(3)

② Remove CHART COVER(4) from CHART BODY(21)

③ To untie 4pcs of SCREW(5) through six angles wrench and

disconnect MASK F/L ASS’Y(6)

④ To untie 4pcs of SCREW(7) through six angles wrench and

disconnect CHART F/L ASS’Y(8)

⑤ To untie 2pcs of SCREW(10) through six angles wrench and

disconnect BODY TUBE ASS’Y(9)

⑥ To untie 1pcs of SCREW(11) and disconnect

LAMP ASS’Y(13) and HARNESS LAMP SOCKET(12)

⑦ To untie 3pcs of SCREW(14) through + driver and

disconnect LAMP HOUSING ASS’Y(15) and remove

LAMP BARREL ASS'Y(16) from CHART BODY(21)

⑧ To untie 2pcs of SCREW(17) through + driver and

disconnect HARNESS(18)

⑨ To untie 2pcs of SCREW(19) through + driver and

Disconnect HARNESS(20)

2. Assembly

① On the contrary to above sentence #1

13
14
Exchage Parts Exchange Items
Sequence

#6 STAND ASS’Y 1. Disassembly

Disassembly and assembly ① To untie 3pcs of SCREW(3) through + driver

and disconnect STAND HOLD GUIDE(2)

② To untie 4pcs of SCREW(5) through + driver

and disconnect FOOT(4)

2. Assembly

① On the contrary to above sentence #1

15
Exchange Parts Exchange Method
Sequence

#7 BODY COVER(L)ASS’Y 1. Disassembly

& ① To untie 2pcs of SCREW(3) through + driver

BUTTON ASS’Y and disconnect BUTTON ASS’Y(2)

Disassembly and assembly * Part No.(1) : BODY COVER(L)

② To untie 2pcs of SCREW(4) through + driver

and disconnect BUTTON(5) & LOCK(L)

2. Assembly

① On the contrary to above sentence #1

16
Exchange Parts Exchange Method
Sequence

#8 BODY COVER(U) ASS’Y 1. Disassembly

Disassembly and assembly ① To untie 2pcs of SCREW(3) through + driver

and disconnect LOCK(U)(2)

z Part No.(1) : BODY COVER(U)

2. Assembly

② On the contrary to above sentence #1

17
Exchange Parts Exchange Method
Sequence

#9 POWER SOCKET ASS’Y 1. Disassembly

Disassembly and assembly ① Take out POWER S/W(1) from POWER SOCKET
PLATE(1)

② Take out FUSE INLET(3) from POWER SOCKET PLATE(1)

③ To untie 2pcs of POST NUT(5) through HEXAGON BOX

driver and disconnect SERIAL DESUB(4)

④ To untie 1pcs of NUT(8) & WASHER(9) through

plier and disconnect CAN HARNESS(6)

2. Assembly

③ On the contrary to above sentence #1

18
Exchange Parts Exchange Method
Sequence

#10 MAIN PLATE ASS’Y 1. Disassembly

Disassembly and assembly ① To untie 3pcs of SCREW(3) & WASHER(4) through

+ driver and disconnect TRANSFORMER(2)

② To untie 3pcs of SCREW(6) through + driver

and disconnect CYLINDER SUPPORT(5)

z Part No.(1) : MAIN PLATE

2. Assembly

③ On the contrary to above sentence #1

19
Exchange Parts Exchange Method
Sequence

#11 CHART ASS’Y 1. Disassembly

& ① To untie 2pcs of SCREW(3) through + driver

MOTOR and disconnect CHART SUB ASS’Y(2)

Disassembly and assembly z Part No.(1) : STEPPING MOTOR

② To untie 2pcs of SCREW(6) through + driver

and disconnect SENSOR GUIDE(5)

z Part No.(4) : CHART ASS’Y

2. Assembly

③ On the contrary to above sentence #1

20
Exchange Parts Exchange Method
Sequence

#12 MASK ASS’Y 1. Disassembly

& ① To untie 2pcs of SCREW(3) through + driver

MOTOR and disconnect CHART ASS’Y(2)

Disassembly and assembly z Part No.(1) : STEPPING MOTOR

② To untie 2pcs of SCREW(6) through + driver

and disconnect SENSOR GUIDE(5)

z Part No.(4) : CHART(4)

2. Assembly

③ On the contrary to above sentence #1

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3-2-3 CCP-7000 DRAWING

22
3-2-4 PART LIST

<Exchange Sequence #1>

NO CODE PARTS NAME REMARK

1 - BODY ASS’Y

2 - STAND ASS’Y

3 - STAND HOLD GUIDE & STAND HOLD SCREW

<Exchange Sequence #2>

NO CODE PARTS NAME REMARK

1 E0MASSY004 BODY COVER(U) ASS’Y

2 - WRENCH SCREW , M3*25L , BLACK

3 - -

4 EOMASSY005 FRONT COVER ASS’Y

5 - PH SCREW , M3X12L, FZY , WITH WASHER &

WASHER Φ4XΦ10X0.6T

6 - PH SCREW , M2X6L , FZY & WASHER Φ2XΦ6X0.5T

<Exchange Sequence #3>

NO CODE PARTS NAME REMARK

1 E0EPCB7001 MAIN PCB ASS’Y

2 - TAPING SCREW , Φ3X7L, FZY

3 E0MASSY019 POWER SOCKET ASS’Y

4 - TAPING SCREW , Φ3X7L, FZY

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<Exchange Sequence #4>
NO CODE PART NAME REMARK

1 - MECHA ASS’Y

2 - PH SCREW ,M4X6L , FZY

<Exchange Sequence #5>

NO P/N PARTS NAME REMARK

1 - PH SCREW , M3X8L, FZB , WITH WASHER

2 - PH SCREW , M3X8L, FZB , WITH WASHER

3 - MAIN PLATE ASS’Y

4 2010A00E001 CHART COVER

5 - WRENCH SCREW , M4X10L , BLACK , NYLOCK

6 E0MASSY009 MASK F/L ASS’Y

7 - WRENCH SCREW , M4X10L , BLACK , NYLOCK

8 E0MASSY008 MASK F/L ASS’Y

9 E0MASSY021 BODY TUBE ASS’Y

10 - WRENCH SCREW , M3X10L , BLACK

11 E0MASSYO16 CAP STOPPER SCREW

12 E0EHAR5000 HARNESS LAMP SOCKET

13 E0MASSY014 LAMP ASS’Y

14 - PH SCREW , M3X12L, FZY , WITH WASHER

15 - LAMP HOUSING ASS’Y

16 E0MASSY017 LAMP BARREL ASS’Y

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 17 - PH SCREW , M3X6L, FZY OPTION

18 EOEHAR3001 HARNESS(PHOTO INTERRUPTER CHART)

19 - PH SCREW , M3X6L, FZY

20 EOEHAR3001 HARNESS(PHOTO INTERRUPTER MASK)

21 1100MP0E003 CHART BODY(20W)

<Exchange Sequence #6>

NO P/N PARTS NAME REMARK

1 1100MS0E001 STAND

2 1210A00E001 STAND HOLD GUIDE

3 - PH SCREW , M3X12L, FZY , WITH WASHER

4 3000A00E001 FOOT

5 - PH SCREW , M3X8L, FZB , WITH WASHER

<Exchange Sequence #7>

NO P/N PARTS NAME REMARK

1 2000MP0E002 BODY COVER(L)

2 - BUTTON ASS’Y

3 - TAPING SCREW , Φ3X7L, FZY

4 - PH SCREW , M3X6L, FZY , WITH WASHER

5 2000MP0E003 BUTTON

6 1060A00E002 LOCK(L)

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 <Exchange Sequence #8>
NO P/N PARTS NAME REMARK

1 2000A00E001 BODY COVER(U)

2 1020A00E001 LOCK(U)

3 - TAPING SCREW , Φ3X7L, FZY

<Exchange Sequence #9>

NO P/N PARTS NAME REMARK

1 1030MP0E004 POWER SOCKET PLATE

2 7600S0F0010 POWER S/W

3 7604ACI0002 FUSE INLET(SCHURTER)

4 E0EHAR2001 HARNESS(SERIAL DESUB)

5 - POST NUT , M3/5L

6 E0EHAR2000 HARNESS(CAN)

7 - WASHER - HARNESS(CAN)

8 - NUT -HARNESS(CAN)

<Exchange Sequence #10>

NO P/N PARTS NAME REMARK

1 1030MP0E003 MAIN PLATE

2 7500PI07607 TRANSFORMER

3 - PH SCREW , M4X6L, FZY

4 - WASHER , M4 TYPE

5 2010A00E002 CYLINDER SUPPORT

6 - PH SCREW , M3X6L, FZY

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 <Exchange Sequence #11>
NO P/N PARTS NAME REMARK

1 6430TMT2300 STEPPING MOTOR

2 - CHSRT SUB ASS’Y

3 - SCREW , M4X10L

4 E0MASSY003 CHART ASS’Y

5 1030MP0E001 SENSOR GUIDE

6 - PH SCREW , M2X4L, FZB

<Exchange Sequence #12>

NO P/N PARTS NAME REMARK

1 6430TMT2300 STEPPING MOTOR

2 - MASK SUB ASS’Y

3 - SCREW , M4X10L

4 E0MASSY010 MASK ASS’Y

5 1030MP0E001 SENSOR GUIDE

6 - PH SCREW , M2X4L, FZB

27
3-3 Troubleshooting Procedure
This section deals with potential problems mainly associated with the electric system
that can be corrected only by PCB or unit replacement.

1. Abnormalities in Transformer
· Pilot lamp does not light.

2. Incorrect initial setting

· Chart or mask keeps scrolling.
· Halogen lamp does not light.

3. Abnormalities in remote control

· Remote control is inoperable.
· Stop position is incorrect.

4. Other
· Auto shut-off function is inoperable.

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 3-3-1 Abnormalities in power transformer

MAIN
1
BOARD
2

1
2
J11 J1
1
2

1
2
6VAC 6VAC 18VAC 18VAC
RED RED WHITE WHITE

INLET
SWITCH

1 RED 220V/AC
1 220V/AC
FUSE
BROWN 110V/AC 110V/AC
2 2
FUSE
0V 0V/AC
3 3
TRANSFORMER 4 FG

< Fig E5 >

CHECK POINTS

Check J1 AC input
-> If abnormal: When Inspect the J1, voltage level is 18V/AC(±3V/AC).
-> If abnormal: When Inspect the J1, voltage level is not 18V/AC(±3V/AC).
Then replace the Transformer.

Check J11 AC input

-> If abnormal: When Inspect the J11, voltage level is 6V/AC(±1V/AC).
-> If abnormal: When Inspect the J11, voltage level is not 6V/AC(±1V/AC).
Then replace the Transformer.

29
 3-3-2 Incorrect initial setting

z Chart or Mask keeps scrolling.

z Halogen lamp does not light

Initial setting sequence:

1. Chart zero detection
2. Mask zero detection
3. Halogen lamp lighting

CHECK POINTS

- In the case of abnormal zero detection(to be checked for by connecting a oscilloscope).

At this time, GND should be connected to GND. < See the pin map of Fig E1 >

Abnormal Check point Correct output Correct action

Zero detection (Main PCB)
Chart PI J5 5V Output available: Main board is
malfunctioning and should be replaced.
Output unavailable: Chart PI ASSY is
malfunctioning and should be replaced.
Mask PI J7 5V Output available: Main board is
malfunctioning and should be replaced.
Output unavailable: Large Mask PI ASSY
is malfunctioning and should be
replaced.

- In the case of that halogen lamp does not light:

1. Check the Fuse in main PCB. -> If the Fuse is off, replace the fuse.

2. Check the voltage between pin1 and pin2 of J12.

If Voltage level is 6V/AC(±1V/AC), then replace the halogen lamp. If voltage level is very low, replace
main PCB.

30
 3-3-3 Abnormalities in remote control

z Remote control is inoperable.

1. Inspect battery of remote controller.

2. Change the remote controller. And check again
3. If it does not work, change the main PCB

3-3-4 Misalignment

z Operation is impossible.

z Operating position is incorrect.

CHECK POINTS

- Malfunctions of Main PCB

1. D5 LED does not light. → ＋5V output is unavailable. Replace the main PCB.
2. D4 LED does not light. → ＋12V output is unavailable. Replace the main PCB.
3. Pilot lamp does not light. → Main PCB is unavailable. Replace the main PCB.
4. Measure the voltage between pin1 and pin2 of J1. If the voltage level is 18V/AC(±3V/AC).
→ Replace the main PCB.
5. Inspect fuse of main PCB. It is break an electric current → Replace the Fuse.
6. Inspect alignment. If misalignment is occurred, it should be corrected.

3-3-5 Other

· Auto shut-off function is inoperable. → Malfunctions of relay in the Main PCB

If the Main PCB is malfunctioning, replace it.

31