table of contents - noodlez.org courses pdf... · 2018-03-10 · medium with a higher refractive...

$: Table of Contents - Noodlez.org Courses PDF... · 2018-03-10 · medium with a higher refractive index to one with a lower refractive index. For example, it will occur when passing$

Table of Contents

Chapter 1 Principles and Theory of Fiber Optics a. History and Timeline Fiber Optics b. Progression to Fiber Networks c. Basic Components of a Light wave d. Properties of glass (Reflection & Refraction) e. Types of Fiber Optic Cables – Single

mode/Multi-Mode f. Fiber Fabrication

Chapter 2 Fiber Optic Safety

Chapter 3 Cable Preparation a. Fiber Optic Color Code & Markings b. Inspect Fiber Optic Cable c. How To Strip Fiber Cable

Chapter 4 SC, FC and ST Hot Melt Fiber Optic Connector a. Lab – ST/SC/LC Connector

Chapter 4.1 LC Hot Melt Fiber Optic Connectors

Chapter 5 Anaerobic Connector Installation a. Lab – ST Connector

Chapter 6 No Polish Connector a. Lab SC Connector b. Fan-Out Kit

Chapter 7 Fibrlok II Splice Installation/Mechanical Splice a. Lab

Chapter 8 Fusion Splicing a. Lab

Chapter 9 TFOCA II Termination a. Lab – Termination/Splicing

Chapter 10 Testing and Troubleshooting a. Test Equipment/OTDR b. Power Budget Calculation c. Troubleshooting & Restoration d. Lab

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Principles and Theory of Fiber Optics

2

3

Fiber Timeline (1)

1840’s

Turn of the 19th century

1960

• In the 1840’s, a Swiss physicist showed that light could be guided along jets of water

• By 1900, inventors realized that bent quartz rods could carry light

• 1960 The first Laser was invented

• 1970 Corning Glass Works created first singlemode fiber with less than 20 dB

per km loss

• 1974 The first fiber with 4 dB/km loss

4

TAT-8 Transoceanic fiber cable 1988

Fiber Timeline (2)

Chicago 1977

1997

• 1977 The first commercial fiber systems placed in service

• 1988 AT&T installed the world’s first Transoceanic fiber cable and had the capacity equivalent to 40,000 calls, 10 times that of the last copper cable.

• 1997 Service providers began installing optical fiber infrastructure

• 1999 High speed internet enters market

5

Progressing to Fiber Networks (1)

LANs or Local Area Networks based on copper (CAT-5) required Telecom closets on every floor and repeaters were needed every 100 meters. Fiber optic cable does not have this limitation; therefore many telecom closets can be eliminated reducing equipment and power requirements. Many fiber cables are up to 50 kilometers between repeaters and the bandwidth is also increased with fiber networks. CAT-5 is rated at 100 Mb/s, where multimode fiber can handle up to 10 Gb/s. Today, most large LANs use fiber optics in the backbone and UTP (Unshielded Twisted Pair) cabling to the desktop.

6

AMPS

COAX

FIBER


The reason fiber is used in CATV networks is that the fiber pays for itself in enhanced reliability. The enormous bandwidth requirements of broadcast TV require frequent repeaters. The large number of repeaters used in a broadcast cable network is a big source of failure. Also, CATV systems' tree and branch architecture means upstream failure which causes failure for all downstream users. High Speed internet is now available over the same line as the CATV. Coax could not handle the higher bandwidth requirements with the addition of Video-On-Demand.

7

• 900 pair copper cable at 3 in diameter weighs 16,000 pounds per km

• 1 pair fiber cable at 1/8 inch each weighs 64 pounds per km


The application for fiber in telephone systems is simply connecting switches over fiber optic links. Today, commercial systems carry more phone conversations over a single pair of fibers then over thousands of copper pairs.

8

Other Uses of Fiber

Cellular systems are not wireless - most antennas are connected via buried fiber optic cables. Utilities have used fiber for managing their grids and communications throughout their networks for many years. Security systems and closed circuit TV cameras use fiber to extend their reach, for example in large airport terminals, power plants inside and outside and large office buildings.

9

Other Advantages of Fiber

•Non-Conductive • Free from Radio Frequency and electromagnetic interference • Highly secure / tap proof • No electrical hazard

10

Basic Components of a Light Wave (1)

Propagation

Wavelength

Frequency

1 wavelength

F = V

Propagation is the power with which a wave is transmitted through a something such as air or water. As a light bulb blinks the light waves travel away from the bulb. The further the light waves travel the less power they have. Wavelength is the distance from one wave crest to the next or 1 cycle. Optical fiber wavelengths are measured in nanometers. A nanometer is 1 billionth of a meter (1x10 -9 meter). Frequency is the number of complete cycles per second. Frequency is expressed in Hertz, Kilohertz, Megahertz, etc. Frequency is determined by dividing the speed of light by the wavelength.

11

Basic Components of a Light Wave (2)Frequency Increasing

Wavelength Decreasing

Fiber Optic wavelengths are in the near Infrared spectrum right below the visible light spectrum. Therefore, fiber optic systems operate in the non-visible light spectrum and are not affected by visible light sources. The biggest factor in optical fiber loss is scattering. Light photons (particles of light) bounce off the glass molecules. Scattering is very sensitive to the color wavelength of the light, so as the wavelength of the light gets longer, the scattering becomes less. Double the wavelength and you cut the scattering by sixteen times. That’s why fiber optics uses infrared light for transmission.

12

Total Internal Reflection

Critical angle

Little light is reflected, most passes through

Total internal reflection is an optical phenomenon that occurs when light strikes a medium boundary (air, water, glass, etc) at an angle greater than the critical angle for the medium. The critical angle is the angle of incidence above which the total internal reflection occurs. Total internal reflection can only occur where light travels from a medium with a higher refractive index to one with a lower refractive index. For example, it will occur when passing from glass to air, but not when passing from air to glass. If the refractive index is lower on the other side of the boundary then no light can pass through and all of the light is reflected. The larger the angle that the light strikes, the smaller the amount of light is reflected. Once light strikes at the critical angle, total internal reflection occurs.

13

Examples of Internal Reflection

14

Index of Refraction

Velocity in Free Space

Velocity in Material

INDEX OF REFRACTION =

A key parameter in the movement of light in anything, including optical fiber, is the index of refraction. The index of refraction is a ratio of the speed of light in the material relative to that in vacuum or free space. The speed of light is approximately 300 million meters per second. The index of refraction will always be greater than 1.

15

Indices of Refraction

material

vacuum

v

vn

Vacuum 1.0Air 1.0003Water 1.33Optical Fiber Core (MM) typical 1.457Optical Fiber Core (SM) typical 1.471Glass 1.5-1.9Diamond 2.42

The typical value for the cladding of an optical fiber is 1.46. The core value is typically 1.48. The larger the index of refraction, the slower light travels in that medium. From this information, a good rule of thumb is that signal using optical fiber for communication will travel at around 200 million meters per second. Another way to put it, to travel 1000 kilometers in fiber, the signal will take 5 milliseconds to propagate.

16

Index of Refraction

Spacen = 1.0

Atmospheren = 1.0003

Watern = 1.33

Perpendicular to the surface also called the Normal

Due to the differences in the index of refraction of different materials, light slows down and “bends” as it passes from one material to the next. When passing into a higher index of refraction material, the light bends away from the surface. This is also called toward the Normal. The normal is perpendicular to the surface.

17

Total Internal Reflection

Core

Clad

Using the knowledge of the index of refraction of two materials and its effect on total internal reflection it is possible to restrict light to propagate within a layer of material. This is accomplished by having the index of the material higher than the material which surrounds it. In an optical fiber this is accomplished by having concentric layers of material with the index of refraction of the cladding being less than that of the core where the light will propagate.

18

Refraction in Real Life

Actual location

Refraction of the light causes the fish to appear farther away and nearer the surface than it really is.

19

Numerical Aperture

Light within this cone will be carried by the fiber due to total internal reflection

Light outside of the cone is beyond the critical angle and will not be carried in the core by total internal reflection

There is a maximum angle from the fiber axis at which light may enter the fiber so that it will propagate, or travel, in the core of the fiber. The sine of this maximum angle is the Numerical Aperture (NA) of the fiber. The NA is also referred to as the cone of acceptance.

20

Basic Layers of an Optical Fiber

Core

Cladding

Acrylate Coating

Buffer

Optical fiber is comprised of a light carrying core surrounded by a cladding which traps the light in the core by the principle of total internal reflection. Most optical fibers are made of glass, although some are made of plastic. The core and cladding are usually fused silica glass which is covered by an acrylate coating. This coating helps to ensure flexibility of the glass. On top of this a plastic coating called the buffer is added which protects the glass fiber from physical damage and moisture. Depending on the type of fiber, the core is normally 9um, 50 um, or 62.5 um in diameter. The cladding is normally 125um, the acrylate coating is 250um, and the buffer is commonly 900um.

21

Types of Fiber Optic Cable

1 index

many indexes

1 index

Optical fiber has two basic types, multimode and singlemode. Multimode fiber means that light can travel many different paths (called modes) through the core of the fiber, which enter and leave the fiber at various angles. Two types of multimode fiber exist, distinguished by the index profile of their cores and how light travels in them.

1. Multimode fiber is made with core/cladding sizes of 50/125 um and 62.5/125 um. 50/125 um is often referred to as “laser rated” fiber for its higher bandwidth capacity with laser sources.

2. Singlemode fiber is made with core/cladding size of 9/125 um.

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How Large is a Micron?

88.9 microns0.0889 mm0.0035 inch(Human Hair)

9 microns0.009 mm0.000354 inch(SM fiber core)

62.5 microns0.0625 mm0.00246 inchMM fiber core

1 micron0.001 mm0.000039 inch

23

Decrease in power of an optical signal from input to output

InputOutput

Attenuation

Attenuation is a very important characteristic of an optical fiber. As light propagates down the fiber its intensity is reduced. This is important because at some point the signal would become too weak to transmit the data to the other end. Attenuation is measured in decibels and is dependent upon the operating wavelength in fiber; the longer the wavelength, the lower the attenuation.

24

Attenuation (dB & dBm)

• Loss is measured in “dB”• dB means decibel• Log scale: dB=10 log (power ratio)

I. 10 dB= 10 timesII. 0 dB = 1timeIII. 3 dB = 2 timesIV. -10dB = 0.1 times

• dBm is dB referenced to 1 mwI. 0 dBm = 1 mwII. 10 dBm = 0.1 mw = 100w

dB is a measure of optical power on a log scale, simplifying measurements over a wide dynamic range. Fiber optics uses power levels from +20 to -40 dBm, a range of 1,000,000 to 1. That translates to 60 dB, an easier number to deal with. Absolute power is measured in dBm or dB referenced to 1 mw. Positive dBm means the power is greater than 1 mw, while negative numbers mean the power level is less than 1 mw. A nice thing about dB, is loss is easily measured by subtracting the reference level for “0” dB from the measured value of the loss. That is, if you measure -20 dBm from the end of the reference cable, then -22 dBm when testing cables, the cable loss is 2 dB.

25

• There are two types of attenuation– Intrinsic loss

• Absorption

• Scattering

• Core variations

– Extrinsic loss• Connectors

• Splices

• Attenuators

• Couplings

Attenuation

1. Intrinsic loss is due to the properties of the fiber. The technician cannot affect intrinsic loss.

2. Extrinsic loss is due to external influences. Absorption and backscattering are caused by impurities introduced into the fiber during manufacturing. Some examples of intrinsic/extrinsic loss are:

• Cleave quality: If angle is greater than 1 degree splice will not align properly. • Lateral offset of the core: If the 2 cores don’t match up loss will result. • Core mismatch: When 2 different core sizes are coupled together attenuation will

occur. Even if core sizes are the same but different manufacturers are used there could be a +/-3 micron difference which could also result in loss.

• Fiber contamination: If fiber ends aren’t kept clean loss will also occur.

26

Sources of Attenuation

Micro-bend Irregular End Finish

Bubble

Macro-bend

Impurity (Absorption)

Density Change in Fiber (Scattering)

Fibers often exhibit excess loss when they are spooled or cabled as the result of small deflections of the fiber axis that are of random amplitude and are randomly distributed along the fiber. The loss induced in optical fiber by these small random bends and stress in the fiber axis is called micro-bend loss, bending a fiber smaller than the Minimum Bend Radius results in Macro-bend loss.

27

Modal Dispersion (1)

Output pulseInput pulse

Step index multimode

A light pulse will send many different rays of light into the fiber, each taking a different path, these paths are called modes. Each mode or angle of light travels a different path. The arrival of different rays of the signal at different times distorts the shape and the pulse spreads out limiting the bandwidth of the fiber. Modal Dispersion is more common in step index multimode fiber, which has a core composed of only one type of glass.

28



Graded index multimode

Graded index multimode fiber has a core composed of many different layers of glass, chosen with indices of refraction to produce an index profile approximating a parabola. Since the light travels faster in lower index of refraction glass, the light will travel faster as it approaches the outside of the core. Likewise, the light traveling closest to the core center will travel the slowest. A properly constructed index profile will compensate for the different path lengths of each mode, increasing the bandwidth capacity of the fiber by as much as 100 times that of step index fiber.

29



Singlemode

Singlemode fiber just shrinks the core size to a dimension about 6 times the wavelength of the fiber, causing all the light to travel in only one mode. Thus, modal dispersion disappears and the bandwidth of the fiber increases by at least another factor of 100 over graded index fiber.

30

Fiber Fabrication

• Making of a preform– MCVD (Modified Chemical Vapor Deposition)

– OVD (Outside Vapor Deposition )

– VAD (Vapor Axial Deposition )

• Drawing of the fiber

Now we can move on to more about the fiber itself. First, it is important to understand how a fiber is made. It is made in a two step process.

1. In the first step a preform is made. This is a large rod of glass that has been “doped” with impurities.

2. The second step, “drawing”, involves heating the preform and drawing a fiber

from the end of it

31

Making of a Preform (1)

• Modified Chemical Vapor Deposition (MCVD) Method

Hollow Glass Preform

Gases Soot deposits inside tube

A hollow glass tube about 3 feet long and 1 inch in diameter is spun while a chemical gas is passed through the tube. When enough layers are built up, the tube is collapsed into a solid rod called a Preform. The preform can then be pulled into fiber.

32


• Outside Vapor Deposition (OVD) Method

Soot Preform

Gases

Target Rod

A glass rod is spun while a chemical gas with dopants is passed between the glass and a flame. The gas reacts and fuses to the glass rod. When enough layers are built up, the target rod is removed and the soot preform is collapsed into a solid rod. The preform can then be pulled into fiber.

33

• Vapor Axial Deposition (VAD) Method

Soot Preform

Gases

Target Rod


A short glass rod is suspended by one end and the gases are applied from below. The preform lengthens as soot is deposited on the glass when enough layers are built up, the target rod is removed. The preform can then be pulled into fiber.

34

Drawing a Fiber

• Typically 10-25 km of fiber with up to 150 km per preform

• Preform is drawn into it’s final diameter by varying

– Preform feed rate– Winding rate – Furnace temperature– Draw tension

Preform Feed

Preform

FurnaceFiber DrawingDiameter Monitor

Coating Applicator 1

Ultraviolet Lamps 1

Coating Applicator 2

Ultraviolet Lamps 2

After the fiber is drawn from the preform, a protective coating is applied immediately afterwards. The coating provides mechanical protection and prevents the ingress of water into any cracks. Two coatings are normally applied and the final diameter is normally 250um.

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Fiber Optic Safety

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37

Fiber Optic Safety

The broken ends of fibers and scraps of fiber created during termination and splicing can be extremely dangerous. The ends are extremely sharp, can easily penetrate your skin, and are very hard to find and remove. Obviously do not eat or drink anywhere close the work area. Fiber scraps can get into food or drink and be swallowed. The scraps can imbed themselves in your digestive system and never be found.

38

Eye Safety

Optical sources used in fiber optics, especially LED’s used in premises networks, are of much lower power levels than used for laser surgery or cutting materials. A typical laser pointer at the visible wavelength (650 nm), is probably more danger to the retina than a LED fiber optic link. However, laser fiber optic links are a much stronger and damaging light. It's not a good idea to look into a fiber unless you know that no light is being transmitted down it. Since the light is infrared, you can't see it, and could damage your eye without feeling it. You should always check the fiber with a power meter before examining it.

39

Eye Safety

The real issue of eye safety is getting fiber scraps into the eye. As part of the termination and splicing process, you will be continually exposed to small scraps of bare fiber, cleaved off the ends of the fibers being terminated or spliced. Whenever you are working with fiber, wear safety glasses!

40

Safety Rules

• Keep all food and beverages out of the work area. • Always wear safety glasses with side shields to protect your eyes from fiber shards

or splinters. • Keep track of all fiber and cable scraps and dispose of them properly. • Never look directly into the end of fiber cables – especially with a microscope. Use a

fiber optic power meter to make certain the fiber is dark. • Contact lens wearers must not handle their lenses until they have thoroughly

washed their hands. • Do not touch your eyes while working with fiber optic systems until your hands have

been thoroughly washed. • Only work in well-ventilated areas. • Keep all combustible materials safely away from curing ovens and fusion splicers. • When finished with the lab, dispose of all scraps properly. • Thoroughly clean your work area when you are done.

TAB

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Cable Preparation

42

43

Cable Preparation

44

Optical Cable Markings

NEC Rating Description

OFN optical fiber non-conductive

OFC optical fiber conductive

OFNG or OFCG general purpose

OFNR or OFCRriser rated cable for vertical

runs

OFNP or OFCPplenum rated cables for use

in air-handling plenums

OFN-LS low smoke density

All optical fiber cable is marked but not necessarily in to same order and with the same information. The markings can include: The manufacture, the outer jacket fire rating (OFNR), the number of fibers in the cable, the core and cladding size (62.5/125), the date the cable was made, and a distance marker. Fire codes: OFN: Optical Fiber Non-conductive OFNP: Optical Fiber Non-conductive Plenum (for circulated air space/vertical run) OFNR: Optical Fiber Non-conductive Riser (not for circulated air space) OFC: Optical Fiber Conductive OFCP: Optical Fiber Conductive Plenum OFNC: Optical Fiber Conductive Riser OPGW: Optical Path Ground Wire LSZH: Low Smoke Zero Halogen (Less toxic then plenum)

45

ST Connector

BNC Connector

The ST were the standard during the 1980’s and 90’s. ST connectors have a key which prevents rotation of the ceramic ferrule, and a bayonet lock similar to a BNC (Bayonet Neill-Concelman) shell. Commonly referred to as “stab and twist”. ST is still one of the most popular connector for multimode networks, like most buildings and campuses. Its’ bayonet mount and a long cylindrical ferrule hold the fiber. Most ferrules are ceramic, but some are metal or plastic. Because they are spring-loaded, you have to make sure they are seated properly. If you have high loss, disconnect and reconnect them to see if it makes a difference.

46

SC Connector

Standardized in 1992 and recognized as the preferred connector, SC connectors have a mnemonic of "Square Connector" and some people believe it to be the correct name. This refers to the fact the connectors themselves are square. Another term often used for SC connectors is "Stick and Click". SC connectors offer excellent packing density, and their push-pull design reduces the chance of fiber end face contact damage during connection. SC is widely used in single mode systems for it's excellent performance. It's a snap-in connector that latches with a simple push-pull motion. It is also available in a duplex configuration.

47

FC Connector

FC connectors' floating ferrule provides good mechanical isolation. FC connectors need to be mated more carefully than the push-pull types due to the need to align the key, and due to the risk of scratching the fiber end face while inserting the ferrule into the jack. FC connectors have been replaced in many applications by SC and LC connectors. FC has been one of the most popular single mode connectors for many years. It screws on firmly, but make sure you have the key aligned in the slot properly before tightening.

48

LC Connector

LC connector is a small form-factor fiber optic connector. LC connector resembles a small SC connector. LC connector makes use of a 1.25 mm ferrule, half the dimension of the ST, SC, & FC ferrules. LC has excellent performance and is greatly preferred for single-mode transmission. The LC’s smaller size allows for more port density than other connectors.

49

Inspecting Fiber Cable

A good example of how it can save time and money is testing fiber on a reel before you pull it to make sure it hasn't been damaged during shipment. Look for visible signs of damage (like cracked or broken reels, kinks in the cable, etc). Visual fault locators and continuity testers should also be used to test for breaks in the fibers.

50

Stripping the Outer Jacket

Removing the outer jacket: Step 1: Mark the armor (if the cable has armor) with the tip of your knife to note a length sufficient to expose the cable's ripcord, being careful not to go through the armor and cut the ripcords. Step 2: Cut and remove the armor at this mark to expose the two ripcords (usually one each on opposite sides of cable). Step 3: Nick the armor on each side with your knife to provide a starting point for the ripcords. Get a good grip on one ripcord and pull at 90 degrees to the cable; it will cut through the armor and jacket with ease. Do the same with the other ripcord, and the outer jacket and armor will come off in two pieces, with no strain on the cable itself. (With some cables, you'll find a gel-type adhesive on the cable under the armor, which you'll need to clean off at this point. There are many products on the market; make sure you use a safe, environmentally friendly, and effective product.)

51

Stripping the Inner Jacket

Removing the inner jacket: Step 1: Cut and remove a few inches of the inner jacket at the end of the cable to expose one or two ripcords. Step 2: Nick the jacket and mark it to the length you want removed. Remember, the fibers inside has little protection, so use the knife sparingly. Step 3: Grip the ripcords and pull to remove the inner jacket. This will expose nylon binding strings and a plastic covering over the fiber units. Step 4: Using a small binder cord cutter (which is quite similar to a seam ripper), cut the cords. Cutting every second or third is enough.

52

Stripping the Inner Jacket

Removing the inner jacket continued: Step 5: Using a wipe well soaked with gel remover, wipe the cable. As the gel dissolves, the binder threads will come off. Make sure you remove all of the gel. Step 6: Unwind the loose tubes from around the center strength member. Cut off the filled tubes and discard them. Loose tubes have a bend memory; to make a neat bundle some technicians prefer to heat them with a heat gun or even a hair dryer to straighten them out. This writer's preference is to leave well enough alone and not look for trouble. Step 7: Attach the strength member to the enclosure. Step 8: Remove the buffer tube. You'll find the same gel on the fibers in this tube. This buffer tube is extremely hard plastic; if you over bend this tube, it will kink and break the fibers inside. Using a small cutter cut around the tube, being careful not to cut through it. Then, grasp the tube on each side of the cut with the thumb and forefinger of each hand. Bend it each way carefully to make it snap. Step 9: Carefully clean the gel from the fibers using an appropriate cleaner. Make sure you have good ventilation and a way of disposing your wipes.

TAB

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SC, FC and ST

Hot Melt Fiber

Optic Connectors

54

55

SC, FC and ST Hot Melt Fiber Optic Connectors

56

Field Termination Kit Contents

Oven Cooling Stand ST Connector Holder FC Connector Holder

SC Connector Holder Polishing Pad Polishing Jig Crimp Tool

Jacket Removal Tool Scissors Fiber Buffer and Coating Stripper

Scribe

57

ST Installation on 900 µm Buffered Fiber (1)

Turn on the Hot Melt Oven. The oven requires 5 minutes towarm up.

Open the connector package and remove the components.

Each connector packagecontains a connector (A), strain relief boot (B) and clear strain relief tube (C).

58


Load the connector onto the ST connector holder.

Latch the connector bayonet housing to the connector holder.

Place the connector holder and connector into the oven.Note: The connector should be in the oven for at least one minute, but no more than ten minutes.

59


Place the strain relief boot and clear strain relief tube on thebuffered fiber.

Remove the buffer in small pieces until 5/8“ to 3/4" (16-19 mm) of thebuffer has been stripped.

Clean the fiber with a lint free cloth moistened with isopropyl alcohol.

60


Remove the connector holder from the oven.

CAUTION:VERY HOT.

Gently insert the fiber into the connector.

Push the buffered fiber until it stops.

61


Slide the clear strain relief tube into the backbone of theconnector until it stops.

Bare fiber should be visible in the bottom of the connector holder.

Place the buffered fiber in the cable holder.

62

Scribing

Remove the connector from the connector holder.

Caution: Be careful so that you do not break the protruding fiber.

Score the fiber by gently sliding the blades across the fiber just above the adhesive bead. Scoring means that you are making a small scratch on the outside of the fiber. Be very gentle.

Pull the fiber away from the connector. Pull along the axis of the fiber, not to one side or the other. If the fiber does not breakaway, score the fiber again.

Caution: Dispose of the fiber per company practice.

See pages 81-86 for polishing procedures

63

Turn on the Hot Melt Oven. The oven requires 5 minutes towarm up.

Open the connector package and remove the components.

Each connector package contains a connector (A), strain relief boot (B) and clear strain relief tube (C).

A B C

Load the connector onto the ST connector holder.

Latch the connector bayonet housing to the connector holder.

Place the connector holder and connector into the oven.

ST Installation on Jacketed Cable (1)

64


Place the strain relief booton the cable.

Score the jacket 3/4" (19 mm) to 7/8" (22 mm) from the end.

Remove the jacket from the end of the cable.

Gather the aramid yarntogether and hold them against the cable jacket.

To prevent the buffered fiber from being pulled out, lace the cable through your fingers.

Remove 5/8" (16 mm) of the buffer.

65



Cut the aramid yarn to 1/4“ (6 mm) long.


CAUTION: VERY HOT.


Push the cable until the aramid yarn is inside the connector.

Bare fiber should be visible in the bottom of the connector holder.

66

Secure the cable to the cable holder.

Place the connector holder intothe cooling stand. The coolingtime is about 3 minutes.

See previous page (62) for scribing


67

SC Installation on 900 µm Buffered Fiber (1)

Turn on the Hot Melt oven. The oven requires 5 minutes to warm up.

Open the package and remove the components.

Each package contains aconnector (A), strain relief boot (B), clear strain relief tube (C), black crimp ring for 3 mm cable (D) and connector shell (E).

A B C D E

Load the connector into the SC connector holder.

Push down on the connector and turn it 90 degrees so that the arms hold the connector in place.

Place the connector holder and connector into the oven.

Note: The connector should be in the oven for at least one minute, but no more than ten minutes.

68

Place the strain relief boot, clear strain relief tubing and crimp ring on the fiber.

Remove the buffer in smallpieces until 9/16“ to 5/8" (14-16 mm) of buffer has been stripped.



CAUTION: VERY HOT.


Push the buffered fiber until it stops.


69

Slide the crimp ring over the backbone until it is against the connector.

Slide the clear strain relief tube into the crimp ring.

Verify that the bare fiber isvisible in the bottom of theconnector holder.

Crimp the larger part of the crimp ring with the .190 cavity of the crimp tool.

Crimp the smaller part of the crimp ring using the .137 cavity.

Place the connector holder into the cooling stand. The cooling time is about 3 minutes.



70

A B C D E

Turn on the Hot Melt oven. The oven requires 5 minutes towarm up.


Each package contains aconnector (A), strain relief boot(B), clear strain relief tube (C),black crimp ring for 3 mm cable(D) and connector shell (E). Thestrain relief tube is not used onjacketed cable.

Load the connector into the SC connector holder.

Push down on the connector and turn it 90 degrees so that the arms hold the connector in place.

Place the connector holder andconnector into the oven.Note: The connector should be in the oven for at least one minute, but no more than ten minutes.


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SC Installation on Jacketed Cable (1)

Place the strain relief boot and crimp ring on the cable.

Score the jacket 1 3/16" (30 mm) from the end.


Gather the aramid yarntogether and hold them against the cable jacket.


Remove the buffer in small pieces until 9/16“ to 5/8" (14-16 mm) of the buffer remains.

72




CAUTION: VERY HOT.


Push the cable until it stops against the connector. The aramid yarn should flare outover the backbone.

Slide the crimp ring over the aramid yarn until it is seated against the connector.


73


Crimp the larger part of thecrimp ring with the .190 cavity of the crimp tool.





74

FC Installation on 900 µm Buffered Fiber (1)



Each package contains aconnector (A), strain relief boot(B), clear strain relief tube (C)and black crimp ring for 3 mmcable (D).

A B C D

Load the connector into the FC connector holder. Align the key on the connector with the key way on the connector holder.

Place the connector holder andconnector into the oven.

Note: The connector should be in the oven for at least one minute, but no more than ten minutes.

Place the strain relief boot, clear strain relief tube and crimp ring on the fiber.

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Remove the buffer in small pieces until 9/16“ to 5/8" (14-16 mm) of buffer has been stripped.

Stripping template. Clean the fiber with a lint free cloth moistened with isopropyl alcohol.

Remove the connector holderfrom the oven.

CAUTION: VERY HOT.


Push the fiber until it stops.


76

Slide the crimp ring over the backbone until it is against the connector.

Slide the clear strain relief tube into the crimp ring.


Crimp the larger part of thecrimp ring with the .190 cavity of the crimp tool.





77

FC Installation on Jacketed Cable (1)



A B C D

Each package contains aconnector (A), strain relief boot (B), clear strain relief tube (C) and black crimp ring for 3 mm cable (D). The strain relief tube is not used on jacketed cable.

Load the connector into the FC connector holder. Align the key on the connector with the key way on the connector holder.

Place the connector holder andconnector into the oven.

Note: The connector should be in the oven for at least oneminute, but no more thanten minutes.

Place the strain relief boot and crimp ring on the cable.

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Score the jacket 13/16" (30 mm) from the end.


Gather the aramid yarn together and hold them against the cable jacket.


Remove the buffer in small pieces until 9/16" (14 mm) of the buffer remains.

Stripping template.


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CAUTION: VERY HOT.


Push the cable until it stopsagainst the connector. Thearamid yarn should flare out over the backbone.

Slide the crimp ring over the aramid yarn until it is seated against the connector.


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Crimp the larger part of thecrimp ring with the .190 cavityof the crimp tool.

Crimp the smaller part of thecrimp ring using the .137 cavity.

Place the connector holder intothe cooling stand. The coolingtime is about 3 minutes.



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Multimode Polishing Procedure (1)

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Single-Mode Polishing Procedure (1)

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TAB

Insert Tab # 5 Here

LC Hot Melt Fiber Optic Connectors

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LC Hot Melt Fiber Optic Connectors (1)

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A. LC Hot Melt Connector Holder (4) B. LC Polishing Jig Assembly with Weight B1 Spare Polishing Jig C. LC Crimp Tool D. LC Adapter for View Scope E. Heat Shrink Fixture F. Cleaning Pins (3) G. Laminated Strip Template H. Polishing Pads 4.5" × 5.5" I. Lapping Film

A

B

C

D

E

F

GH I

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The Behind The Wall (BTW) LC is used for simplex 900 micron applications. The connector contains (A) dust cap, (B) connector, and (C) strain relief boot.

Note: The BTW LC multimode connector has a beige extender cap at the rear of the connector. The singlemode connector has a blue extender cap at the rear of the connector.

A B C

The duplex 900 micron LC contains (A) dust cap, (B) connector, (C) duplex clip, and (D) strain relief boot.

Note: Do not confuse the multimode or singlemode duplex connectors as they both have black outer housings. Multimode connectors are packaged with beige duplex yokes and singlemode connectors are packaged with blue yokes.

A B C D

A B C D

1.6–2.0 mm LC connector contains a (A) dust cap, (B) connector, (C) heat shrink crimp sleeve, and (D) strain relief boot.


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The 3.0 mm LC connector contains (A) dust cap, (B) connector, (C) metal strength sheath, (D) metal crimp sleeve, (E) strain relief boot. Note: Multimode simplex yokes are beige and singlemode yokes are blue.

A B C D E

Plug in the 120V or 230V power cord. Turn on the Hot Melt Oven. The oven requires 6 minutes to warm up (red exposed on switch indicates power on).

Open the connector package and remove components. Attach hot melt holder handle to the load adapter with the slot aligned to the front.


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Insert the connector into the hot melt connector

holder.

Place the load adapter, with slot aligned with handle, into an available port in the oven.

IMPORTANT: Do not place connector in a hot load adapter. This may cause adhesive to flow to the outside of the ferrule. Load adapter should be at room temperature when connector is inserted.

The LC Hot Melt Connector should be in the oven for at least 75 seconds. The connector should not be in the oven longer than 5 minutes.Place the heat shrink fixture in an available port in the oven.

Note: This step is only necessary for use with the 1.6–2.0 mm jacketed LC hot melt connector.


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900 micron Cable Connector Preparation

Place strain relief boot on cable as shown.

1.6 – 2.0 mm Jacketed Cable Connector Preparation

Place the strain relief boot first and then the heat shrink crimp sleeve on the cable as shown.

3.0 mm Jacketed Cable Connector Preparation

Place the strain relief boot first and then the metal crimp sleeve on the cable as shown.


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Strip Guide

Place the cable on the strip template. Mark buffer at 11 mm. Using the stripping tool, remove the buffer in small increments until 11 mm of buffer has been removed.

Using a lint-free cloth moistened with isopropyl alcohol, clean the bare fiber to remove any oils or acrylate coating debris.

Stripping Procedure for 900 micron Fiber

Stripping Procedure for 1.6 – 2.0 mm

Jacketed Fiber

Place the jacketed fiber on the strip template and use a fiber marking pen to mark the location of the jacket cut.

Remove 33 mm (1 1/3") of jacket off the cable.


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Snip the aramid yarn to 5-6 mm (approx. 3/16").

Flare aramid yarn evenly around buffer.

Remove the buffer in small increments until 21–22 mm (approx. 7/8") of buffer is left.


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Stripping Procedure for 3 mm Jacketed Fiber

Place the jacketed fiber on the strip template and use a fiber marking pen to mark the location of the jacket cut. Using the stripping tool, remove 33 mm (1 1/3") of jacket off cable.

Holding the aramid yarn firmly away from the buffer tube, insert the metal strength sheath over the buffer tube and push down until fully inserted into the jacket. Top of sheath should be even with the upper edge of jacket


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Snip the aramid yarn to 5-6 mm (approximately

3/16").

Flare aramid yarn evenly around buffer tube.

Using the stripping tool, remove the buffer in small increments until 21–22 mm (approx. 7/8") of buffer is left.



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Connector Mounting

While connector is still in oven, mount fiber into connector inserting until buffer stops inside the connector. Be sure to insert fiber within the guide tube at the rear of the connector.

Note: Removing the connector holder from the oven prior to fiber insertion will cause adhesive to thicken rapidly, greatly limiting the time to insert the fiber.

Cable jackets should be approximately 1mm from the rear of crimp area when buffer is correctly located.

IMPORTANT: Do not lift the connector while in the load adapter during the heating process. This will prevent adhesive from bonding to the load adapter. If adhesive does adhere itself to the inside of the load adapter, use the cleaning pin to remove adhesive prior to inserting next connector. Use alcohol with the pin, if needed.

Note: To ease fiber insertion, make sure fiber is kept very straight when mounting. If resistance is felt when within 1/8” of buffer, you are stubbing and should back out a short distance and re-enter making sure that the fiber is kept straight at all times.


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Maintaining fiber position in connector, push the jacketed fiber into the cable v-slot feature on the load adapter until secure.

Attempt to line up the holder arm to keep cable as straight as possible.

Remove the load adapter from the oven by grasping the cool-touch handle.

Rest the load adapter in one of the available cooling ports located on both sides of the oven. Let cool for a minimum of 3 minutes.


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Boot Placement for 900 micron Fiber

Remove connector from the load adapter and slide the boot over connector until fully seated.

IMPORTANT: Remove connector gently so that you don’t break the fiber. If connector sticks to the sides of the load adapter when trying to remove, re-heat the connector slightly until connector can be removed from the load adapter. Use the cleaning pin furnished in the kit to scrape the adhesive out of the load adapter hole before proceeding with next connector.

Crimping and Boot Placement for 1.6 – 2.0 mm Jacketed Fiber

Slide crimp/shrink tube down and over aramid yarn.

Remove the connector from the load adapter.


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Using the die labeled “A” with the 3M lettering facing to the left, crimp the metal portion of the sleeve once.

Note: Crimp sleeve must be bottomed against connector prior to crimping. The 3M lettered side of the crimp die should be touching the rear of the connector.

Place the crimp/shrink tube in the shrink fixture assembly and heat for 8 to 10 seconds. Tube should shrink snug around the jacket. Rotate, if needed, to complete shrink.

Slide boot over crimp/shrink tube.

Note: Jacketed boots appear the same in the photos but the boots for all 3 types of connectors are different sizes and can not be interchanged.


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Crimping and Boot Placement for 3 mm Jacketed Fiber

Remove connector from load adapter

Slide metal crimp sleeve down and over aramid yarn. It should rest over the metal strength sheath as shown.

Using the LC die labeled “A” with the 3M lettering facing left, crimp the left half of the crimp ring once making sure that the 3M lettered side of the die is flush with the connector prior to crimping.Note: The crimp ring must be flush against the connector prior to crimping. The 3M-lettered side of the crimp die should be touching the rear of the connector.

Using the LC die labeled “B” line up the non-lettered side of the die with the rear of the crimp die and crimp the right half of the crimp ring.


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The completed 3 mm crimp should look like this:

Slide boot over crimp until boot is flush against the connector.

Note: Jacketed boots appear the same in the photos but the boots for all 3 types of connectors are different sizes and cannot be interchanged.


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Scribing:

Position the scribe blade so the flat side of the blade is resting on the bead of adhesive and the blade is perpendicular to the fiber.

Score the fiber by gently sliding the blade across the fiber just above the bead of adhesive. Scoring means that you are making a small scratch on the outside of the fiber.

IMPORTANT: The fiber should not break during this step.

Pull the fiber straight away from the connector. Pull along the axis of the fiber, not to one side or the other. If the fiber does not pull away, score the fiber again.

Dispose of the scrap fiber in the designated container.


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Multimode Polish:

Perform an air polish by holding the 9 micron lapping film firmly in one hand and gently moving the film in a circular motion for approximately 10 strokes or until approximately one half of the bead height is removed.

Note: You can polish approximately 20 connectors with each piece of 9 micron lapping film.

Using a lint-free cloth and isopropyl alcohol clean the connector after the air polish to remove all debris left by the 9 micron lapping film.

Clean the round polishing pad found with a lint-free cloth moistened with isopropyl alcohol.

Place several drops of alcohol onto the round polishing pad.

Before alcohol evaporates, place a sheet of the pale green 2 micron lapping film, shiny side down on the pad. The alcohol creates suction on the lapping film and helps hold it in place.

Clean the lapping film with a lint-free cloth moistened with isopropyl alcohol.

Note : The 2 micron lapping film can be used for up to 4 connectors.


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Clean the flat side of the polishing jig with a lint-free cloth moistened with isopropyl alcohol.

Place the polishing jig assembly on the lapping film.

Place the ferrule in the polishing jig aligning the latch side of the connector with the slot until it stops.

Note: The ferrule must be able to slide freely inside the hole in the polishing jig. If not, the ferrule may have adhesive on it which needs to be cleaned off with alcohol and a lint-free cloth.


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Insert the polishing weight into the adapter/jig assembly covering the connector.

Note: The weight should pop up slightly (1/16") when holding the jig flat against the lapping film, indicating that the ferrule can move freely.

Polish 10 figure-eight strokes or until bead of adhesive is no longer visible.

Note: Do not hold polishing jig assembly by the weight when polishing. Hold only by the textured polishing adapter.

Note: Because bead is 3 to 4 times smaller than classic hot melt connectors you will not feel the bead of adhesive being removed as you polish.

IMPORTANT: Make sure that polishing jig stays flat on lapping film at all times.

After bead of adhesive is no longer visible, polish an additional 5 strokes.

Remove the connector from the polishing jig assembly and clean the connector end face with a lint-free cloth moistened with isopropyl alcohol.


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Inspect the connector end face with the fiber view scope. Use the thumb toggle switch to activate the light onto the fiber end face. There are two light settings—coaxial and oblique angle lighting.

Good Polish (Coaxial light)

Good Polish (Oblique light)


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Bad Polish – Cut or scratch going through center of core. In this picture half of fiber is missing.

Singlemode Polish to –40dbComplete previous steps of the multimode polish before proceeding further with the singlemode polish.

Clean the gray rectangular polishing pad with a lint-free cloth moistened with isopropyl alcohol.

IMPORTANT: Do not use the black 4.5" x 5.5" pads for the singlemode LC polish. Use only the pale gray pads.

Place several drops of alcohol on to the rectangular rubber pad.

Before the alcohol evaporates, place a sheet of the 0.5 micron pale gray diamond lapping film on the polishing pad, shiny side down.

Clean the lapping film with a lint-free cloth moistened with isopropyl alcohol.

Note: The 0.5 micron diamond lapping film can be used for up to 10 connectors.


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Place the polishing jig assembly on the wet diamond lapping film. Perform 3 to 4 figure eights.

Leaving the polishing jig assembly positioned on the lapping film, rotate 180 degrees. Perform 3 to 4 additional figure eights.


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Singlemode Polish to –55db

Note: Complete steps of the multimode polish and of the singlemode polish before proceeding further.

Place several drops of alcohol on to the second gray rectangular rubber pad.

Before the alcohol evaporates, place a sheet of the white frosted final lapping film on the polishing pad, shiny side down. Clean the lapping film with a lint-free cloth moistened with distilled water.

IMPORTANT: Do not clean the white frosted lapping film with alcohol. Use only distilled water.

Note: The frosted final lapping film can be used for up to 5 connectors.


Place the polishing jig assembly on the wet frosted lapping film. Perform 4 figure eights on the wet frosted lapping film.


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Leaving polishing jig assembly positioned on the lapping film rotate 180 degrees. Perform 4 additional figure eights.

Inspecting the connector with the fiber view scope before proceeding to final step.

If connector is not to be immediately put into service, install the protective dust cap.

Duplex yokes may be mounted after connector has been terminated.

With the anti-snag clip facing connector press cable into slot on the duplex yoke and then slide the yoke up and over the boot.


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Taper on the boot will cause the yoke to spread allowing the correct placement at the rear of the connector.

Pinch the top and bottom of the yoke closed and press together the outer edges of the yoke, snapping firmly into connector.

A design improvement includes a live hinge on the bottom of the duplex yoke (currently available in multimode). The new duplex yokes will be installed in the same manner as the current yoke, however, the live hinge allows the yoke to be re-opened without damage.


TAB

Insert Tab # 6 Here


Anaerobic

Connector

Lab

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Anaerobic Connector Lab (1)

1. Slide the boot over the cable

2. Place a mark at 1 1/4 inch.

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3. Strip the outer jacket.

4. Fold the Kevlar strength members back over the jacket and slide the crimp sleeve over them.


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5. Place a mark at 3/4 inch onto the buffered fiber.

6. Strip the buffer and acrylate coating from the fibers. Strip in 1/8 inch or shorter pieces to prevent breaking the fiber. Clean the bare fibers with alcohol wipes.


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7. Take a syringe with Loctite adhesive and squeeze on the plunger until a bead of adhesive appears at the tip of the ferrule.

8. Carefully slide the stripped fiber through the connector ferrule. Slide the crimp sleeve in position and crimp.


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9. Slide the boot over the back of the connector.

10. Once the adhesive has cured, cleave the fiber as close to the adhesive bead as possible.


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11. Air polish the fiber stub with a 3 or 5 um polishing sheet using a figure 8 motion. Polish the tip lightly until the fiber is even with the adhesive bead.

12. Using the polishing plate/pad and the 3um paper. Using a figure 8 motion, apply very light down pressure and polish until the ferrule starts sliding very smoothly.


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12. Change to 1um paper, with very light down pressure polish about 10 more figure 8’s.

13. Wipe the ferrule clean with alcohol wipes or a fiber cleaning solution before inspecting the ferrule with a microscope or the microscope will become contaminated.


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13. Inspect the polished end of the ferrule with the microscope to see that the adhesive is completely removed and that the tip is smooth and free of scratches. The fiber must be polished even with the top of the ferrule, but do not over polish!

Direct Core Illumination

Angle Illumination, some adhesive remains.


TAB

Insert Tab # 7 Here

No Polish Connector

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Note: Gel inside the connector may cause minimal eye irritation. Contains phenyl methyl silicone, hydrophobic silica. Avoid eye contact, wash hands before eating or smoking. Carefully follow safety, health and environmental information given on the product label or the MSDS sheet for the no polish connector.

No Polish Connector Assembly (1)

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• 2. Clean the fiber holder with a lint-free cloth soaked with alcohol. Move guide funnel forward on fiber holder until it stops; open fiber covers and fiber clamp.

1. Remove the dust caps from the front and rear of the connector. Open the actuator button on the assembly tool. Insert the connector with the white actuation cap facing up into the coupling, pushing forward until it clicks.


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3. Strip, clean and cleave fiber to 8mm +/-0.5 (0.4 inches). Use the cleave length marker on the assembly base to verify the length. For semi-tight fiber, utilize the fiber holder in the stripping process by placing the fiber into the holder with the fiber to be stripped protruding from the rear of the holder, opposite the guide funnel. Close the rear clamp and proceed to strip the fiber. This will prohibit the buffer from moving or stretching during the stripping process. Once the fiber has been stripped remove the fiber from the holder.


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4. Lay the fiber in the proper grove of the fiber holder making sure that the natural bow in the fiber is facing down extending beyond the guide funnel end.

900μm semi-tight buffer fiber 900μm tight buffer fiber 250 μm fiber


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5. Close the guide funnel and middle covers on the fiber holder. Ensure that the funnel is pushed completely forward to the end of the fiber holder. Pull fiber back until fiber end is flush with funnel end. Close the back clamp.

6. Place fiber holder in assembly base and slowly slide fiber holder forward.


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Guide funnel cover is opened by cam on the assembly base

7. Continue to slowly slide fiber holder toward the connector. A bow in the fiber should start when the whole line on the fiber holder aligns with the white line (BOW START) on the assembly base. If a bow is not seen, slide the fiber holder back and re-strip, clean and cleave the fiber and begin the termination process again. If a bow is seen before the two white lines meet, slowly move the fiber holder back without removing the fiber completely from the connector until there is no bow. To assist insertion, placing finger on the middle cover to keep it from opening, then slowly re-insert the fiber into the connector. If a bow still starts before the white lines meet, re-strip, clean and cleave the fiber and start the termination process again.

Fiber bow should start when the white line on fiber holder aligns with the “BOW START” mark on the assembly base.


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8. Continue to slowly slide fiber holder towards connector until it stops. Verify fiber bow again. The fiber will bow and lift the middle cover for rigid fibers and remain closed for flexible fibers. This ensures proper fiber insertion force.


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9. Firmly press button to actuate splice element while maintaining fiber bow.


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10. Press release lever to allow forward motion of funnel. Push on ears to move funnel forward and actuate buffer clamp.


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11. Lift fiber clamp and fiber covers to release fiber.


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12. Slide fiber holder from actuation tool.


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13. Lift element actuation button.


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14. Pull connector from coupling.


TAB

Insert Tab # 8 Here


Fibrlok™

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1.1 The 3M™ Fibrlok™ II Universal Optical Fiber Splice 2529 provides permanent mechanical splices for single- or multimode fiber having 125 μmdiameter cladding.

The 2529 universal splice is designed to accommodate any combination of fibers with coating diameters from 250 μm to 900 μm.

All 2529 splices are gray in color and are marked with the 3M Fibrlok™ II logo on the splice cap.

Fibrlok™ Splice

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Splicing Set-Up (1)

2.1 The splicing area should be clean, dry and well-lit. A clean, well-organized splicing area will improve splice efficiency and minimize the risk of contamination of fibers or splices.

2.2 Open the buffer tubes, expose and clean the fibers per your company practice.

Note: Storage, use and disposal of isopropyl alcohol should be per your company health, safety and environmental instructions. Refer to solvent label or Material Safety Data Sheet.

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2.3 Remove Fibrlok splice from protective package. Load the splice into the assembly tool by pressing firmly at the ends of the splice.

2.4 If using the 3M™ Fibrlok™ Assembly Tool, 2501 rotate the toggle arms for the appropriate fiber size.

NOTE: Carefully follow health, safety and environmental information on Fibrlok II splice label or Material Safety Data Sheet.

Splicing Set-Up (2)

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Fiber Preparation (1)

3.1 Remove the minimum length of fiber required to prepare andsplice the fibers.3.2 Strip approximately 1 to 2 inches (25 mm to 51 mm) of plastic coating from the fiber using a mechanical stripper.

Note: The stripper should be in good operating condition to prevent scratches or other damage to the glass cladding. 1" to 2" (25 mm -51 mm)Note: Do not wipe the fibers more than two times, and limit the time that the bare fiber is exposed to the atmosphere.Note: Carefully follow health, safety and environmental information on container label or Material Data Sheet for isopropyl alcohol being used.

3.3 Clean the bare glass by pulling the fiber through an alcohol soaked lint-free wipe. This will remove any fragments or dirt remaining on the fiber.

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3.4 Cleave fiber to 12.5 mm ±0.5 mm (0.492 ±0.020 inches).

3.5 Check the cleave length using the 12.5 mm cleave lengthgauges on the 3M™ Fibrlok™ Assembly Tool. Adjust the cleaver to provide the prescribed cleave lengths. Check cleave lengths periodically during subsequent splicing operations.

• Note: The cleaver should be in good operating condition and used in accordance with the manufacturer's instructions.

• It is recommended that the cleaver provide a consistent cleave-to-coating length within ±0.5 mm. In addition, standard cleavers should produce cleaved ends within 2° of perpendicular and free of major defects. Cleavers specifically designed to produce controlled, angled cleaves of greater than 2°, but not more than 6°, may also be used with the Fibrlok™ II optical splice.

• Note: Do not allow cleaved end to contact tool. Do not clean the fibers again after they have been cleaved.

Fiber Preparation (2)

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Splice Assembly (1)

4.1 Push the fiber down into the fiber retention pad on the proper side of the splice.

4.2 Grasp the coated fiber about .25 inches (6 mm) from the bare glass and move the fiber end onto the fiber alignment guide on the assembly tool such that the end is resting on the alignment guide outside of the splice.

Note: Hold the coated portion of the fiber ONLY. Do not allow the cleaved end to contact any surface before insertion into the splice.Note: When splicing 250 μm to 900 μm coated fiber, always insert the 250 μm coated fiber first.Note: Fiber should be placed in the retention pad and Inserted into the splice immediately following cleaning to minimize exposure to the atmosphere and reduce the risk of contamination.Note: Push fiber straight into fiber alignment guide, NOT AT AN ANGLE.

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4.3 Gently continue pushing the fiber into the splice until resistance is felt. When fully inserted, the first fiber should be straight or have a slight bow – up to .1 inch (3 mm).

Note: If properly inserted, bare glass should not be visible outside of splice. If bare glass is visible, pull back slightly on fiber and continue insertion until resistance is met. Never fully remove fibers from splice after initial insertion. Do not pull on fiber after it has been properly inserted.

4.4 Prepare second fiber (strip, clean and cleave) as described in Section 3.4.5 Lay fiber into foam retention pad and begin to insert the fiber end into the splice, as in 4.01 and 4.02 4.6 Gently push the second fiber in small increments straight through the Alignment guide into the fiber entry port. As the coating of the second fiber enters the fiber entry port, watch for the bow in the first fiber to increase. This occurs when the end face of the second fiber contacts the first fiber and pushes the first fiber slightly back out of the splice. Continue gently pushing the second fiber until it meets resistance.

Splice Assembly (2)

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4.7 Following proper insertion, the second fiber will be approximately straight, but may have up to a .1 inch (3mm) maximum bow. At this point, the first fiber will have a larger bow than the second fiber and larger than it had initially.

4.8 Push the first fiber back against the second fiber until there areequal bows in both fibers.

• Do not pull on either of the fibers following establishment of the bows in the first and second fibers. The fiber ends must be held together by the compressive forces induced by the bows to produce a low loss splice.

• If fiber bows are NOT observed to move as described, repeat Steps 4.02 – 4.07 of Splice Assembly but DO NOT fully remove fibers from the splice. If bow movement is still not observed, remove fibers, strip, clean and recleave, checking for proper cleave length. Re-splice per splicing procedure using a new splice.

• Do not attempt to “tune” or optimize the splice as this may result in higher splice loss. The 3M™ Fibrlok™ II “tuned.” Fiber alignment.

Splice Assembly (3)

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4.10 Remove the 3M™ Fibrlok™ Splice from the assembly tool by first removing the fibers from the foam retention pads and then lifting the splice from the splice holding cradle.

Note: In the event a splice must be re-fabricated, simply cut the fibers at each end of the splice (this will remove 1-1/2“ of fiber from the loop) and re-splice per instructions. Splice fabrication will require a new splice and a length of 2 inches on each fiber.

Note: Do not remove fibers and re-use Fibrlok splices.

4.9 Pivot the handle of the Fibrlok assembly tool down until it contacts the cap of the Fibrlok splice. Squeeze the handle of the assembly tool as shown in order to close cap and actuate the splice. When possible, secure the tool to a work surface for added support. A snap sound will be heard when the splice is actuated.

Splice Assembly (4)

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Splicing any combination of 250 μm coated fiber and 900 μm buffered fiber.

5.3 If using the 3M™ Fibrlok Assembly Tool 2501, be sure that the retention pad toggle arms are in the inward position for 250 μmfibers and in the outward position for splicing 900 μm fibers.

5.1 Keep Fibrlok splices clean. Do not remove splices from sealed cavity until ready to use.

5.2 Place Fibrlok splice into splice holding cradle in assembly tool.

Splice Assembly (5)

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5.6 Insert first fiber into the end port until coating bottoms out. If splicing 250 μm coated fiber to 900 μm buffered fiber.

5.4 Strip and cleave first fiber to 12.5 mm ± 0.5 mm (0.492 ± 0.20 in).

5.5 Taking care not to touch fiber end face, place fiber into foam retention pad.

Splice Assembly (6)

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5.7 Strip and cleave second fiber to 12.5 mm ± 0.5 mm (0.492 ±0.020 in).

5.8 Taking care not to touch fiber end face, place second fiber into the other foam retention pad.

5.9 Insert second fiber into the other end port of splice until it contacts the first fiber.

5.10 Push the first fiber back against the second until there are equal bowls of approximately 5 to 8 mm (0.2 to 0.3 inches) in both fibers.

Splice Assembly (7)

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5.11 Push down the assembly tool handle until splice cap snaps closed.

5.12 Lift handle, remove the fibers from the foam retention pads, and remove completed splice from the tool.

Splice Assembly (8)

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Fiber Repositioning (1)

6.2 While the splice is in the splice holding cradle, insert the short prongs of the 3M™ Fibrlok™ II Splice cap lifter into the two holes on the side of the splice. The cap lifter will be at an angle to the splice. The long prongs will be resting against the top of the splice cap.

Note: Do not completely remove fiber from Fibrlok splices.

6.1 If high loss is observed after splice has been actuated, it is

possible that the fiber ends are separated. In this case, lift the splice

cap and reposition fiber ends, as instructed below.

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6.3 Slide the bottom of the cap lifter inward until it is in a vertical

position, lifting the splice slightly out of the cradle.

6.4 Hold the cap lifter in place with one hand and push down on the ends of the splice with the other hand. This action should reseat thesplice into the holding cradle and lift the cap at the same time.

6.5 Repeat fiber centering and splice actuation (See step 4.06 – 4.09.)If after two attempts an acceptable splice loss is not obtained, remove fiber, strip, clean and re-cleave. Resplice using a new splice.

Fiber Repositioning (2)

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Fiber Organization and Splice Storage (1)

Note: The following procedure must be followed when splicing 900 μm coated fibers and will improve fiber organization when splicing all fiber types.

7.2 Secure the buffer tubes of the fibers to be spliced to the tray sothat the fibers are free to rotate through the point of attachment.

7.3 Select the first two fibers to be spliced and lay them into the tray. Trim the fibers so they are the right length for splicing plusapproximately 1 to 2 inches (2.5 to 5 cm) for fiber end preparation.

7.1 When storing fiber slack in a splice tray, the spliced fiber ends will twist One full turn for each full loop of fiber being stored. This rotation places stress on the fibers. This rotational stress makes fiber organization more difficult and may affect fiber/splice performance, particularly in 900 μm coated fibers. The stiffness of the 900 μm fiber does not distribute this stress in the same manner as 250 μm coated fiber.

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7.4 Place the splice assembly tool close to or on top of the splice tray. Match the orientation of the tool to that of the splice holder or tray whenever possible.

7.5 Remove the minimum amount of fiber required for fiber preparation and splicing. Remove less than one loop if possible.

7.6 Prepare fibers and complete splice as described in Section 3 and 4.

7.7 Carefully lay the splice on top of the holder without securing theSplice into the holder.


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7.8 For 250 to 250 μm and 900 to 900 μm splices:a. Store the shorter of the two fibers in the tray.b. b. Observe how the splice lays in its relaxed state.

Rotate the splice through the smallest possible angle to install it in the tray.

c. Store the second fiber.

7.9 For 250 to 900 μm splices:a. Store the 900 μm fiber first.b. Grasping the splice by the 900 μm fiber, observe how the

splice lays in its Relaxed state. Rotate the splice through the smallest possible angle to install it in the tray.

c. Store the 250 μm fiber.


TAB

Insert Tab # 9 Here


TFOCA Fusion Splicing Lab

2

3

TFOCA Fusion Splicing Lab (1)

1. Take the parts from one end of the splice protection sleeve and slide them over one cable. Use the appropriate rubber seal, there are 2 included.

2. Slide the remaining parts and splice protection sleeve over the other cable.

Cable seal fittings

Rubber seal

Strain-relief

Cut end of cable

Cut end of cable

Cable protection sleeve

4

3. Place a mark 7 inches from the end of the cable.

4. Strip the jacket using the jacket removal tool.


5

5. Cut the Kevlar to 1.50 inches and bend it over the crimp support tube. Slide the crimp sleeve over the crimp support tube.

6. Insert the crimp sleeve with about 1/8 inch protruding from the die then crimp it.


6

7. Trim the Kevlar flush with the edge of the crimp sleeve.

8. Mark the buffers at 5.5 inches and at 6.5 inches from the cable strain-relief. Cut the fibers at the 6.5 inch mark.


7

9. Place the fibers through the fiber protection sleeve

10. Strip the buffer and acrylate coating from the fibers with the stripping tool. Strip in 1/8 inch or shorter pieces to prevent breaking the fiber. Clean the bare fibers with alcohol wipes.


8

11. Place two fibers into a holder. Use the correct holders, 250u or 900u holders. The coating should only protrude about 1/8 inch from the holder edge.

12. Insert the fiber holder into the one-action precision cleaver and cleave the fibers. Repeat steps 11 – 12 for the other piece of cable.


9

13. Hold the cable in position using adhesive tape and the clamps at the side of the case

14. Insert the fiber holders into the splicer. Ensure the bare fibers lay in the blue plastic V-grooves.


10

15. Press the green button to start the splicing procedure.

16. If the fibers are aligned correctly and clean, they will be fused. An estimated splice loss will be displayed when complete.


11

17. Remove the fibers from the splicer and carefully slide the splice protection sleeve over the fusion splice area making sure to center the splice protection sleeve.

18. Insert the fibers into the shrink compartment. Make sure the sleeve is centered between the length markers. (40mm or 60 mm sleeve)


12

19. Press the yellow button to start the shrinking procedure. The heat cycle is approximately 90 seconds. Carefully remove the fibers from the heater after the timer has buzzed.

Repeat steps 11 – 19 to splice the other 2 fibers.

20. Slide the strain-relief in position over the crimp sleeve and tighten the set screw.


13

21. Slide the cable seal fitting into position and tighten to the strain-relief.

22. Slide the cable protection sleeve over the splice protection sleeves.


14

23. Tighten the cable protection sleeve to the strain-relief.

24. Slide the other strain-relief fitting in position over the crimp sleeve. Tighten the cable protection sleeve to the strain-relief.


15

25. Tighten the set screw on the strain-relief.

26. Slide the other cable seal fitting into position and tighten to the strain-relief.

27. A completed cable protection sleeve.


TAB

Insert Tab # 10 Here

TFOCA II Connector Termination Lab

176

177

1. Slide the housing end, bend limiter, strain-relief, and crimp support tube over the cable

2. Place a mark 5 inches from the end of the cable.

TFOCA II Connector Termination Lab (1)

178

3. Remove the jacket with the jacket removal tool.

4. Cut the Kevlar to 1.50 inch and bend it over the crimp support tube. Slide the crimp sleeve over the crimp support tube.


179

5. Insert the crimp sleeve with about 1/8 inch protruding from the die then crimp it.

6. Trim the Kevlar flush with the edge of the crimp sleeve.


180

7. Mark the buffers 3.75 inches from the strain relief then cut them with the scissors.

8. Mark the buffers 3 inches from the strain relief according the template


181

9. Strip the buffer and acrylate coating from the fibers. Strip in 1/8 inch or shorter pieces to prevent breaking the fiber. Clean the bare fibers with alcohol wipes.

10. Mix the two parts of the epoxy and empty them into a syringe. Holding the syringe vertically, push the air out ensuring there are no air bubbles inside.


182

11. Holding the syringe firmly in the back of the ferrule, fill the ferrule until a bead of epoxy covers less then half the tip.


183

12. Carefully slide the fiber into the ferrule.

13. Slide the curing sleeves over the ferrule termini.


184

14. Secure the ferrules to the buffers using superglue.

15. Cure the glued ferrules in the oven. Curing time is about 15 minutes.


185

16. Scribe the fiber very close to the epoxy bead and break the fiber. Dispose of the fiber properly.

17. Air polish the ferrule using the brown 5 um paper until the fiber is even with the epoxy bead..


186

18. Using the polishing plate/pad and the brown 5um paper. Using a figure 8 motion, apply very light down pressure and polish until there is a light haze of epoxy remaining on the ferrule tip.

19. Polish about twenty figure 8's using the violet 1 um paper.


187

20. Polish another twenty figure 8’s using the light-grey 0.5um diamond paper.

21. Polish another twenty figure 8’s using the dark-grey 0.1 um diamond paper.


188

22. Inspect the polished end of the ferrule with the microscope to see that the epoxy is completely removed and that the tip is smooth and free of scratches.

Broken fiber Cracked fiberEpoxy ring

Marginal polish Good polish


189

23. Compress the spring on the termini using the diagonal cutters, install the termini in the termini retaining plate.

24. Slide the ceramic alignment sleeves over channels S1 and S2


190

25. Slide the ferrules into the black ferrule block

26. Slide the strain-relief over the crimp sleeve and align the slot on the black ferrule block with the nose of the strain-relief.

Align slot to nose


191

27. Insert the spacer. Tighten the set screw locking the strain-relief to the crimp sleeve

28. Align the slot on the ferrule block with the slot in the housing and slide the block into the housing until it mates correctly.

set screw


192

29. Slide the strain-relief and the bend limiter into position. The nose of the strain-relief will slide into the slot on the housing.

30. Screw the rear end onto the housing. Tighten the set screw on the rear end.


193

31. Screw the cap onto the housing to protect the ferrules from contamination.


TAB

Insert Tab # 11 Here

Testing and Troubleshooting

195

196

Fiber Optic Testing Equipment (1)

Continuity testing & visual fault locating

Microscopes

Testing fiber optic cables is normally performed prior to installation. Connectors and splices are normally tested immediately after the termination phase in the inside/outside plants. Continuity testing is done with a visible light source such as an LED or incandescent bulb in a fiber tracer, or a higher power visible laser in a visual fault locator. This testing tells you if the fiber is continuous and if the connections from end to end are set up correctly. A visual fault locator can also find problems like bending losses and broken fibers in short lengths of cable. Visual inspection with a microscope allows checking connector ferrule ends for scratches, cracks, dirt, and other contamination. It is always used in termination, but is also a valuable troubleshooting tool.

197

Fiber Optic Power Meter & Source

Optical Time Domain Reflectometer• Splice verification• Finding faults• Testing bare fiber on the reel

Fiber Optic Testing Equipment (2)

Fiber optic power meters are used for measuring power levels. Power meters are calibrated to read in either watts (milliwatts), or in dBm and operate at the standard wavelengths of fiber optic networks (850, 1300, & 1550 nm). They can be used for testing for loss when used with a compatible source. Connectors and splices have a set standard for loss that should not be exceeded. The fibers’ loss is wavelength dependent and therefore should be tested at the operating wavelength. OTDR testing uses a unique property of fiber, backscatter, to create a picture of the fiber and find faults. The OTDR sends out a high power pulse and measures the light scattered back to it. It is generally used for splice verification and troubleshooting, but some users also test bare fibers in cables on spools before installing it. Another advantage it has over a power meter & source is that it only requires access to one end of the fiber.

198

Microscope & VFL Testing

Needs cleaned Good Bad, fiber is chipped

Bad Mechanical SpliceBroken fiber in connector

Top: Fiber connectors under a microscope. Lower left: Mechanical splice being tested with a visual fault locator. This style splice has a window for easier testing. Lower right: A connector being tested with a visual fault locator. The end may be polished correctly and looks good under a microscope however the fiber is broken inside the connector. Continuity testers and visual fault locators are used for testing and troubleshooting short pieces of fiber that are accessible such as patch cords.

199

Insertion Loss Testing

POWER SOURCE

POWER METER

-16.9 dBm

POWER SOURCE

POWER METER

-16.9 dBm

LAUNCH REFERENCE

CABLE

LAUNCH REFERENCE

CABLE

CABLE BEING

TESTED

CABLE BEING

TESTED

RECEIVE REFERENCE

CABLE

COUPLER COUPLERS

Prior to testing any cable, ensure that reference cables have clean connectors. In single-ended testing only a launch reference cable may be used. In double-ended testing both a launch reference & a receive reference cable are used. It is also important to ensure the reference cables match the cable being tested. (62.5 um or 50 um multimode, 9 um singlemode.) Once you set the reference value, do not remove the reference cables from the source as it may not couple exactly the same power, voiding the reference value.

200

Insertion Loss TestingFOTP-171

POWER SOURCE

POWER METER

-16.9 dBm

LAUNCH REFERENCE

CABLE

CABLE BEING

TESTED

POWER SOURCE

POWER METER

-16.7 dBm

LAUNCH REFERENCE

CABLECOUPLER

FOTP-171 or single-ended testing A FOTP-171 test uses only a single launch reference cable to test. This method allows testing a single cable from either end to find out if one connector is bad. Its main use is testing patch cords to insure both connectors are good, but it can also be used to troubleshoot installed cables where one connector is suspected of being bad. The 0 dB reference is made by connecting the power meter to the output of the launch cable and measuring the power output. The cable under test is then connected to the launch cable and the meter. The loss measured is only the loss of the connector coupled to the launch cable. Any loss in the cable itself is negligible and can be ignored. If the loss is greater than 0.5 dB the connector could be bad and may need replaced. Take the cable being tested and reverse its connection to test the other connector. Average the two loss values to get the total loss of the cable.

201

Insertion Loss TestingOFSTP-14 and OFSTP-7

POWER SOURCE

POWER METER

-16.4 dBm

POWER SOURCE

POWER METER

-16.9 dBm

LAUNCH REFERENCE

CABLE

LAUNCH REFERENCE

CABLE

CABLE BEING

TESTED

RECEIVE REFERENCE

CABLE

RECEIVE REFERENCE

CABLE

COUPLERSCOUPLER

OFSTP-14 (multimode) and OFSTP-7 (singlemode) double ended testing. OFSTP-14/OFSTP-7 is used for testing installed and terminated cables. These tests are performed when testing the entire cable run including all connectors and splices. A meter and source with two reference cables, one on each end, are used. There are 3 methods for setting the 0 dB reference, which uses 1, 2, or 3 reference cables. This section will cover the two reference cable method. This method sets the 0 dB reference with the launch cable coupled to the receive cable, so that one coupled connector loss is included when setting the reference. Then when testing a cable with both launch and receive cables, the loss includes the loss of connectors on the cable under test and the loss of all the components in between, minus the loss of the coupled connectors included in the reference.

202

OTDR Testing

Unlike power sources and power meters which measure the loss of the fiber optic cable directly, the OTDR works indirectly. It uses backscattered light of the fiber to imply loss. The OTDR works like RADAR, sending a high power laser light pulse down the fiber and looking for return signals from backscattered light in the fiber itself or reflected light from connectors or splices.

203

OTDR Trace

Slope shows attenuation coefficient of the fiber

Connector or Mechanical splice

events

Fusion splice

Distance

dB orPowerlevel

Noise

End of Fiber

There is a lot of information in an OTDR display. The slope of the fiber trace shows the attenuation coefficient of the fiber and is calibrated in dB/km by the OTDR. In order to measure fiber attenuation, you need a launch cable (150 – 300 meters) attached to the OTDR. Connectors and splices are called events. Both should show a loss, but connectors and mechanical splices will also show a reflective peak so you can distinguish them from fusion splices. Understanding how to interpret OTDR traces requires lots of training and practice, and misinterpreting traces can be very expensive if good cables are rejected or bad ones accepted. The average recovery of an OTDR event is 0.5 to 1.5 meters. Which means that cables this short cannot be tested. Because of the price of an OTDR compared to a continuity tester or a visual fault locator, it is not cost effective to purchase an OTDR for premise cable testing / troubleshooting.

204

TIA/EIA 568 Standards for Fiber

Loss per kilometer of fiber

Connector Mating Loss: 0.75 dB for all connectors and wavelengths

Mechanical & fusion Splice Loss: 0.3 dB for all wavelengths

TIA (Telecommunications Industry Association) is accredited by the American National Standards Institute (ANSI) to develop voluntary industry standards for a wide variety of telecommunications products. EIA (Electronic Industries Alliance) is a trade organization composed as an alliance of trade associations for electronics manufacturers in the United States. Those associations in turn govern sectors of EIA standards activity. TIA 568 defines telecommunications cabling installation standards. The section covered here is the losses for cables, connectors, and splices.

Fiber Loss: For multimode fiber, the typical loss is about 3 dB per km for 850 nm sources, 1 dB per km for 1300 nm. (3.5 and 1.5 dB/km max per EIA/TIA 568).

For singlemode fiber, the typical loss is about 0.5 dB per km for 1310 nm sources, 0.4 dB per km for 1550 nm. (1.0 dB/km for premises, 0.5 dB/km max for outside plant at either wavelength per EIA/TIA 568).

Splice Loss: For a mechanical splice, the typical loss is 0.2 dB. For a fusion

splice, 0.05 dB. (0.3 dB max for both splices per EIA/TIA 568).

Connector Loss: For each connector, use 0.5 dB loss for most adhesive/polish connectors. The loss spec for pre-polished/splice connectors will be higher (0.75 max for any connector per EIA/TIA 568).

205

Power Budget Calculation (1)

Example OTDR trace of above network

In order to operate correctly, a fiber optic link must have an acceptable optical loss margin, simply meaning that the fiber optic link loss cannot exceed the difference between the transmitters’ output power and the receivers’ input sensitivity. For example: Transmitter output power: -10 dBm Receiver sensitivity: -25 dBm Difference (Dynamic Range): 15 dB Therefore, the fiber optic link loss cannot exceed 15 dB. However, don’t forget to add in a Link Loss Margin. As a general rule, the Link Loss Margin should be approximately 3 dB to allow for link degradation over time. Aging transmitters may lose power, connectors or splices may degrade or connectors may get dirty if opened. If cables are accidentally cut, excess margin will be needed to accommodate for restoration splices.

206

There are six steps in calculating the optical loss margin.

1. Fiber loss at the operating wavelength.2. Connector loss.3. Splice loss4. Total cable run attenuation5. Equipment Link Loss6. Loss Margin calculation.


For example: Step 1. Fiber loss at the operating wavelength 5 kilometers of singlemode @ 1310nm 0.5 dB/km (typical) = 2.5 db loss Step 2. Connection loss Where the cable connects to each piece of equipment is a connection. 5 connections @ 0.5 dB/ea (typical) = 2.5 dB loss Step 3. Splice loss 1 splice @ 0.2 dB (typical) = 0.2 dB loss Step 4. Total cable run attenuation Add steps 1-3. 2.5 + 2.5 + 0.2 = 5.2 dB loss

207

There are six steps in calculating the optical loss margin.

1. Fiber loss at the operating wavelength.2. Connector loss.3. Splice loss4. Total cable run attenuation5. Equipment Link Loss6. Loss Margin calculation.


Example Continued: Step 5. Equipment Link Loss Receiver sensitivity -30 dBm Transmitter output (average) -15 dBm Difference (Dynamic Range): 15 dB Recommended excess margin 3 db Maximum cable run loss 12 dB Step 6. Loss Margin calculation Maximum cable run loss - Total cable run attenuation = Link loss margin 12 dB – 5.2 dB = 6.8 dB

208

Troubleshooting & Restoration

Equipment used in Troubleshooting and Restoration:

Inspection Microscopes

Fiber Optic Cleaning Kit

Optical Loss Test Set

Continuity Testers / Visual Fault Locators

OTDR

Inspection Microscopes are used to identify dirty, damaged, or poorly finished connectors. Fiber Optic Cleaning Kit: Since many faults are caused by dirty connectors, a simple cleaning will fix these problems. Optical Loss Test Set: Used to isolate the problem to equipment or fiber cable connecting the equipment. Is the transmitter outputting the correct power level? Is enough power reaching the receiver? Continuity Testers / Visual Fault Locators: Continuity testers are inexpensive and use white light or LEDs to test short cables such as in a LAN. Visual fault locators use red diode lasers which are used to check for broken fibers as long as the cable jacket is translucent. OTDRs are better for long distance networks. They cannot easily identify most problems in a LAN due to their distance resolution.

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