ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle Instruction Sheet 408-9971 08 DEC 08 Rev H Small Diameter Tubing m (Used with 250- m Coated Fiber) Short Boot Connector Kit Bare Buffer Boot m PVC Tubing (Used with 900- m Buffered Fiber) D Tubing Connector TYGON Assembly Crimp Bend-Limiting Eyelet Strain Relief Right-Angle Boot Coupling Receptacle Kit (Used with Jacketed Protective Cable) Protective Cover Cap Nut Lockwasher Protective Cap Coupling Receptacle Figure 1 1. INTRODUCTION Read these instructions and all referenced instructions thoroughly before starting assembly. This instruction sheet covers the application of all Ceramic and Polymer Ferrule Epoxy Style ST Fiber Optic Connector Kits to fiber optic cable with a jacket diameter no larger than 3.0 mm [.118 in.]. NOTE i Coupling Receptacle 501381-1 is used to mate two bayonet connectors in free-hanging or panel-mount applications. Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures and i This instruction sheet supercedes Instruction Sheet 408-9645. For Stainless Steel Ferrule ST Connectors, refer to Instruction Sheet 408-4151. NOTE Reasons for reissue of this instruction sheet are provided in Section 5, REVISION SUMMARY. illustrations are for reference only and are not drawn to scale. DTrademark of Saint-Gobain Performance Plastics Corp. 2. DESCRIPTION (Figure 1) Each connector kit typically consists of a connector assembly, a protective cover, a crimp eyelet, and strain relief or boot. Some kits include other components like a clear tubing and a bare buffer boot (both used with 900 mm buffered fiber), small diameter tubing (for use with 250 mm coated fiber), PVC tubing (for use with cables having a jacket diameter less than 2.5 mm [.098 in.], right-angle boots, or bend-limiting strain relief (for use with jacketed cable). The coupling receptacle kit consists of a coupling receptacle, lock washer, nut, and two protective caps. E2008 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. All International Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 7 LOC B ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle 3. ASSEMBLY PROCEDURE 3.2. Cable Preparation 3.1. Required Tools and Consumables DANGER The following tools and consumables are recommended for assembling the connector kits (related instruction sheets are in parenthesis). A. Tools -- Cable Preparation Template 501814-1 or Template Kit 501818-1 -- Aramid Shears 1278637-1 -- Cable Strip Tool 1754708-1 or Jacket Stripper 501198-1 (408-9394) and No-Nik{ Fiber Stripper 504024-1 (size 203 for 125-mm fiber - red handle) -- Epoxy Mixer 501202-1 -- PRO-CRIMPER* II Assembly Tool 1976850-1 and Die Assembly 58424-1 for 3.0 mm [.118 in.] cable diameter (408-4090) -- Protective Sleeve 502259-2 -- Heat Cure Oven Assembly 502134-1 (120V) (408-9460) -- Fiber Optic Sapphire Scribe Tool 504064-1 (408-4293) -- Polish Bushing 503337-1 (metal) or 503304-1 (black polymer) -- Polish Plate 501197-1 -- Inspection Microscope Kit 1754767-1 B. Consumables -- Alcohol Fiber Wipe Packet 501857-2 -- Epoxy Adhesive 1918652-1 or an anaerobic adhesive and anaerobic primer (LOCTITE 648 anaerobic adhesive and LOCTITE 7649 activator is recommended) NOTE For characteristics and safety data on epoxy, refer to material safety data sheet (MSDS) i supplied by the manufacturer. ALWAYS wear safety glasses when working with optical fibers. BE VERY CAREFUL to dispose of fiber ends properly. The fibers create slivers that easily puncture the skin and cause irritation. A. Jacketed Cable 1. Slide the short strain relief (small diameter end first) onto the cable. If the cable jacket diameter is less than 2.5 mm [.1 in.], slide the PVC tubing onto the cable. Slide the crimp eyelet (rolled end first) onto the cable. 2. Refer to the "OPTIMATE 2.5mm Bayonet (Polymer Composite)" strip length template (from the cable preparation template kit) or refer to Figure 2, Detail A, and using the cable stripper, strip the jacket to the dimension shown. Using the shears, trim the strength members to dimension shown. Using the fiber stripper, strip the buffer, then the coating to the dimension shown. NOTE For specific techniques on stripping (using the fiber stripper), see Instruction Sheet 408-9485. i 3. Clean the fiber thoroughly using an alcohol fiber wipe. 4. Evenly "fan out" the strength members from the buffer. B. 900 mm Buffered or 250 mm Coated Fiber 1. For buffered fiber, slide the bare buffer boot (small diameter end first), crimp eyelet (rolled end first), and clear tubing onto the buffered fiber. For coated fiber, slide the bare buffer boot (small diameter end first), crimp eyelet (rolled end first), clear tubing, and small diameter tubing onto the coated fiber. -- Epoxy Applicator Kit 501473-3 -- Resilient Polishing Pad 501523-1 -- Polishing Pad 501858-1 -- 5-mm Polishing Film 228433-8 -- 1-mm Polishing Film 228433-7 -- .3-mm Polishing Film 228433-5 -- lint-free cloth or tissue -- Final Polishing Film 502748-2 NOTE 408-9971 2. Strip the buffer and/or coating so that 16-17 mm [.630-.670 in.] of bare-glass is exposed, refer to the strip template, or Figure 2, Detail B. NOTE For specific techniques on stripping (using the fiber stripper), see instruction sheet 408-9485. i Professional Installer's Tool Kits 501258-7, -8, and -9 include all the tools and consumables i (except epoxy) required for assembly. 3. Clean the fiber thoroughly using an alcohol fiber wipe. { Trademark of Capewell Components Co. 2 of 7 Tyco Electronics Corporation Rev H 408-9971 ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle NOTE Recommended Stripping Dimensions follows: Detail A Jacketed Cable i Polymer Ferrule Connectors Y An alternate method in preparing the epoxy is as 1. Remove the tip of the epoxy applicator by twisting it one-quarter turn and pulling it away from the body of the applicator. X 8.89 [.35] 2. Install the open end of the epoxy applicator Note: Not to Scale into the epoxy, and pull back on the plunger to 6.35 [.25] draw epoxy into the applicator. See Figure 3. 3. Slide the tip onto the applicator, making sure it is firmly secured. Hold the applicator vertically, and slowly push on the plunger until a bead of 27.94 [1.10] epoxy appears at the tip. 29.21 [1.15] 35.56 [1.40] 38.10 [1.50] Epoxy Applicator (Tip Removed) Ceramic Ferrule Connectors Y X 8.89 [.35] Package Epoxy 6.35 [.25] 18.54 [.73] 19.81 [.78] 35.56 [1.40] Figure 3 38.10 [1.50] 3.4. Terminating the Fiber Detail B Buffered Fiber, or Coated Fiber 16 [.63] Note: Not to Scale 2. Inject the epoxy into the connector until a small bead with a diameter of approximately 0.76 mm [.030 in.], appears at the tip of the ferrule. DO NOT allow the bead get too large or smear. 17 [.67] Figure 2 3. Withdraw the applicator while simultaneously injecting the epoxy into the bore of the connector until it is approximately three-quarters full. 3.3. Preparing the Epoxy 1. Remove the separating clip from the epoxy package, and mix the epoxy thoroughly for 20 to 30 seconds. It is recommended to use the epoxy mixer for thorough mixing of the components. 2. Install the needle tip on the epoxy applicator. Make sure it is secure. Remove the plunger. 3. Cut the epoxy packet open, and squeeze the epoxy into the back of the applicator. Re-assemble the plunger. Hold the applicator vertically, and slowly push on the plunger until the entrapped air escapes and a bead of epoxy appears at the tip. Rev H 1. Remove the protective cap from the connector. Hold the connector with the knurled end up. Insert the tip of the epoxy applicator as far as possible into the connector body. See Figure 4, Detail A. 4. For jacketed cable, apply a drop of epoxy to the outside of the knurled end of the connector, and distribute it evenly around the circumference of the knurled end. See Figure 4, Detail B. DO NOT allow any epoxy on the coupling nut or spring area. 5. Using a twisting motion, gently insert the fiber into the connector until it bottoms. The fiber should appear at the tip of the ferrule. Refer to Figure 4, Detail C. For jacketed cable, make sure that the strength members are spread out evenly over the knurled end of the connector. See Figure 4, Detail C. Tyco Electronics Corporation 3 of 7 408-9971 ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle Detail A Detail C Detail B Cable For Jacketed Cable, Strength Members Spread Evenly Over Knurled End Epoxy of Connector Applicator Knurled End of Connector Epoxy Connector Body Ferrule Fiber Tip Figure 4 6. Twist the connector, and move it back and forth axially approximately 1.5 mm [.060 in.] to distribute the epoxy in the bore of the connector. Jacketed Cable For coated fiber, slide the small diameter tubing and clear tubing against the back of the connector, then slide the crimp eyelet over the clear tubing and onto the connector. See Figure 5. Crimp Eyelet If Using PVC Tubing Crimp For buffered fiber, slide the clear tubing against the back of the connector, then slide the crimp eyelet over the clear tubing and onto the connector. See Figure 5. Terminating the Connector 1 Eyelet Hand Tool 58433-4 2 PVC Die Assembly Tubing Clear Tubing Buffered Fiber Small Diameter Tubing and Clear Tubing (Under Crimp Eyelet) Alignment Key Crimp Eyelet (Under Crimp Eyelet) Crimp Eyelet Coated Fiber Resting Against Die Figure 6 Crimp Eyelet 3.5. Crimping the Connector Figure 5 CAUTION 7. For jacketed cable, slide the crimp eyelet toward the connector until it contacts the connector shoulder, trapping the strength members against the knurled end. If using the PVC tubing, slide it under the crimp eyelet until it bottoms. See Figure 5. 4 of 7 Make sure to crimp the connector before the epoxy cures. ! 1. Position the connector in the die assembly as shown in Figure 6. Tyco Electronics Corporation Rev H 408-9971 ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle NOTE i On all multi-fiber cable where the fibers lie in a DANGER BE VERY CAREFUL to dispose of fiber ends plane, position the connector alignment keys in properly. The fibers create slivers that can easily the same orientation during crimping. puncture the skin and cause irritation. 2. Actuate the tool according to the instructions packaged with the tool. 4. Insert the connector into the polishing bushing. See Figure 8. 3. Slide the protective sleeve onto the connector, and snap it into place using the coupling nut. Polishing Bushing 4. Clean excess epoxy from the connector, tool, and die assembly. 5. Taking care not to break the protruding fiber, firmly hold the front of the connector, and slide the short strain relief or bare buffer boot over the crimp eyelet and onto connector shoulder until it bottoms. Short Strain Relief (Ref) 3.6. Curing the Epoxy Figure 8 1. Hang the connector vertically with the tip down. 2. Using the heat cure oven assembly, cure the assembly 1 hour at 65_C [149_F]. 3.7. Cleaving the Fiber DANGER 3.8. Polishing the Fiber 1. Choose a flat end finish or physical contact (PC) end finish. NOTE ALWAYS wear safety glasses when working with optical fibers. BE VERY CAREFUL to dispose of connector might be exposed to a tough i fiber ends properly. The fibers create slivers that 2. Firmly support the connector assembly. 3. Place the blade of the scribe tool directly above the epoxy, and lightly draw the beveled edge across the fiber parallel to the tip of the ferrule. See Figure 7. After scoring the fiber, pull it straight away from the connector. mechanical environment, and the PC end finish is recommended for singlemode connectors and will provide better performance by reducing the easily puncture the skin and cause irritation. 1. Carefully remove the protective sleeve from the connector. The flat end finish is recommended when the optical power reflected back to the source. 2. For the flat end finish, place the white polishing pad on the polishing plate. For the PC end finish, place the green polishing pad on the polishing plate. 3. Place the 5-mm polishing film on top of the polishing pad. CAUTION ALWAYS place the polishing bushing on a clean area of the polishing film. NEVER start polishing ! on or across a dirty section of the film. Pull Fiber Straight Away Fiber Epoxy Ferrule Scribe Tool Tip Figure 7 Rev H 4. Holding the polishing bushing, not the connector, start polishing very lightly. Polish in an elongated figure 8 pattern. See Figure 9. Initially a small amount of exposed fiber will be worn away. This is indicated by a narrow white trace on the film. As the exposed fiber wears away, the trace will widen and darken, indicating that epoxy is being removed. At this point a moderate downward force may be applied while polishing. Check the tip of the ferrule often, and stop polishing on the 5-mm film when the epoxy is light blue. 5. Clean the polishing bushing and connector assembly with an alcohol fiber wipe. Tyco Electronics Corporation 5 of 7 408-9971 ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle Figure 8 Pattern This indicates that dirt was present during the polishing process. For PC end finish, some scratches can be removed by further polishing with polishing compound. Apply a fresh drop of compound to an unused area of the polishing cloth, and polish for 10 seconds. Re-examine the endface. DO NOT polish again if scratches remain. For flat end finish, polish for 15 seconds on the .3-mm film. Re-examine the endface. Figure 9 6. For the flat end finish, use the 1-mm film on the white polishing pad, and polish the fiber until only a very light blue trace of epoxy remains. For the PC end finish, use the 1-mm film on the green polishing pad, and polish the fiber for about 20 seconds. 7. Clean the polish bushing and connector assembly with an alcohol fiber wipe. 8. For both type end finishes, using the .3-mm film on the appropriate polishing pad, polish the fiber until all the epoxy is gone. Use only a light force on the polishing bushing. DO NOT over polish. Using the microscope, examine the tip of the ferrule. Stop polishing as soon as all the epoxy has been removed. 9. For the flat end finish, clean the connector with an alcohol fiber wipe, and dry with a lint-free cloth or tissue. For the PC end finish, remove the connector from the polishing bushing and place the final polishing film on the polishing pad. Apply a few drops of water to an unused area of the film. Move the connector on the water in 20 mm [.75 in.] diameter circles for 25 seconds to polish the fiber. NOTE S Small pits in the endface. This indicates that the fiber was polished too long on either the 5- or 1-mm film. Some pitting might not interfere with connector performance if it is not in the core area. S A lot of pits in the endface. This indicates that the fiber was polished too long on the 5-mm film. S A large fracture at the edge of the fiber (small chips in the outer rim of the fiber are permissible). This indicates that the fiber was broken below the surface of the ferrule during cleaving or initial polishing. 2. Place the protective cap on the ferrule of the connector if the connector is not going to be mated immediately. Acceptable Ferrule Tip Small Peripheral Chips One piece of final polishing film will be sufficient Fine Polishing Lines for 10 to 20 connectors. i Unacceptable 10. Clean the connector with an alcohol fiber wipe, and wipe dry with a lint-free cloth or tissue. Ferrule Tip 3.9. Inspecting the Endface DANGER Fiber Dark Scratches Fiber A Lot of Pits NEVER inspect or look into the end of a fiber when optical power is applied to the fiber. The infrared light used, although it cannot be seen, can cause injury to the eyes. 1. Inspect the polished fiber and ferrule (endface) with the microscope. Refer to Figure 10, and check for the following: Figure 10 S Dark scratches on the endface. 6 of 7 Tyco Electronics Corporation Rev H ST Ceramic and Polymer Ferrule Connector Kits and Coupling Receptacle Recommended Panel Cutout 408-9971 2. Assemble the coupling receptacle, lockwasher, and nut as shown in Figure 11. 7.88 [.311] (Min) 3. Lock the connectors into place using the coupling nut. NOTE Note: Not to Scale After coupling, ALWAYS push in axially on the back of each connector to ensure intimate i contact. 4. Place the protective caps on the coupling receptacle if the connectors are not going to be mated immediately. 9.68 [.381] Dia (Min) Coupling Receptacle 4. REPLACEMENT AND REPAIR Kit components are not repairable. Replace any damaged or defective components. DO NOT re-use terminated connectors by removing the cable. Panel 5. REVISION SUMMARY Lockwasher Revisions to this instruction sheet include: Nut Figure 11 3.10. Using the Coupling Receptacle Kit The coupling receptacle can be used free hanging, or it can be mounted on a panel. To mount the receptacle on a panel, proceed as follows: 1. Cut out the panel according to the dimensions given in Figure 11. Rev H S S S S S S S S S S S S Updated document to corporate requirements New title of document Added new artwork to Figure 1 Deleted table in Figure 1 Deleted and added text in Sections 1 and 2 New tools listed in Paragraph 3.1.A Deleted Paragraph 3.2.B and re-numbered Deleted and added text in Paragraph 3.2.B.2 Changed dimensions and callouts in Figure 2 Deleted text in Paragraph 3.4.7 Deleted NOTE in Paragraph 3.7.3 Deleted artwork in Figures 5 and 6 Tyco Electronics Corporation 7 of 7