Applications Engineering Notes

Copyright 2018 US Conec, Ltd.

Document Title PRIZM® LightTurn® Connector Installation

Onto 1.8 mm Jacketed Round Cable With Loose Fibers and No Aramid Yarn

Document Number AEN-1416

Revision Number 2.0

Effective Date March 20, 2015

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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THE USE OF SAFETY GLASSES FOR EYE PROTECTION IS RECOMMENDED 0.0 Laser Safety

CAUTION – Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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1.0 Document Purpose

This document describes the termination, thermal curing method, and housing assembly procedure for US Conec PRIZM® LightTurn® brand multifiber optical connectors onto 1.8 mm jacketed round cable with loose fibers and no aramid yarn.

2.0 Required Equipment and Materials

Scissors or fiber optic side cutters

Permanent marker

Measuring scale

CLAUSS WS-5 cable jacket tool

LOCTITE® 4861 Instant Adhesive

US Conec disposable loose fiber ribbonizing die (USC P/N 14316)

Modified ribbon holder for 2.0 mm round cable (USC P/N 14446) or US Conec®

Fiber Holder (USC P/N 13926) and Fiber Stacker (USC P/N 13928)

Thermal ribbon matrix stripper (USC P/N MFA-001)

MicroCare Sticklers® Fiber Optic Splice and Connector Cleaner (USC P/N 8307)

Isopropyl alcohol, 99.8% pure

Lint-free wipes

Foam wrapped swabs (ChemTronics P/N 20050)

Laser cleaver, fixturing and software, Keyence 3 axis CO2 Laser Marker (USC P/N 13729)

AB9320, 2-part thermal cure epoxy (USC P/N 16874)

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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3cc syringe with barrel tipped cap installed

Centrifuge or other outgassing device

27-gauge (EFD P/N 7018404) or 30-gauge (EFD P/N 7018434) 45° bent metal needle tip

45X magnification stereoscope of other microscope

Domaille Engineering Universal Cure Oven

• Domaille Engineering P/N CO-6700 (120 volts)

• Domaille engineering P/N CO-6800 (240 volts)

Domaille engineering PRIZM® LightTurn® 12-position Curing Oven Tray

(Domaille Engineering P/N CO-15401

30µm SC polishing film (USC P/N MTA-030-SMC-300)

Ultrasonic cleaner

NEOCLEAN-PZ PRIZM® connector cleaner (USC P/N 14554) 3.0 Cable Preparation

3.1 Terminate both ends of the cable using MTP® brand connector parts according to US Conec document # AEN-1419, “MTP® Brand Connector Installation Onto 1.8 mm Jacketed Round Cable With Loose Fibers and No Aramid Yarn”.

3.2 Test the MTP® brand connectors for proper optical performance, then cut the

cable in the middle using scissors or fiber optic side cutters.

3.3 Slide the PRIZM® LightTurn® connector boot (P/N 13195) onto the cable in the orientation shown in photo 3.3a. Pull the MTP® brand connector 2.0 mm round boot from the connector crimp body/spring push as shown in photo 3.3b.

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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3.3a 3.3b

3.4 Slide the jacket out of the crimp body/spring push of the MTP® brand connector. Measure and mark a line at 10 mm from the end of the cable jacket.

3.4 3.5

3.5 Slide the jacket into the crimp body/spring push of the MTP® brand connector so

that the marked line is even with the end of the crimp body.

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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3.6 On the opposite end of the cable, mark a line at 40 mm using a permanent marker. Etch and remove the jacket using the 1.0mm (18 gauge) position of the CLAUSS cable jacket tool.

3.6a 3.6b

CAUTION: STRIPPING THE JACKET WITH THE TOOL MAY CAUSE DAMAGE

TO THE FIBERS.

ATTENTION: Follow Steps 3.7 through 3.13 for modified Fujikura ribbon holders (P/N 14446). For US Conec® Fiber Holder (USC P/N 13926), see instructions in section 4.0 of US Conec document # AEN-1422, “Operating Instructions for US Conec Fiber and Ribbon Holders”.

3.7 Mark a line on the fibers at 10mm from the end of the jacket. This line will be the start point for the ribbonization process.

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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3.7

3.8 Ribbonize the fibers according to US Conec document # AEN-1414, “Operating

Instructions for the US Conec Disposable Loose Fiber Ribbonizing Die”.

3.9 Mark a line on the fibers at 15mm from the end of the jacket.

3.9

3.10 Position the ribbonized cable into a modified ribbon holder (P/N 14446). Align

the marked 15mm line with the end of the clip in the ribbon tray. The jacket should seat in the recess of the ribbon holder. Close the cover on the jacket end of the holder to secure the cable in place

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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NOTE: The dark blue (#1) fiber should be positioned opposite the hinges of the ribbon holder as shown for proper orientation during PRIZM® LightTurn® ferrule installation.

3.10 3.11

3.11 Position the ribbon into the ribbon tray of the holder. Close the cover on the

ribbon end of the holder.

3.12 Place the ribbon holder with fibers into a thermal ribbon matrix stripper (P/N MFA-001) to remove the LOCTITE® 4861 instant adhesive and fiber coating.

3.12a 3.12b

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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NOTE: The length of the matrix extending from the ribbon clip after stripping should measure 2.5 - 3mm from the end of the ribbon clip.

3.13 Carefully clean the bare fibers with lint-free wipes and MicroCare Sticklers®

Fiber Optic Splice and Connector Cleaner (USC P/N 8307) to remove any remaining coating residue and other contaminants. Check for damaged or broken fibers, fiber cross-overs, or fiber tangles.

4.0 Laser Cleaving

4.1 Switch the key on the laser cleaver from the “OFF” position to the “LASER ON” position.

4.1

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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4.2 Place the ribbon holder (P/N 14446) and stripped fiber on the fixture within the laser cleaver. Align the notch on the ribbon holder with the ball plunger within laser cleaving fixture. The opposite side of the ribbon holder should seat squarely and securely against the fixture.

4.2a 4.2b

4.2c

Notch Ball Plunger

Ball Plunger In Notch

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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4.3 If using the US Conec® Fiber Holder (USC P/N 13926), install an additional fiber stacker (USC P/N 13928) onto the end of the holder to aid in supporting the fibers. Place the ribbon holder and stripped fiber on the fixture within the laser cleaver.

4.3a 4.3b

4.3c 4.3d

4.4 Open the laser cleaving software “Marking Builder 2”. Select

“File/Open/USConec/Laser Cleave Program”. Choose “Test Marking” to open the cleaver settings window.

Obtain Fiber Stacker

Fiber Stacker Properly Seated

Insert onto the Ribbon Fiber

Ball Plunger

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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4.4

4.5 Verify the laser cleaver settings. “Marking Laser” should be selected from the

“Test Marking Mode”. Then click the “Trigger” button shown.

4.5

4.6 Remove ribbon holder from the laser cleaver. Remove Fiber Stacker if

applicable. Leave the fibers in the ribbon holder.

4.7 Verify the cleaved fibers measure 2.5 – 3.0mm from the end of the ribbon matrix.

Trigger

Marking Laser

Select “Test Marking”

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4.7

NOTE: The cable must remain in the ribbon holder throughout the PRIZM®

LightTurn® ferrule installation and the epoxy filling/curing process. 5.0 PRIZM® LightTurn® Termination

5.1 When using the US Conec® Fiber Holder (USC P/N 13926), apply a bead of LOCTITE® 4861 Instant Adhesive approximately halfway between the ribbon holder and the stripped fibers on both side of the ribbon.

5.1

Verify Length 2.5 – 3 mm

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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NOTE: Skip step 5.1 for Modified Ribbon Holder (P/N 14446).

5.2 Identify the number 1 fiber position of the PRIZM® LightTurn® ferrule as shown.

5.2

5.3 Insert the fibers into the ferrule up to the middle of the front epoxy well and

gently blow the front epoxy well with clean pressurized air.

5.3

Stop Plane Fiber Tips

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6.0 Thermal Termination Procedure

6.1 Combine two parts of AB 9320 epoxy (USC P/N 16874). Slide the plastic clamp (divider) off of the epoxy bi-pak. Mix thoroughly for approximately 2 minutes until the epoxy has a consistent color throughout.

6.1a 6.1b

6.2 Pour the mixed epoxy into a 3 cc syringe with a barrel tipped cap installed,

covering the open end with tape to prevent epoxy leakage. Place the syringe into the centrifuge (or other outgassing device) and spin (outgas) for five (5) minutes.

NOTE: Failure to outgas will result in air being trapped in the epoxy. During

curing, the air will expand, causing voids which will compromise the adhesive properties of the epoxy. This, in turn, may result in fiber pistoning, which will adversely affect the optical performance of the connector.

6.3 Remove the syringe from the centrifuge and install the plunger into the syringe

approximately ½ inch. Invert the syringe and allow the epoxy to thoroughly settle against the plunger.

6.4 Remove the barrel tipped cap from the syringe and replace with a 27 gauge 45°

bent metal needle tip. Compress the plunger until all air has been removed from the syringe.

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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6.5 Make sure the fiber ribbon is inserted into the ferrule as described in Section 5.2.

6.5

6.6 Fill the front epoxy well first. Then push the fibers to the fiber stop plane and

verify the epoxy level in the front window. Additional epoxy can be added at this time, if needed. Proper epoxy level should be enough such that there is a smooth layer over the ribbon, but not so much that it sits flush with the top of the well walls. Be sure there are no air bubbles in epoxy at the fiber stop plane.

6.6

6.7 Fill the rear epoxy well with epoxy until level with top surface.

Stop Plane Fiber Tips

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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6.7a 6.7b

7.0 Thermal Curing Procedure

7.1 Insert the ribbon holder with fiber and PRIZM® LightTurn® ferrule assembly into the curing oven, sliding the ribbon holder along the insulator with the ferrule placed under the PRIZM® LightTurn® ferrule positioner plate.

7.1

PRIZM ® LightTurn® Ferrule Positioner Plate

Insulator

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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7.2 Close the oven lid.

7.3 Set the oven timer at 55 minutes and the temperature at 115° C according to US Conec document # AEN-1817, “US Conec PRIZM® Ferrule Curing Oven Operation”. Cure the epoxy for 55 minutes at 115˚C.

NOTE: Setting the temperature to 115°C on the US Conec PRIZM® LightTurn®

connector thermal curing oven allows the ferrule to reach 85°C as recommended by the epoxy manufacturer.

8.0 Visual Inspection and Final Cleaning

8.1 Remove the PRIZM ® LightTurn® connector from the curing oven and the ribbon holder.

8.2 Examine epoxy level in both the heel and toe windows using 45X magnification

stereoscope.

8.3 Remove any excess epoxy on the top surface of the ferrule using a 30µm SC polishing film. Gently polish away epoxy on the film with the guide pins up, taking care to not touch the exit window.

8.3

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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8.4 Clean the ferrule in ultrasonic cleaner bath with isopropyl alcohol for 10-15 seconds.

8.5 Blow dry with pressurized air concentrating on the lens area first.

8.6 Using 45X magnification stereoscope, inspect window areas for debris/residue

and remove with foam wrapped swabs (Chemtronics® P/N 20050) and isopropyl alcohol.

9.0 Housing Installation

9.1 Locate the toe and heel latches on the housing. The toe latch is smaller than the heel latch.

9.1

9.2 Insert the toe of the PRIZM® LightTurn® ferrule under the heel latch with the

guide pins facing upwards and slide toward the toe latch. See image 9.2a for the correct position. Jacket should rest against the ledge creating a positive stop within the connector housing. The length from the end of jacket to the end of the connector should measure 15mm for proper assembly.

Toe Latch Heel Latch

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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9.2a 9.2b

9.3 Assemble the two halves of the connector taking care that the loose fibers are captured in the fiber tray. Insert the front of the connector first, as shown, and snap the back half into place. Press the ends of the snap and cover to ensure the jacket is captured well within the two parts.

9.3a 9.3b

9.4 Slide the PRIZM® LightTurn® boot over the back half of the PRIZM® LightTurn®

connector.

NOTE: See Appendix A for housing removal instructions.

9.5 Align the tabs of the PRIZM® LightTurn® connector housing with the cutouts on the dust cap.

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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9.5 9.6

9.6 Squeeze the tabs on dust cap to insert the PRIZM® LightTurn® connector. The cap can be removed by pressing tabs on the dust cap.

10.0 MTP® Connector Final Assembly

10.1 Slide the MTP® brand connector 2.0mm boot over the back end of the spring push.

10.2 Refer to AEN-1413, “PRIZM® LightTurn® Visual Inspection Procedure” for the visual inspection requirements.

Appendix A – PRIZM® LightTurn® Housing Removal

Document Title: PRIZM® LightTurn® Connector Installation Onto 1.8 mm Jacketed Round Cable With

Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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1.0 Slide back the PRIZM® LightTurn® boot from the housing.

2.0 Separate the two connector housing halves.

3.0 Holding the housing, the toe end of the PRIZM® LightTurn® ferrule can be depressed with a small, blunt tipped object through the toe latch until the housing latches release.

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Loose Fibers and No Aramid Yarn Document Number: AEN-1416 Rev. 2.0

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