Applications Engineering Notes

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1 Applications Engineering Notes Document Title Document Number MTP Brand Connector Installation Onto AEN-1420 Revision Number 1.1 Effective Date January 17, 2017

2 THE USE OF SAFETY GLASSES FOR EYE PROTECTION IS RECOMMENDED 1.0 Document Purpose This document describes the ribbonization, termination and housing assembly procedure for US Conec MTP brand fiber optic connectors onto 2.0 millimeter jacketed round cable containing 12 loose fibers and aramid yarn. 2.0 Required Equipment and Materials 3.0 mm round cable strip template (P/N 12392) Permanent marker ½ adhesive tape CLAUSS WS-5 cable jacket tool Heat-Shrink Tubing, ATUM (size = 3/1), 3:1 shrink ratio, High-Shrink-Ratio, Adhesive- Lined, Polyolefin Tubing. For use with 2.0 mm round cable OD. Heat-Shrink Tubing, Flexible Polyolefin with Adhesive Liner 2:1 Shrink Ratio, Nominal Size 3/16. For use with 2.5 mm round cable OD. Scissors US Conec fiber ribbonizing tool (P/N 8040) ½ Scotch 810 Magic Tape New razor blade or XACTO knife US Conec disposable fiber ribbonizing die (US Conec P/N 14316) LOCTITE 4861 Instant Adhesive US Conec cable holder P/N Thermal ribbon matrix stripper US Conec fiber cleaver MFA-004 or of 27

3 Isopropyl alcohol and lint free wipes Centrifuge or other outgassing device Epoxy Technologies 353 N/D epoxy bi-pak 3 cc syringe with a barrel tipped cap installed #25PPS.014 x.50 plastic needle tip US Conec vacuum pump kit, P/N MTA-021 (includes): ULVAC DAP-12S low-pressure vacuum pump (P/N 5683) 12 plastic tubing (P/N 5684) ¼ x ⅛ adapter for vacuum pump (connects tubing to pump) (P/N 6225) MT suction nozzle (P/N ) MT-RJ suction nozzle (P/N ) Horizontal epoxy curing oven (Domaille Engineering, LLC P/N CO-6500) US Conec scribing tool (P/N ) 3.0 mm round MTP brand crimp tool and die set (P/N 8202) OPTIPOP R optical connector cleaner (Male P/N 6226, Female P/N 6227) 3 of 27

4 3.0 Cable Preparation 3.1 Slide the round MTP brand hardware onto the cable in the following order: 1) 2.0 mm (P/N 14922) or 2.5 mm (P/N 8041) MTP brand round cable boot 2) 10 mm heat-shrink tubing (use applicable heat-shrink tubing size) 3) 2.0 mm (P/N 16424) or 2.5 mm (P/N 16425) round cable MTP crimp band 4) MTP brand 3.0 mm round crimp body/spring push (P/N 8272) 5) MTP brand 10N oval spring (P/N MTP-A12-03) Place a piece of tape around the cable to prevent the parts from falling off Place a mark on the cable jacket at 48 mm and 55 mm from the end. 3.3 Using the 1.0 mm/18 GA position of the CLAUSS WS-5 cable jacket tool, etch the jacket at the 48 mm mark. Using your fingers, pull the end of the jacket straight away from the cable, allowing the two to separate at the etched area. 4 of 27

5 1.0 mm 18 GA 3.3a 3.3b CAUTION: STRIPPING THE JACKET WITH THE TOOL MAY CAUSE DAMAGE TO THE FIBERS. 3.4 Using the scissors, remove the aramid yarn even with the cable jacket Using the 1.0 mm/18 GA position of the CLAUSS WS-5 cable jacket tool, etch the jacket at the 55 mm mark. Using your fingers, pull the end of the jacket straight away from the cable, allowing the two to separate at the etched area. 5 of 27

6 CAUTION: STRIPPING THE JACKET WITH THE TOOL MAY CAUSE DAMAGE TO THE FIBERS. 4.0 Fiber Ribbonization 4.1 See US Conec Document # AEN-1408, Operating Instructions for the US Conec Loose Fiber Ribbonizing Tool or US Conec Document # AEN-1414, Operating Instructions for the US Conec Disposable Loose Fiber Ribbonizing Die" for complete instructions for loose fiber ribbonization. 4.2 Trim the ribbonized fiber to 50 mm length MT Ferrule Termination 5.1 Fiber Ribbon Preparation Position the cable into the US Conec cable holder (P/N 13923) with the tape side of the ribbon facing up (if using the tape method for ribbonization). Close the cover on the jacket end of the holder. NOTE: The cover over the cable jacket does not secure the cable in place. 6 of 27

5.1.1 5.1.2 5.1.2 Position the ribbon into

side of the ribbon facing up (necessary for

Close the cover on the ribbon end of the

3 Using a thermal ribbon matrix stripper,

7 Position the ribbon into the ribbon tray of the holder with the tape side of the ribbon facing up (necessary for tape method ribbonization only). Close the cover on the ribbon end of the holder, securing the ribbon in place Using a thermal ribbon matrix stripper, remove the tape/adhesive and the fiber coating a 5.1.3b 7 of 27

5.1.3c 5.1.4 Place the cable holder into a fiber cleaving device and cut the fibers evenly at a length of 10 ( 2) millimeters.

8 5.1.3c Place the cable holder into a fiber cleaving device and cut the fibers evenly at a length of 10 ( 2) millimeters. Check for damaged or broken fibers. NOTE: Smooth, evenly cut fibers will aid insertion into the ferrule a 5.1.4b 8 of 27

5.1.4c 5.1.4d 5.1.5 Remove the cable from the cable holder.

millimeters. 5.1.6 Slide a rubber ferrule boot (P/N 20002-01) onto the ribbon.

Take care not to break the bare fibers. Larger End 5.1.

9 5.1.4c 5.1.4d Remove the cable from the cable holder. The length of un-stripped ribbon extending from the jacket should be approximately 30 millimeters Slide a rubber ferrule boot (P/N ) onto the ribbon. Position the boot so that the larger end will insert into the rear of the ferrule. Take care not to break the bare fibers. Larger End 5.1.6a 5.1.6b Carefully clean the bare fibers with lint-free wipes and isopropyl alcohol to remove any remaining coating residue and other contaminants. 9 of 27

NOTE: NOTE: Take care not to pull the boot off of the fibers while cleaning. If using the tape method for ribbonization, do not allow isopropyl alcohol to penetrate the tape of the ribbons.

10 NOTE: NOTE: Take care not to pull the boot off of the fibers while cleaning. If using the tape method for ribbonization, do not allow isopropyl alcohol to penetrate the tape of the ribbons. Doing so will cause the tape to lose adhesive properties, releasing the fibers. 5.2 Epoxy Preparation US Conec recommends use of EPO-TEK 353ND epoxy for all MTP brand products. However, different cure schedules are required for multimode and single-mode products. The recommended cure schedule for multimode products is 85 C ( 5 ) for 55 minutes minimum. The recommended cure schedule for single-mode products is 100 C ( 5 ) for 20 minutes minimum Obtain an EPO-TEK 353ND epoxy bi-pak 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. 10 of 27

5.2.2a 5.2.2b 5.2.3 Put the mixed epoxy into a 3 cc syringe with

Place the syringe into the centrifuge (or other outgassing

2.3b Failure to outgas will result in air being trapped in the

During curing, the air will expand, causing voids which will

11 5.2.2a 5.2.2b Put the mixed epoxy into a 3 cc syringe with a barrel tipped cap installed. Place the syringe into the centrifuge (or other outgassing device) and spin (outgas) for ten (10) minutes a NOTICE: 5.2.3b Failure to outgas will result in air being trapped in the epoxy. During curing, the air will expand, causing voids which will reduce the adhesive properties of the epoxy. This in turn may result in fiber pistoning, which will adversely affect the optical performance of the connector. 11 of 27

5.2.4 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. 5.2.5 Remove the barrel tipped cap from the syringe and replace with a #25PPS.

12 5.2.4 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 Remove the barrel tipped cap from the syringe and replace with a #25PPS.014 x.50 plastic needle tip. Compress the plunger until all air has been removed from the syringe. 5.3 Ferrule Installation Obtain a ferrule for the fiber type and number (4, 8, 12, etc.) you are working with and locate the M (multimode), S (single-mode), or E (single-mode MT Elite ) identifier mark located on the ferrule shoulder in the lower right-hand corner below the window. The fiber count is visible on the back shoulder. 12 of 27

side and an ME on the fiber count side. 5.3.

13 Identifier Mark Fiber Count NOTE: Multimode MT Elite ferrules have an M on the window side and an ME on the fiber count side Turn on the vacuum pump with the MT nozzle (P/N ) installed Apply epoxy through the front edge of the ferrule window along the fiber u-grooves. Ensure all fiber grooves are covered. Fiber U-Grooves 5.3.3a 5.3.3b 13 of 27

5.3.4 Place approximately 2 ( 1) millimeters of the ferrule, endface first, into the suction nozzle. Continue for approximately 5 seconds or until epoxy has filled all the fiber holes. 5.3.4a NOTICE: 5.

This may cause fiber pistoning, which will adversely affect the optical performance of the connector.

14 5.3.4 Place approximately 2 ( 1) millimeters of the ferrule, endface first, into the suction nozzle. Continue for approximately 5 seconds or until epoxy has filled all the fiber holes a NOTICE: 5.3.4b Failure to perform the previous step or performing it improperly could yield an inconsistent epoxy bond between the fibers and ferrule material. This may cause fiber pistoning, which will adversely affect the optical performance of the connector. After removal from the nozzle, an epoxy bead should be visible on the ferrule endface covering the fiber holes and should remain there through fiber insertion. CAUTION: Keep the guide pin holes free of epoxy. Epoxy in the guide pin holes will prevent connector mating With the #1 (dark blue) fiber aligned with the M, S, or E identifier mark, insert the fibers into the opening in the rear of the ferrule Tilt the ribbon slightly. Watch through the ferrule window as the fibers settle into the u-grooves of the shelf. This may be aided by gently moving the fibers within the ferrule window. 14 of 27

5.3.5.2 Slowly push the fibers along the u-grooves and insert them into the fiber holes in the ferrule.

15 Slowly push the fibers along the u-grooves and insert them into the fiber holes in the ferrule. The fibers should slide smoothly into the holes and pass through the ferrule end face; however, if any resistance is felt, back out slightly and try again, watching through the window to ensure all fibers are in the proper groove. Any bending of a fiber signifies misalignment and will cause fiber breakage Push the fibers through the ferrule until 0.5 to 1.0 millimeter of fiber coatings are visible through the window. Do not push the fiber coatings beyond the step marking the end of the guide grooves. CAUTION: Pushing the edge of the fiber coatings beyond the guide grooves may cause the fibers to break inside the ferrule Carefully slide the ferrule boot into the opening in the rear of the ferrule until it stops. When in proper position, the edge of the boot will be visible in the lower edge of the window of 27

5.4 Ferrule Curing 5.4.1 Apply epoxy into the window until the cavity is full and even with the top of the ferrule. Take care that no air pockets are formed inside the ferrule cavity.

Once all connectors to be cured are placed in the oven, set the oven to the temperature and cure time (if oven is programmable) for the type of ferrule and/or epoxy being cured.

16 5.4 Ferrule Curing Apply epoxy into the window until the cavity is full and even with the top of the ferrule. Take care that no air pockets are formed inside the ferrule cavity. NOTICE: Care should be taken not to overfill the cavity as excess epoxy must be removed after curing Place the ferrules into a horizontal curing oven with the window facing upward. Once all connectors to be cured are placed in the oven, set the oven to the temperature and cure time (if oven is programmable) for the type of ferrule and/or epoxy being cured. NOTE: Recheck epoxy level after five (5) minutes to ensure it is correct. See US Conec Document AEN-1904, US Conec Recommended MT Ferrule Epoxy Well Levels for more information. 16 of 27

5.4.3 5.4.4 After the cure time has elapsed, open the lid and remove the cured connectors. Allow to cool for ten (10) minutes. 5.4.5 Scribe the fibers along the epoxy bead.

17 After the cure time has elapsed, open the lid and remove the cured connectors. Allow to cool for ten (10) minutes Scribe the fibers along the epoxy bead. Grasp the fibers between the thumb and forefinger and gently pull the fibers straight away from the ferrule endface. See US Conec Document # AEN-1906, Recommended US Conec Diamond Usage Procedure for more information. 6.0 Ferrule Polishing For ferrule polishing please refer to the polishing equipment manufacturers guide for recommended processes or contact US Conec for more information. See US Conec Document # AEN-1512, US Conec Recommended Between-Step Cleaning Procedure for Flocked Cloth Polishing of MT Ferrules for more information on ferrule cleaning during and after polishing. 17 of 27

18 7.0 MTP Brand Connector Housing Assembly MTP brand connectors may be assembled as either females or males. Female connectors have a plastic pin clamp spacer with guide pin stubs (P/N 9386). Male connectors have a metal pin clamp with guide pins pre-installed. Standard multimode pin clamps have no punch-outs (PN 16739). Standard single-mode and multimode MTP Elite pin clamps have one punch-out (P/N 16740) Single-mode MTP Elite pin clamps have two punch-outs (P/N 16238) Follow the instructions for the type connector you are assembling. Standard Multimode Single-mode Elite Female Only Standard Single-mode and Multimode Elite Pin Clamps 18 of 27

7.1 Female Connectors: 7.1.1 Obtain a female pin clamp and position it on the ribbon. 7.1.1a 7.1.1b 7.1.2 Insert the guide pin stubs into the holes in the rear of the ferrule.

19 7.1 Female Connectors: Obtain a female pin clamp and position it on the ribbon a 7.1.1b Insert the guide pin stubs into the holes in the rear of the ferrule. Push the clamp over the ferrule boot and securely against the rear of the ferrule Slide the spring against the clamp and apply a slight pressure in order to hold the clamp in place. 19 of 27

7.2 Male Connectors: 7.2.1 Obtain a male pin clamp assembly and position it on the ribbon. 7.2.1a 7.2.1b 7.2.2 Insert the guide pins into the holes in the rear of the ferrule.

20 7.2 Male Connectors: Obtain a male pin clamp assembly and position it on the ribbon a 7.2.1b Insert the guide pins into the holes in the rear of the ferrule. Push the clamp over the ferrule boot and securely against the rear of the ferrule Slide the spring against the clamp. 20 of 27

21 7.3 Housing Installation 62.5µ multimode applications use beige housings (P/N MTP-A12-11) Standard 50µ multimode applications use black housings (P/N MTP-A12-02) Laser-optimized 50µ multimode applications and multimode MTP Elite applications use aqua housings (P/N 7871) Standard single-mode 8 angled applications use green housings (P/N 16007) Single-mode MTP Elite 8 angled applications use yellow housings (P/N 16918) Slide the ferrule into the outer housing, making sure the dot on the housing and the identifier mark on the ferrule are aligned. Push the ferrule through the outer housing until it stops with the end face protruding from the housing a 7.3.1b Slide the crimp body/spring push against the rear of the housing. Gently insert into the housing until the initial resistance is overcome. Insert the crimp body/spring push approximately one-half way into the housing. 21 of 27

7.3.2 7.3.3 7.3.3 While holding the crimp body (knurled)

straight back from the crimp body until the ferrule moves

4 Once the initial resistance is overcome, gently push the

22 While holding the crimp body (knurled) portion of the crimp body/spring push, gently pull the cable straight back from the crimp body until the ferrule moves freely up and down within the housing Once the initial resistance is overcome, gently push the crimp body/spring push into the housing until an audible click is heard of 27

7.4 Connector Crimping 7.4.1 Carefully pull the aramid yarn from the under the crimp body. EXTREME CARE MUST BE TAKEN TO NOT BREAK FIBERS! 7.4.1a 7.4.1b 7.4.2 If necessary, cut the aramid yarn even with the back of the crimp body/housing assembly.

3 Pull the crimp band over the crimp body until it seats securely against the back of the crimp body/housing assembly, capturing the aramid yarn between the crimp

23 7.4 Connector Crimping Carefully pull the aramid yarn from the under the crimp body. EXTREME CARE MUST BE TAKEN TO NOT BREAK FIBERS! 7.4.1a 7.4.1b If necessary, cut the aramid yarn even with the back of the crimp body/housing assembly. Gently pull the yarn to remove any slack that may be present. Evenly distribute the yarn around the circumference of the crimp body Pull the crimp band over the crimp body until it seats securely against the back of the crimp body/housing assembly, capturing the aramid yarn between the crimp body and crimp band. NOTE: No jacket should be captured between the crimp body and crimp band. 23 of 27

7.4.3 7.4.4 Gently pull the crimp band and jacket in opposite directions to remove any slack that may be in the fibers, aramid yarn, or jacket.

24 Gently pull the crimp band and jacket in opposite directions to remove any slack that may be in the fibers, aramid yarn, or jacket. CAUTION: Make sure the jacket is NOT pulled from under the back end of the crimp band Crimp the crimp band to the crimp body Place the connector into the cavity of the 3.0 mm round MTP brand crimp tool and die set (P/N 8202). Ensure the crimp band does not slide out of position. Squeeze the handles of the crimp tool together until a click is heard. Release the handles and remove the crimped connector. 24 of 27

25 a b c Slide the 10 mm heat-shrink tubing over the rear of the crimp band so that the rear of the crimp band and the cable jacket are covered Shrink the tubing over the crimp band and cable jacket using a heat gun. 25 of 27

26 a b 7.5 Connector Completion Slide the boot over the crimp band and shrink tube until it seats completely against the back of the crimp body/housing assembly Clean the ferrule endface with the OPTIPOP R optical connector cleaner. 26 of 27

7.5.2 7.5.3 7.5.3 Install the protective cap

27 Install the protective cap over the endface of the completed connector. 27 of 27

Applications Engineering Notes

Applications Engineering Notes Document Title Document Number MTP Brand Connector Installation Onto 3.0 mm Jacketed Round Cable With Loose Fibers AEN-1407 Revision Number 2.1 Effective Date November 15,