CONNECTOR ASSEMBLY INSTRUCTION MANUAL
FOREWORD Thank you for purchasing FOCI s MT-RJ Optical Fiber Connectors. We are confident that our excellent manufacturing procedures and stringent quality control guarantee you have purchased a product that will provide many years of trouble-free service. By following the simple step-by-step assembly instructions and with competent polishing, you will be able to produce fiber terminations of high stability, featuring low insertion loss and low back reflection loss. This manual describes the assembly procedure of the P-CM-FX-02 & P-CM-MX-02 type connectors. We strongly advise careful reading of this entire manual before commencing assembly and use of this product. CONTENTS 1. Preparation and tools required for assembly 2. Complete parts 3. Step-by-step instructions a) Cable preparation b) Ferrule termination c) MT-RJ housing assembly 1. PREPARATION: a) Ensure the work surface is clean and dust-free with good lighting b) Assemble all necessary tools and equipment: Connector assembly tools: (from top to bottom, left to right) Shears PVC stripper Fiber stripper Sharp scissors Crimper Crimper
2. COMPLETE PARTS: Parts for FOCI MT-RJ connector (from left to right) Dust cover Body, connector Pin keeper Ferrule (MM) Ferrule, Boot, Spring Spring push Crimp eyelet Boot 3. STEP-BY-STEP ASSEMBLY INSTRUCTIONS: A: Cable preparation A.1 Insert firstly the boot (10) and then the crimp ring (9) onto the cable. A.2 Remove the cable jacket with the PVC stripper (1.3mm) according to the length as shown in the diagram below 2 7 5 1 7 5
A.3. Trim kevlar with shears to within 5 millimeters of the jacket using shears. A.4. Use sharp scissors to separate the 4 fibers of the ribbon cable. A.5.a) If you are using ribbon fiber, remove the middle two fibers as close as possible to the ribbon matrix material. Then strip the plastic and coating off the two outer fibers. A.5.b) If you are using FOCI duplex MTRJ cable, simply strip the plastic coating off the fibers to a length of 5mm. A.6. Clean the bare fiber strands with a lint-free wipe and alcohol to remove any coating residue.
A.7. Carefully slide the spring push over the fibers and over the kevlar ensuring that it gathers all the kevlar stands and holds them neatly out of the way. Slide the spring over the fibers up to the spring push. B. MT-RJ Cable Termination B.1. Using a clean toothpick, place a small drop of epoxy on the fibers. Spread evenly. B.2. Insert the ferrule boot into the back end of the ferrule until it stops.
B.3. Determine which edge of the ribbon is the #1 fiber. (Typically the #1 fiber is colored blue.) Take the MT-RJ ferrule and locate the #1 fiber side, then with the proper fiber orientation in the ferrule, carefully insert the fibers into the rear of the ferrule. The fibers should slide into the holes and pass smoothly through the ferrule end-face. If any resistance is felt, back the fiber out slightly and try again, watching through the window to ensure that both fibers are in the proper track. Any bending of a fiber signifies misalignment and may cause fiber breakage. B.4. Look into the ferrule window and make sure the edgeof the ribbon matrix is located betweek the back edge of the ferrule window and the step marking the end of the grooves. CAUTION: Pushing the edge of the ribbon matrix past the step and onto the grooves may cause the fibers to break. This problem is negated when using FOCI duplex MT-RJ cable. B.5. Using a toothpick, place a small drop of epoxy into the ferrule window and also into the holes on the ferrule end-face to form a small bead around the protruding fibers. B.6. Place the ferrule into the ferrule heater. Recheck the epoxy level in the window and add if necessary (some settling may occur due to the epoxy spreading to fill the cavity). Be careful not to overfill the cavity as excess epoxy must be removed after curing.
B.7. After curing, remove the ferrule from the oven and allow to cool. Break the fibers that protrude from the ferrule with carbide scribe. NOTE: Connectors are assembled as male or female type plugs. Male plugs have a pin guide with guide pins pre-installed, while female plugs have a pin clamp without guide pins. If assembling male connectors, ferrules must first be polished before completing MT-RJ housing assembly. C. MT-RJ Housing Assembly C.1. For female connectors: Take a female pin clamp and position it on the ribbon. Push the clamp over the ferrule boot securely against the rear of the ferrule. Slide the spring against the clamp and apply a slight pressure with the spring in order to hold it in place. Note: The pin clamp is not necessary if FOCI duplex MT-RJ cable is used. C.1. For male connectors: Obtain a male pin clamp and position it on the ribbon. Insert the guide pins into the holes in the rear of the ferrule. It is important for the pin clamp to sit securely against the ferrule rear in order for the housing to assemble properly. Slide the spring against the clamp.
C.2. Align the housing with the window side of the ferrule facing towards the latch of the connector, then slide the connector housing onto the ferrule until a click is heard as the spring push inserts into the housing. C.3. Using a clean toothpick or tweezers, pull the kevlar strands from underneath the spring push. C.4. Slides the crimp ring over the cable jacket ensuring at the kevlar strands are held between the crimp ring and the rear of the spring push. The crimp ring should be pushed all the way up to the spring push. C.5. Using the crimping tool (mm), crimp the large upper ring around the kevlar and spring push, then crimp the small lower ring around the cable jacket with the mm crimping hole. C.6. Slide the connector boot up over the crimp ring.