Corning Cable Systems Enhanced FuseLite Termination System

Corning Cable le Systems Enhanced FuseLite Termination System Instruction Manual

Corning Cable Systems reserves the right to improve, enhance, and modify the features and specifications of Corning Cable Systems products without prior notification. FuseLite is a registered trademark of Corning Cable Systems Brands, Inc. OptiStrip, TBII, and Splice Pak are trademarks of Corning Cable Systems Brands, Inc. Fiber-Clean is a trademark of ELV Technologies Inc. ST is a registered trademark of Lucent Technologies. No-Nik is a registered trademark of Clauss Cutlery, Inc. All other trademarks are property of their respective holders. 2000 Corning Cable Systems LLC All rights reserved. Corning Cable Systems SRP-006-322 Issue 1 October 2000 100 pages Corning Cable Systems LLC PO Box 489 Hickory, NC 28603-0489 USA 1-800-743-2675 FAX: 828-327-5973 International 828-327-5000 http://www.corning.com/cablesystems 2 FuseLite Termination System

Notes about this manual This two-part operator manual describes the operation of Corning Cable Systems FuseLite fusion splicers, which have built-in key pads and text displays. Section A describes the use of the unit for assembling enhanced FuseLite SC and FC and standard ST -compatible connectors on 900 µm tight-buffered and 250 µm furcated fiber and on 2.9 mm single-fiber and Enhanced OptiStrip (EOS) cables. If you are installing a FuseLite connector on cable other than Corning Cable Systems, call your customer service representative to inquire if a different procedure is necessary. Section B describes general maintenance procedures. Read this operator s manual carefully and follow its recommendations to ensure trouble-free operation of your fusion splicer. Definitions of terms used in warning notices This manual section uses a hierarchy of warning terms to provide you an indication of the severity of each precaution or warning notice. This hierarchy of warnings is intended only as a guideline, as unforeseen circumstances or an individual s health could escalate what could be a minor injury for an average person into a potentially life-threatening situation. Always read and carefully follow all warning notices. All warning notices that indicate that personal injury or property damage can result if proper precautions are not taken are clearly marked by this warning sign. DANGER, for the purpose of this manual, indicates that death, severe personal injury, or substantial property damage can result if proper precautions are not taken. WARNING, for the purpose of this manual, indicates that severe personal injury or substantial property damage can result if proper precautions are not taken. CAUTION, for the purpose of this manual, indicates that minor personal injury or property damage can result if proper precautions are not taken. Italics (e.g., as used in the previous paragraphs), or IMPORTANT, for the purpose of this manual, indicate information that has a special emphasis. NOTE, for the purpose of this manual, indicates a suggestion or additional information about the unit or process being described. Qualified Person, for the purpose of this manual, indicates a craftsperson who is trained and familiar with the installation, construction, and operation of the equipment and the hazards involved. FuseLite Termination System 3

Warranty Information The Corning Cable Systems FuseLite fusion splicer is warranted against defects in material and workmanship for a period of one year from date of shipment. Any FuseLite unit found to be defective during the warranty period may be returned, transportation prepaid, to the factory for repair without charge. This warranty does not apply to units that have been repaired or altered by an unauthorized person, or that have been subject to misuse, negligence, or accident. This warranty does not cover the following consummable items: electrodes, cleaver blades or protective lenses. A complete explanation of Corning Cable Systems warranties, and terms and conditions of sale may be found on the reverse side of Corning Cable Systems Quotations, Order Acknowledgement and/or invoice forms and only the Warranty appearing thereon is to be considered Corning Cable Systems Warranty. Repairs and Replacement Parts All inquiries regarding FuseLite splicer repairs, replacement parts, or additional copies of this manual should be directed to: Corning Cable Systems Customer Service Department P.O. Box 489-CS Hickory, NC 28603-0489 For US and Canada 1-800-743-2673 International 828-327-5000 This will assure you the fastest possible service. 4 FuseLite Termination System

Table of Contents Notes about this manual... 3 Warranty Information... 4 Repairs and Replacement Parts... 4 Section A FuseLite Termination System - Connector Assembly 1. Introduction... 11 Connector Specifications... 13 Connector Components... 13 Connector Ordering Information... 15 2. Precautions... 16 3. Tools and Materials... 17 Tools You Will Need... 17 The Crimp Tool... 18 The Bench Clamp... 19 4. Preparing the FuseLite Splicer... 20 5. SC and FC Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber... 22 6. SC and FC Connector Assembly on 2.9-mm Single-fiber and EOS Cables... 33 7. ST -Compatible Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber... 49 8. ST-Compatible Connector Assembly on 2.9-mm Single-fiber and EOS Cables... 57 9. Packing the FuseLite Splicer Case... 70 10. Testing FuseLite Connectors... 71 11. Testing FuseLite Connector Jumpers... 71 12. FuseLite Connector Maintenance... 72 FuseLite Termination System 5

Section B FuseLite Termination System Fusion Splicer Operation 1. Introduction... 79 Splicer Overview... 79 Technical Data... 79 2. Precautions... 80 3. Tools and Materials... 81 4. Parameters and Programs... 82 Parameters... 82 Setting the Parameters... 83 Selecting a Fixed Program... 83 Changing the Parameters... 84 5. Packing the FuseLite Splicer Case... 87 6. Maintenance... 88 Precautions... 88 Routine Cleaning... 89 Cleaning the Electrodes... 91 Replacing the Electrodes... 92 Replacing the Lens System Cover... 93 Replacing the Battery... 95 Glossary... 97 Appendix A - Error Messages... 99 6 FuseLite Termination System

Corning Cable le Systems Enhanced FuseLite Termination System Instruction Manual Connector Assembly Section A

Section A FuseLite Termination System - Connector Assembly 1. Introduction... 11 Connector Specifications... 13 Connector Components... 13 Connector Ordering Information... 15 2. Precautions... 16 3. Tools and Materials... 17 Tools You Will Need... 17 The Crimp Tool... 18 The Bench Clamp... 19 4. Preparing the FuseLite Splicer... 20 5. SC and FC Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber... 22 6. SC and FC Connector Assembly on 2.9-mm Single-fiber and EOS Cables... 33 7. ST -Compatible Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber... 49 8. ST-Compatible Connector Assembly on 2.9-mm Single-fiber and EOS Cables... 57 9. Packing the FuseLite Splicer Case... 70 10. Testing FuseLite Connectors... 71 11. Testing FuseLite Connector Jumpers... 71 12. FuseLite Connector Maintenance... 72 FuseLite Termination System 9

10 Connector Assembly Introduction

1. Introduction This manual describes how to assemble Corning Cable Systems enhanced FuseLite SC and FC and FuseLite standard ST -compatible connectors. The FuseLite splicer (Figure 1) joins an optical fiber to a factoryassembled ferrule assembly (Figures 2 and 3). Crimp Button Fiber Guide Plates Ferrule Holder Electrode Cover Retaining Lever Fiber Handler Display Screen (LCD) Carrying Handle Battery Control Panels Figure 1 Ferrule Assembly SC & FC Connectors Figure 2 Connector Assembly Introduction 11

Ferrule Assembly ST -compatible Connector Figure 3 FuseLite connectors are suitable for the following optical fiber types: 900 µm tight-buffered fibers 2.9-mm single-fiber cables 250 µm furcated fibers EOS installations 2.0 mm single-fiber cables Training Videotape A VHS-format videotape is also available for training purposes. Request the videotape from your customer service representative. 12 Connector Assembly Introduction

FuseLite Connector Specifications Attenuation: Reflectance: Durability: Temperature Cycling: 0.35 db typical - 55 db Ultra PC - 65 db Angled PC 200 cycles; 0.3 db -40 C to +75 C (-40 F to +167 F) 0.2 db Connector Components The respective FuseLite connector packages include the components shown in Figures 4, 5, and 6. SC Connector Figure 4 Connector Assembly Introduction 13

FC Connector Figure 5 ST -compatible Connector Figure 6 14 Connector Assembly Introduction

Connector Ordering Information Single-mode Single-mode angled polish Multimode 62.5µm Multimode 50µm SC 95-200-45R FC 95-200-35R ST -compatible 95-200-25 SC 95-200-46R FC 95-200-36R SC 95-000-45R FC 95-000-35R ST-compatible 95-000-25 SC 95-050-45R FC 95-050-35R Connector Assembly Introduction 15

2. Precautions Safety Is No Accident Please read and understand all the precautions below. Eye Protection Fiber Precautions Cable Precautions Laser Precautions Isopropyl Alcohol Precautions WARNING: Always wear eye protection whenever you are stripping or cleaving fiber, handling chemicals, or operating a crimp tool. Failure to do so may result in eye injury. WARNING: Cleaved glass fibers are very sharp and can pierce the skin easily. Do not let cut pieces of fiber stick to your clothing or drop in the work area where they can cause injury later. Use tweezers to pick up cut or broken pieces of the glass fibers and place them on a loop of tape kept for that purpose alone. Good housekeeping is very important. CAUTION: Do not bend fiber optic cable more sharply than the minimum recommended bend radius given in its specification sheet. Do not apply pulling force to the cable or allow it to kink. You may cause damage to the cable to the point it might have to be replaced. WARNING: Laser light, which can be invisible, can damage your eyes. Viewing it directly does not cause pain. The iris or your eye will not close involuntarily as when viewing a bright light, so serious damage to the retina of the eye is possible. Never look into the end of a fiber that may have a laser coupled to it. If you think you have accidentally exposed your eyes to laser light, arrange for an eye examination immediately. WARNING: Flammable. Flash point 59 F. Can cause irritation to eyes on contact. In case of eye contact, flush eyes with water for at least 15 minutes. Inhaling fumes may induce mild narcosis. In case of ingestion, consult a physician. Use with adequate ventilation. 16 Precautions

3. Tools and Materials Tools You Will Need For FC and SC connector installations on 900 µm tightbuffered and 250 µm furcated fiber and on 2.9-mm singlefiber and EOS cables, use the FuseLite kit (p/n FUSELITE2-0SM-T). The kit contains the following tools: Crimp tool (p/n 2812047-01) Bench clamp (p/n 210494-01) 203 µm No-Nik stripper* Scissors Fiber stripping tool (Miller )* Tweezers Buffer stripping tool (wire strippers)* Permanent ink marker pen Small flat blade screwdriver Connector gauge card (p/n 2812052-01) FBC-006F fiber cleaver* Alcohol wipes or Fiber-Clean wipes Electrode cleaning kit ST -compatible connector installations require use of tool kit (p/n FUSELITE-ST-KIT), which contains following ST-compatible-specific tools: ST-compatible ferrule holder, red stripe (p/n - 2812069-01) Crimp tool (p/n -2812003-01) Snap tool (p/n -2812039-01) Gauge card (p/n-2812011-01) In addition, you may need: Lint-free tissues (KimWipes wipes recommended) The TKT-300 Connector Cleaning Kit is recommended for proper connector cleaning. Tools marked with * each come with instructions. If you have not used one of these tools before, take time now to read through the instructions and practice with the tool. Tools and Materials 17

The Crimp Tool You will use a special tool to crimp parts of the FuseLite connector during this procedure. If you have never used a tool like this before, practice with it now. Hold the tool with one hand and squeeze the tool s handles together until the jaws shut. A little more pressure will make the tool jaws release and open. The tool can be manually released by pressing down on the release bar. Figure 7 18 Tools and Materials

The Bench Clamp The bench clamp (p/n 2104094-01) is recommended for the FuseLite crimp tool (Figure 7). To install the crimp tool in the clamp: a) Clamp the bench clamp to your work surface. b) Position the clamp s two thumbscrews until the ends of the screws are clear of the clamp s channel. c) Insert the FuseLite crimp tool into the channel of the clamp as shown in Figure 7. Make sure that the handle of the rigid side of the tool is resting on the channel surface. d) Align the recessed ends of the crimp tool s pivot pin with the thumbscrews. Run the screws into these holes and tighten. Tools and Materials 19

0 4. Preparing the FuseLite Splicer To prepare the FuseLite splicer for connector assembly: 4.1 Remove the FuseLite splicer from its case. If desired, rotate stand out for angled working position. 4.2 If using the unit with its AC adapter, insert the adapter plug into the outlet on the left side of the unit. Plug the adapter into a suitable AC outlet. NOTE: The splicer will operate from either AC or battery power supply. When operating from the battery power source the splicer will switch off automatically if battery capacity is too low. See section B 6.2 and 6.13 for additional battery information. P FuseLite MADE BY IN G SER HICKORY Figure 8 4.3 If operating the unit from its internal battery, ensure that the unit has been properly charged. Press the key on the control panel to turn the unit on. The status report screen will be displayed. Then press the key again and the battery charge level will be displayed momentarily. If the display indicates a charge level lower than 33 percent, use of the AC adapter is recommended. While the unit will work at this charge level, the battery charge level will quickly decrease with use. NOTE: The fusion splicer switches off automatically if no key has been activated for a given period of time. Press the key to switch the fusion splicer back on. 4.4 The splicer memory automatically recalls the last program used. Press the P key to display the parameter menu/program selection 20 FuseLite Splicer - Introduction

screen. To select a fixed program: press the or keys to scroll to the fixed program option. Press the key to enter fixed program menu. Use the or to select the desired program. Press the key to make it the active program. Return the splicer to normal operation by pressing P key. Table A-1 indicates the available programs at the time this manual was printed. To modify the value of any parameter, refer to Section B, page 82. Table A-1 Standard single-mode Multimode 50 µm Multimode 62.5 µm For further information, see Programs and Parameters (Section B, page 82). IMPORTANT: Clean the electrodes as described in Section B, page 91 prior to use and after every 75-100 splices or whenever splice losses increase to unacceptable levels for over 5 consecutive splices. FuseLite Splicer - Introduction 21

5. SC and FC Connector Assembly - on 900 µm Tight-buffered and 250 µm Furcated Fiber SC and FC NOTE: This section describes the installation of FuseLite SC and FC connectors on 900 µm tight-buffered and 250 µm furcated fiber. While much of the procedure is common for both connector types, there are connector-specific differences. The narrow column on the left side of each page and outlined step numbers will indicate text referring to specific connector type or types. Use only the steps appropriate to the connector being installed. To install a FuseLite connector on 900 µm tight-buffered or 250 µm furcated fiber, follow these steps: 5.1 Remove the caps from the front and rear of a ferrule assembly. Save the front cap for later use. 5.2 Load a ferrule assembly into the green ferrule holder. Ensure the slot of the ferrule assembly key aligns with the key in the ferrule holder. Apply slight pressure toward the holder until the key locks into place. 5.3 Open electrode cover and install ferrule holder into splicer, to place the ferrule assembly between the electrodes. Green Stripe Figure 9 5.4 Close the electrode cover. Verify that the stub fiber in the ferrule s fusion area is visible on the LCD. 22 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

5.5 Slide the 900 µm stair step boot, small end first, down the field fiber until it s out of the way. Next slide the crimp body/housing assembly (SC), or crimp body/threaded nut assembly (FC) after removing dust cover, small end first, down the fiber. Figure 10 5.6 Measure and mark 50 mm from the end of the buffer. Then measure and mark an additional 12 mm past the 50 mm mark. Remove the 50 mm section of buffer with the 203 µm No-Nik tool. Work in 10 mm increments and pull in a straight line to prevent fiber breakage, as described in the No-Nik tool s manual, SRP-004-036. Figure 11 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 23

5.7 Position the fiber in the 900/250 fiber handler with the 12 mm mark from the end of the buffer aligned with the 900 end of the handler. Close both fiber clamps starting with the 900 end. 900 µm Tight-buffered Fiber 250 µm Furcated Fiber Figure 12 NOTE: Installation on 250 µm furcated fiber, use 900/900 loose tube fiber handler. IMPORTANT: Ensure that the 12 mm mark is aligned with the end of the handler. If not, open clamps and adjust. NOTE: Used away from the splicer, a heat gun can straighten 900 µm buffer if bends exist. Such bends are typical for retrofits where the fibers were installed in connector modules. 5.8 Clean the bare fiber with an alcohol wipe or Fiber- Clean wipe. Do not touch the bare fiber after cleaning it. CAUTION: Make sure the fiber is completely clean. A fiber with any contamination will cause splicing problems. 5.9 Place the fiber handler in the FBC-006F cleaver. Ensure the end of the 900 µm buffer is even with the 6 mm mark. Slowly close and press the lever to cleave the fiber to 6 mm. Do not apply excessive force when cleaving as this can give bad cleaves and may damage the cleaver. If the fiber will not cleave, clean the cleaver s upper and lower pads. IMPORTANT: Ensure that fiber placement in cleaver is correct to obtain a 6 mm cleave length. If not, adjust the set screw on the cleaver. NOTE: Check cleave length to ensure that it is between 6.0 mm and 6.5 mm. Shorter or longer cleaves will not allow proper connector assembly. 24 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

Set Screw Figure 13 5.10 Return splicer cover to the open position. 5.11 To load the prepared field fiber handler. a) Ensure the retaining lever is in the unlocked position. b) Place the fiber handler in the field fiber stage. Approximately 2 mm of the 900 µm buffer will extend past the fiber guide plates. c) Lock the fiber handler into place. Figure 14 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 25

5.12 Close the electrode cover. 5.13 To fuse the field fiber to the FuseLite ferrule: Press the key to start the fusion process. Do not open the cover at any time during the fusing process, as this will terminate the arc. The automatic mode will include the cleaning arc, contamination detection, and fusion. Upon completion, the screen will display the estimated splice loss. If the splicer displays an error message, refer to Appendix A, page 99, for appropriate action to take. Figure 15 NOTE: Because of the fiber illumination technique used in this FuseLite splicer, the image of the fiber displayed on the screen is less bright than the image displayed by other Corning splicers. 26 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

5.14 Crimp the lead-in tube around the buffered fiber by pressing down firmly on the red crimp button. 900 250 Figure 16 5.15 Open the electrode cover a) Open fiber clamps on the fiber handler. Carefully lift the ferrule holder and fiber as one unit to remove from splicer. 900 250 Figure 17 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 27

b) Holding onto the metal portion of the ferrule assembly, pull the ferrule holder straight off the ferrule assembly. CAUTION: The ferrule assembly may be hot from splicing. c) Reinstall the front cap onto the end of the ferrule. d) Press the key to reset splicer. Figure 18 5.16 Using the crimp tool, apply an additional crimp to the ferrule assembly to further secure the fiber. a) Place the ferrule assembly into the tool s semicircular die so the ferrule key contacts the side of the tool. Make sure that the entire ferrule assembly s lead-in tube is in the flat-groove. b) Close and release the handles of the tool to make the second crimp. For final assembly steps of FC connectors, skip to step 5.17 on page 29. Figure 19 28 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

FINAL ASSEMBLY SC CONNECTORS SC ONLY 5.17 To complete the assembly of the FuseLite SC connector: a) Align the slot of the ferrule assembly key with the white housing s large slot on the beveled side of the housing. Push firmly until the ferrule assembly snaps into place. (The splice notch in the ceramic ferrule must be opposite (180 o ) from the beveled side of the white housing for correct assembly.) Figure 20 b) Slide the boot into place over the rear of the connector assembly. Figure 21 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 29

SC (Cont.) c) Push the shroud over the front of the white housing. The shroud key must line-up with the large slot on the white housing. Wiggling the shroud will help it snap into place. Figure 22 Assembly of the FuseLite SC connector is now complete. 30 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

FINAL ASSEMBLY FC CONNECTORS FC ONLY 5.17 To complete the assembly of the FuseLite FC connector: a) Align the slot of the key on the ferrule assembly with the notch on the front face of the shroud inside the threaded nut assembly. Insert the ferrule assembly into the crimp body/threaded nut assembly. Push firmly until the ferrule snaps into place. Figure 23 b) Slide the boot over the rear of the crimp body. Figure 24 Assembly of the FuseLite FC connector is now complete. Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 31

NOTES: 32 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

6. SC and FC Connector Assembly on 2.9-mm Single-fiber and EOS Cables SC and FC NOTE: This section describes the installation of FuseLite SC and FC connectors on 2.9-mm single-fiber and EOS cables. While much of the procedure is common for both connector types, there are connector-specific differences. The narrow column on the left side of each page and outlined step numbers will indicate text referring to specific connector type or types. Use only the steps appropriate to the connector you are installing. 6.1 To install a FuseLite connector on 2.9-mm jacketed or EOS cable, follow these steps: 6.2 Remove the caps from the front and rear of a ferrule assembly. Save the front cap for later use. 6.3 Load a ferrule assembly into the green ferrule holder. Ensure the slot of the ferrule assembly key aligns with the key in the ferrule holder. Apply slight pressure toward the holder until the key locks into place. The ferrule should not rotate in either direction when locked into position. 6.4 Open electrode cover and install ferrule holder into splicer, to place the ferrule assembly between the electrodes. Green Stripe Figure 25 6.5 Close the electrode cover. Verify that the stub fiber in the ferrule s fusion area is visible on the LCD. Connector Assembly on 2.9-mm Single-fiber and EOS Cables 33

6.6 Slide the 2.9-mm segmented boot, small end first, down the field fiber until it is out of the way. Now slide the crimp ring, small inner diameter end first, and the crimp body/housing assembly (SC), or crimp body/threaded nut assembly (FC), after removing the dust cover, small end first, down the fiber. 6.7 Measure and mark 50 mm from the end of the cable s outer jacket Figure 26 Figure 27 6.8 Strip off the 50 mm section of the outer jacket with the 16 AWG opening of the buffer stripping tool. Figure 28 34 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

6.9 Measure and mark aramid yarn at 10 mm from end of cable jacket. CAUTION: Do not cut the aramid yarn at this time. 6.10 Gather the yarn, fold it back against the cable jacket, and hold it in place. Measure and mark a point 12 mm from the end of the cable jacket on the 900 µm buffer and at the jacket. Figure 29 Figure 30 6.11 Strip the 900 µm buffer to the 12 mm mark with the 203 µm No-Nik tool. Work in 10 mm increments and pull in a straight line to prevent fiber breakage, as described in the No-Nik tool s manual, SRP-004-036. IMPORTANT: Ensure the 12 mm mark on buffer is aligned with end of jacket. Figure 31 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 35

6.12 Place the fiber in the 900/3000 fiber handler. Align the 12 mm mark next to the jacket at the 900 end of the 900/3000 fiber handler; fold the aramid yarn back next to the jacket. Close both fiber clamps starting with the 900 end. 2.9 mm Jacketed Cable EOS Cable Figure 32 NOTE: Installation on EOS cable, use 900/3000 loose tube fiber handler. 6.13 Clean the bare fiber with an alcohol wipe or Fiber- Clean wipe. Do not touch the bare fiber after cleaning it. CAUTION: Make sure the fiber is completely clean. A fiber with any contamination will cause splicing problems. NOTE: Used away from the splicer, a heat gun can straighten 900 µm buffer if bends exist. Such bends are typical for retrofits where the fibers were installed in connector modules 6.14 Place the fiber handler in the FBC-006F cleaver. Ensure the end of the 900 µm buffer is even with the 6 mm mark. Slowly close and press the lever to cleave the fiber to 6 mm. Do not apply excessive force when cleaving as this can give bad cleaves and may damage the cleaver. If the fiber will not cleave, clean the cleaver s upper and lower pads. Set Screw Figure 33 36 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

IMPORTANT: Ensure that fiber placement in cleaver is correct to obtain a 6 mm cleave length. If not, adjust the set screw on the cleaver. NOTE: Check the cleave length to ensure that it is between 6.0 mm and 6.5 mm. Shorter or longer cleaves will not allow proper connector assembly. 6.15 Return the splicer cover to the open position. 6.16 To load the prepared field fiber handler. a) Ensure the retaining lever is in the unlocked position. b) Place the handler in the field fiber stage. Approximately 2 mm of the 900 µm buffer will extend past the fiber guide plates. c) Lock the fiber handler into place. Figure 34 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 37

6.17 Close the electrode cover. 6.18 To fuse the field fiber to the FuseLite ferrule: Press the key to start the fusion process. Do not open the cover at any time during the fusing process, as this will terminate the arc. The automatic mode will include the cleaning arc, contamination detection, and fusion. Upon completion, the screen will display the estimated splice loss. If the splicer displays an error message, refer to Appendix A, page 99, for appropriate action to take. Figure 35 38 FuseLite Termination System

6.19 Crimp the lead-in tube around the buffered fiber by pressing down firmly on the red crimp button. Figure 36 6.20 Open the electrode cover a) Open fiber clamps on the fiber handler. Carefully lift the ferrule holder and fiber as one unit to remove from splicer. Figure 37 FuseLite Termination System 39

b) Holding onto the metal portion of the ferrule assembly pull the ferrule holder straight off the ferrule assembly. CAUTION: The ferrule assembly may be hot from splicing. c) Reinstall the front cap onto the end of the ferrule. Figure 38 d) Press the key to reset splicer. 6.21 Using the crimp tool, apply an additional crimp to the ferrule assembly to further secure the fiber. NOTE: Ensure aramid yarn is folded back and does not interfere with the crimp tool. Figure 39 40 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

a) Place the ferrule assembly into the tool s semicircular die so that the ferrule key contacts the side of the tool. Make sure that the entire ferrule assembly s lead-in tube is in the flatgroove. b) Close and release the handles of the tool to make the second crimp. 6.22 Trim aramid yarn at the 10 mm mark made in step 6.9. After cutting the yarn, roll the end of the jacket between your fingers to redistribute the yarn. Figure 40 For final assembly steps of FC connectors, skip to page 45. Connector Assembly on 2.9-mm Single-fiber and EOS Cables 41

FINAL ASSEMBLY SC CONNECTORS SC ONLY 6.23 To complete the assembly of the FuseLite SC connector: a) Align the slot of the ferrule assembly key with the white housing s large slot on the beveled side of the housing. Push firmly until the ferrule assembly snaps into place. (The splice notch in the ceramic ferrule must be opposite (180 o ) from the beveled side of the white housing for correct assembly.) Figure 41 b) With tweezers, pull aramid yarn out from under the housing. Distribute yarn around base of crimp body/housing assembly. CAUTION: Yarn must be distributed evenly to ensure strain relief. Figure 42 42 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

SC (Cont.) c) Slide the crimp ring over the crimp body/ housing assembly. Figure 43 d) Place the rear of the assembled crimp body/ housing assembly into the hex opening in the Fuselite connector crimp tool so that the connector housing contacts the side of the crimp tool. Figure 44 e) Crimp the 2.9-mm cable by squeezing the handles together until the jaws close and release. Remove the connector from the tool. Figure 45 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 43

SC (Cont.) f) Align the top of the boot with the beveled edges of the housing. While maintaining this alignment, slide the boot into place over the rear of the connector assembly. Figure 46 g) Push the shroud over the front of the white housing. The shroud key must line-up with the large slot on the white housing. Wiggling the shroud will help it snap into place. Figure 47 Assembly of the FuseLite SC connector is now complete. 44 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

FINAL ASSEMBLY FC CONNECTORS FC ONLY 6.23 To complete the assembly of the FuseLite FC connector: a) Align the slot of the key on the ferrule assembly with the notch on the front face of the shroud inside the threaded nut assembly. Insert the ferrule assembly into the crimp body/threaded nut assembly. Push firmly until the ferrule snaps into place. Figure 48 b) Remove front cap and install dust cover. Align large notch in dust cover with notch on front face of shroud. Push dust cover into place. NOTE: Dust cover must be installed to ensure proper crimping. Figure 49 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 45

FC (Cont.) c) With tweezers, pull aramid yarn out from under the housing. Distribute yarn around base of crimp body/threaded nut assembly. CAUTION: Yarn must be distributed evenly to ensure strain relief. Figure 50 d) Slide the crimp ring until it is just behind the threaded nut. Figure 51 e) Place the rear of the assembled crimp body/ threaded nut assembly into the hex opening in the Fuselite connector crimp tool so that the threaded nut contacts the side of the crimp tool. 46 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

FC (Cont.) Figure 52 f) Crimp the 2.9-mm cable by squeezing the handles together until the jaws close and release. Remove the connector from the tool. Figure 53 g) Slide the boot into place over the rear of the connector assembly. Figure 54 Assembly of the FuseLite FC connector is now complete. Connector Assembly on 2.9-mm Single-fiber and EOS Cables 47

NOTES: 48 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

7. ST -compatible Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber NOTE: This section describes the installation of FuseLite standard ST-compatible connectors on 900 µm tight-buffered and 250 µm furcated fiber. To install a FuseLite connector on 900 µm tight-buffered or 250 µm furcated fiber, follow these steps: 7.1 Remove the caps from the front and rear of a ferrule assembly. 7.2 Load a ferrule assembly into the red ferrule holder. Ensure the slot of the ferrule assembly key aligns with the key in the ferrule holder. Apply slight pressure toward the holder until the key locks into place. 7.3 Open electrode cover and install ferrule holder into splicer, to place the ferrule assembly between the electrodes. Red Stripe Figure 55 7.4 Close the electrode cover. Verify that the stub fiber in the ferrule s fusion area is visible on the LCD. Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 49

7.5 Slide 900 mm stair-step boot, small end first, down the field fiber until it is out of the way. Next, slide the crimp body, small end first, and the spring, down the fiber. Figure 56 7.6 Measure and mark 50 mm from the end of the buffer. Then measure and mark an additional 10 mm past the 50 mm mark. Remove the 50 mm section of buffer with the 203 mm No-Nik tool. Work in 10 mm increments and pull in a straight line to prevent fiber breakage, as described in the No-Nik tool s manual, SRP-004-036. Figure 57 7.7 Position the fiber in the 900/250 fiber handler with the 10 mm mark from the end of the buffer aligned with the 900 end of the handler. Close both fiber clamps starting with the 900 end. IMPORTANT: Ensure that the 10 mm mark is aligned with the end of carrier. If not, open clamps and adjust. 900 µm Tight-buffered Fiber 250 µm Furcated Fiber Figure 58 NOTE: Installation on 250 µm furcated fiber, use 900/900 loose tube fiber handler. 50 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

NOTE: Used away from the splicer, a heat gun can straighten 900 µm buffer if bends exist. Such bends are typical for retrofits where the fibers were installed in connector modules. 7.8 Clean the bare fiber with an alcohol wipe or Fiber- Clean wipe. Do not touch the bare fiber after cleaning it. CAUTION: Make sure the fiber is completely clean. A fiber with any contamination will cause splicing problems. 7.9 Place the fiber handler in the FBC-006F cleaver. Ensure the end of the 900 µm buffer is even with the 6 mm mark. Slowly close and press the lever to cleave the fiber to 6 mm. Do not apply excessive force when cleaving as this can give bad cleaves and may damage the cleaver. If the fiber will not cleave, clean the cleaver s upper and lower pads. Set Screw Figure 59 IMPORTANT: Set screw on cleaver may need to be adjusted to ensure proper cleave length. NOTE: Check cleave length to ensure that it is between 6.0 mm and 6.5 mm. Shorter or longer cleaves will not allow proper connector assembly. 7.10 Return electrode cover to the open position. Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 51

FuseLite 0 250 7.11 To load the prepared field fiber handler. a) Ensure the retaining lever is in the unlocked position. b) Place the handler in the field fiber stage. Approximately 2 mm of the 900 µm buffer will extend past the fiber guide plates. c) Lock the fiber handler into place. Locked 7.12 Close the electrode cover. 7.13 To fuse the field fiber to the FuseLite ferrule: Figure 60 Press the key to start the fusion process. Do not open the cover at any time during the fusing process, as this will terminate the arc. The automatic mode will include the cleaning arc, contamination detection, and fusion. Upon completion, the screen will display the estimated 900 P HICKORY NC FuseLite Splicer MADE BY SIEMENS AG IN GERMANY SERIAL NO. 1000 fully automatic? kiep khnjioh jdlsiuerhe skdhr xkduhkgk jurtoeks jfieojfje9o jfduie andk on jdkuwownkfka;doo htyeknkdkwo kdoejfkegeo jeyi km on d oejejs;p oen kdowoekld;sjgpg jdiwqm,sap owponxc,e jdowqpq and pqkmzlrejeied apekwongoting. Figure 61 52 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

splice loss. If the splicer displays an error message, refer to Appendix A, page 99, for appropriate action to take. 7.14 Crimp the lead-in tube around the buffered fiber by pressing down firmly on the red crimp button. Figure 62 7.15 Open the electrode cover. a) Open fiber clamps on the fiber handler. Carefully lift the ferrule holder and fiber as one unit to remove from splicer. Figure 63 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 53

b) Holding onto the metal portion of the ferrule assembly, pull the ferrule holder straight off the ferrule assembly. CAUTION: The ferrule assembly may be hot from splicing. Figure 64 c) Press the key to reset splicer. 7.16 Using the crimp tool, apply an additional crimp to the ferrule assembly to further secure the fiber. a) Place the ferule assembly into the tool s semicircular die so that the ferrule key contacts the side of the tool. Make sure that the entire ferrule assembly s lead-in tube is in the V- groove. Figure 65 54 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

b) Close and release the handles of the tool to make the second crimp. 7.17 To complete the assembly of the FuseLite ST - compatible connector. a) Slide the bayonet assembly up onto the rear of the ferrule assembly. Figure 66 b) Place the dust cover over the bayonet assembly, aligning the posts of the dust cover with the slots of the bayonet. Figure 67 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber 55

c) Using the snap tool, squeeze to apply pressure to the rear of the crimp body to completely snap it into place. Figure 68 d) Rotate the dust cover to lock it in place. U P e) Slide the boot over the back of the bayonet assembly. Figure 69 ST ST U P U P Figure 70 Assembly of the FuseLite ST -compatible connector on 900 µm tight-buffered or 250 µm furcated fiber is complete. 56 Connector Assembly on 900 µm Tight-buffered and 250 µm Furcated Fiber

8. ST -compatible Connector Assembly on 2.9-mm Single-fiber or EOS Cables NOTE: This section describes the installation of FuseLite standard ST-compatible connectors on 2.9-mm single-fiber and EOS cables. To install a FuseLite connector on 2.9 mm jacketed or EOS cable, follow these steps: 8.1 Remove the caps from the front and rear of a ferrule assembly. 8.2 Load a ferrule assembly into the red ferrule holder. Ensure the slot of the ferrule assembly key aligns with the key in the ferrule holder. Apply slight pressure toward the holder until the key locks into place. The ferrule should not rotate in either direction when locked into position. 8.3 Open electrode cover and install ferrule holder into splicer, to place the ferrule assembly between the electrodes. Red Stripe Figure 71 8.4 Close the electrode cover. Verify that the stub fiber in the ferrule s fusion area is visible on the LCD. Connector Assembly on 2.9-mm Single-fiber and EOS Cables 57

IMPORTANT: Internal crimp tube selection. Corning Cable Systems provides two different internal crimp tubes with each connector, If installing connectors on Corning Cable Systems cable manufactured after 1991, use the straight tube. Skip to step 8.5. For older cable, or non-siecor or Corning Cable Systems 2.9 mm cables, perform this simple test to determine which crimp tube to use: a) Slide a crimp body, small end first, down the cable a few centimeters/ inches. Figure 72 Figure 73 b) Measure, mark, and remove 50 mm of outer jacket as described in step 7.6 and 7.7. c) Select the straight tube and slide it over the 900 µm fiber and under the jacket until flush with the end of the jacket. d) Slowly attempt to remove the crimp body from the cable. If it slides off freely or with minimal friction, use the straight internal tube. Figure 74 Figure 75 If the crimp body is difficult or impossible to remove, use the flared internal crimp tube, which has a smaller outside diameter. e) Remove the internal crimp tube and crimp body. Cut the aramid yarn and the 900 µm buffer flush with the cable jacket. Proceed to step 8.5. 58 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

8.5 Slide the 2.9 mm segmented boot, small end first, down the field fiber until it is out of the way. Now slide the bayonet assembly, spring end last, down the fiber. Figure 76 8.6 Using the gauge card or the gauge printed on the connector bag and a permanent pen, measure and place marks 50 mm and 56 mm from the end of the cable s jacket. Figure 77 8.7 Strip off the 50 mm section of the outer jacket with the 16 AWG opening of the buffer-stripping tool. Figure 78 8.8 Blow the aramid yarn to flare it. Connector Assembly on 2.9-mm Single-fiber and EOS Cables 59

8.9 Place the appropriate internal crimp tube onto the 900 µm buffer. Push the tube under the 2.9 mm jacket and aramid yarn. 8.10 Gather the yarn, fold it back against the cable jacket, and hold it in place. Measure and mark a point 10 mm from the end of the cable jacket on the 900 µm buffer and at the end of the jacket. Figure 79 Figure 80 CAUTION: Do NOT cut the aramid yarn at this time. Doing so may allow the internal tube to move out of position and result in decreased strain relief. 8.11 Strip the 900 µm buffer to the 10-mm mark with the 203 µm No-Nik tool. Work in 10 mm increments and pull in a straight line to prevent fiber breakage, as described in the No-Nik tool s manual, SRP-004-036. 60 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

200 µm 10 mm 8.12 If necessary, press the end of the steel tube flush with the end of the 2.9 mm jacket. Figure 81 Figure 82 8.13 Trim the aramid yarn flush with the jacket with scissors. Take your time and do this step correctly excessive yarn protruding from the end of the jacket can cause problems during splicing. 8.14 After cutting the yarn, roll the end of the jacket between your fingers to redistribute the yarn. Figure 83 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 61

8.15 Place the fiber in the 900/3000 fiber handler. Align the 10 mm mark next to the jacket at the 900 end of the 900/3000 fiber handler. Close both clamps starting with the 900 end. 2.9 mm Jacketed Cable EOS Cable Figure 84 NOTE: Installation on EOS cable, use 900/3000 loose tube fiber handler. 8.16 Clean the bare fiber with an alcohol wipe or Fiber- Clean wipe. Do not touch the bare fiber after cleaning it. CAUTION: Make sure the fiber is completely clean. A fiber with any contamination will cause splicing problems. NOTE: Used away from the splicer, a heat gun can straighten 900 µm buffer if bends exist. Such bends are typical for retrofits where the fibers were installed in connector modules 3000 900 3000 900 15 10 5 15 10 5 Set Screw Figure 85 62 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

8.17 Place the fiber handler in the FBC-006F cleaver. Ensure the end of the 900 µm buffer is even with the 6 mm mark. Slowly close and press the lever to cleave the fiber to 6 mm. Do not apply excessive force when cleaving as this can give bad cleaves and may damage the cleaver. If the fiber will not cleave, clean the cleaver s upper and lower pads. Check cleave length to ensure that it is between 6.0 mm and 6.5 mm. Shorter or longer cleaves will not allow proper connector assembly. 8.18 Return the electrode cover to the open position. 8.19 To load the prepared field fiber handler. a) Ensure the retaining lever is in the unlocked position. b) Place the handler in the field fiber stage. Approximately 2 mm of the 900 µm buffer will extend past the fiber guide plates. c) Lock the fiber handler into place. 8.20 Close the electrode cover. Figure 86 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 63

FuseLite 0 3000 8.21 To fuse the field fiber to the FuseLite ferrule: Press the key to start the fusion process. Do not open the cover at any time during the fusing process, as this will terminate the arc. The automatic mode will include the cleaning arc, contamination detection, and fusion. Upon completion, the screen will display the estimated splice loss. If the splicer displays an error message, refer to Appendix A, page 99 for appropriate action to take. 900 P HICKORY NC FuseLite Splicer MADE BY SIEMENS AG IN GERMANY SERIAL NO. 1000 fully automatic? kiep khnjioh jdlsiuerhe skdhr xkduhkgk jurtoeks jfieojfje9o jfduie andk on jdkuwownkfka;doo htyeknkdkwo kdoejfkegeo jeyi km on d oejejs;p oen kdowoekld;sjgpg jdiwqm,sap owponxc,e jdowqpq and pqkmzlrejeied apekwongoting. Figure 87 64 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

8.22 Crimp the lead-in tube around the buffered fiber by pressing down firmly on the red crimp button. 900 3000 HICKORY NC FuseLite Splice E BY SIEMENS N GERMANY AL NO. 10 Figure 88 8.23 Open the cover. a) Unlock the fiber guide. Carefully lift the ferrule holder and fiber guide as one unit to remove from splicer. 900 3000 Figure 89 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 65

b) Holding onto the metal portion of the ferrule assembly pull the ferrule holder straight off the ferrule assembly. CAUTION: The ferrule assembly may be hot from splicing. Figure 90 c) Press the key to reset splicer. 8.24 Using the crimp tool, apply an additional crimp to the ferrule assembly to further secure the fiber. a) Place the ferule assembly into the tool s semicircular die so that the ferrule key contacts the side of the tool. Make sure that the entire ferrule assembly s lead-in tube is in the V- groove. b) Close and release the handles of the tool to make the second crimp. Figure 91 66 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

8.25 To complete the assembly of the FuseLite ST - compatible connector on 2.9-mm single-fiber cable: a) Slide the bayonet assembly up onto the rear of the ferrule assembly. Figure 92 b) Place the dust cover over the bayonet assembly, aligning the posts of the dust cover with the slots of the bayonet. U P U P Post Figure 93 c) Using the snap tool, squeeze to apply pressure to the rear of the crimp body to completely snap it into place. d) Rotate the dust cover to lock it in place. Figure 94 Connector Assembly on 2.9-mm Single-fiber and EOS Cables 67

e) Place the rear of the assembled crimp body into the hex opening in the FuseLite crimp tool so that the bayonet assembly contacts the side of the tool as shown. Do not push on the dust cover during this step. Doing so will cause the crimp body to protrude out the right side of the tool and result in an incorrect crimp. The 56 mm mark on the cable jacket should not be visible at the rear of the crimp body. If necessary, carefully push the cable into the rear of the crimp body until the 56 mm mark just disappears. Bayonet assembly Figure 95 f) Crimp the 2.9 mm cable by squeezing the handles together until the jaws close and release. Remove the connector from the tool. U P Figure 96 68 Connector Assembly on 2.9-mm Single-fiber and EOS Cables

g) Slide the boot into place over the rear of the connector. U P U P Figure 97 Assembly of the FuseLite ST -compatible connector on 2.9 mm single-fiber or EOS cable is now complete. Connector Assembly on 2.9-mm Single-fiber and EOS Cables 69

9. Packing the FuseLite Splicer Case When packing the FuseLite splicer back in its case, be sure to: a) Clean the unit to remove any pieces of fiber or dirt. b) Insert the ferrule holder into place. c) Close the cover. d) Return the stand to its closed position. e) If used, unplug the AC power cord. Wind up the cord and place it in its compartment in the case. Figure 98 illustrates a recommended loading plan for the case. Figure 98 70 FuseLite Termination System

10. Testing FuseLite Connectors 10.1 It is recommended that you test fiber optic connectors according to EIA FOTP-171, using an overfilled launch and mandrel wrap for multimode testing. Pass/Fail criteria should be determined by your link loss budget or your company s practice. This is typically - 1.0 db. 10.2 If you have questions about proper testing and required equipment, etc., call Corning Cable Systems Engineering Services at 1-828-327-5000. 11. Testing FuseLite Connector Jumpers 11.1 If you are testing a FuseLite connector jumper with a power meter, remember that the splice joint loss of the connector at the receiver (Rx) end cannot be referenced out. Figure 99 11.2 The power meter reading will indicate the total loss from joints A, B, and C. Assume a 0.1 db loss at joint C and subtract this value from the reading to get the true connector pair insertion loss (A+B). FuseLite Termination System 71

12. FuseLite Connector Maintenance 12.1 Always keep a clean dust cap on a connector which is not in use. Do not remove the dust cap until immediately before inserting the connector into an adapter. 12.2 To clean a FuseLite connector with the Corning Cable Systems TKT-300 kit: a) Keeping the end of the nozzle approximately 2 inches (5 cm) from the connector, blow any loose dust or dirt off the connector with the aerosol duster. Lever Figure 100 b) Aggressively wipe the end-face and outside diameter of the connector ferrule with an alcohol wipe. c) Aggressively wipe the end-face and outside diameter of the connector ferrule with a dry lint-free tissue. Make sure that the cloth makes full contact with the end-face surface. d) Continue cleaning the connector by using the connector cleaning cassette as described in SRP-006-060. TYPE A Wiping Direction Shutter Cleaning tape Figure 101 72 FuseLite Termination System

NOTES: FuseLite Termination System 73

NOTES: 74 FuseLite Termination System

Corning Cable Systems Enhanced FuseLite uselite Termina ermination System Instruction Manual Fusion Splicer Operation Section B

FuseLite Termination System Fusion Splicer Operation 1. Introduction... 79 Splicer Overview... 79 Technical Data... 79 2. Precautions... 80 3. Tools and Materials... 81 4. Parameters and Programs... 82 Parameters... 82 Setting the Parameters... 83 Selecting a Fixed Program... 83 Changing the Parameters... 84 5. Packing the FuseLite Splicer Case... 87 6. Maintenance... 88 Precautions... 88 Routine Cleaning... 89 Cleaning the Electrodes... 91 Replacing the Electrodes... 92 Replacing the Lens System Cover... 93 Replacing the Battery... 95 Glossary... 97 Appendix A - Error Messages... 99 FuseLite Termination System 77