LuxCs Fber Optc Connector Instructon Sheet Termnus Kts 408-10275 1828199-1 and 1828200-1 16 NOV 09 ML MM Termnus Kt 1828199-1 (For Loose and Tght Cable Structure) MT MM Termnus Kt 1828200-1 (For Ultra Tght Cable Structure) Crmp Sleeve Crmp Sleeve Termnus Termnus Protectve CapG Protectve CapG G Connector kt s shpped wth protectve cap nstalled onto termnus. Keep t n place untl ready for assembly. Fgure 1 1. INTRODUCTION Ths nstructon sheet covers the applcaton of LuxCs Fber Optc Connector Termnus Kts 1828199-1 and 1828200-1 (shown n Fgure 1) to multmode fber optc cable wth a ceramc sze of 128 mm and havng the cable structure shown n Fgure 2. Read these nstructons thoroughly before startng assembly. 2. DESCRIPTION Each connector termnus kt conssts of a termnus, crmp sleeve, and protectve cap. See Fgure 1. All numercal values n ths nstructon sheet are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Fgures are not drawn to scale. 3. ASSEMBLY PROCEDURE 3.1. Requred Tools and Consumables The followng tools and consumables are recommended for assemblng the connector termnus kt (related nstructon sheets are n parenthess). A. Tools safety goggles (for eye protecton) ruler wth metrc and US customary unts 125-mm Fber Cable Structure 900-mm Buffer 250-mm Prmary Coatng Loose (ML) Movement s possble between the buffer and the jacket. Movement s possble between the fber and buffer. Tght (ML) Movement s possble between the buffer and the jacket. Movement s not possble between the fber and buffer. Ultra Tght (MT) Movement s not possble between the buffer and the jacket. Movement s not possble between the fber and buffer. Fgure 2 Aramd Strength Members 1.6 to 2-mm Dameter Jacket LuxCs s a trademark of Radall, SA. Product s manufactured by TE under lcense from Radall, SA. E2009 Tyco Electroncs Corporaton, Harrsburg, PA TOOLING ASSISTANCE CENTER 1-800- 722-1111 All Internatonal Rghts Reserved PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electroncs are trademarks. *Trademark. Other products, logos, and company names used are the property of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 6 LOC B
LuxCs Fber Optc Connector Termnus Kts 1828199-1 and 1828200-1 aramd shears Fber Jacket Strpper 1278531-1 Mller Strp Tool 1754708-1 Epoxy Dsh 502282-2 Ferrule Resn Injector 1918509-1 PRO -CRIMPER* III Hand Tool Frame Assembly 58532-1 (408-4020) LuxCs De Set 1828889-1 Heat Cure Oven 502130-1 Curng Oven Block 1918510-1 Fber Optc Sapphre Scrbe Tool 504064-1 (408-4293) LC Polshng Bushng 1754074-1 Polshng Pad 501523-1 Polshng Plate 501197-1 200 Mcroscope 1754767-1 1.25 -mm Mcroscope Adapter 1754765-1 All tools lsted are ncluded n LuxCs Termnaton Kt 1828644-2. B. Consumables Alcohol Fber Wpe Packet 501857-2 lnt -free cloth or tssue sopropyl alcohol The followng consumables are ncluded n LuxCs Termnaton Kt 1828644-2. Epoxy 504035-1 or EPO -TEK 353ND epoxy For characterstcs, safety and reactvty data, and handlng nstructons for the epoxy, refer to Materal Safety Data Sheet (MSDS) 125-6353. Resn Injector Tp 1918509-2 5-mm Polshng Flm 228433-8 9-mm Polshng Flm 1374484-1 Fne Damond Polshng Flm 503887-1.3-mm Polshng Flm 228433-5 EPO-TEK s a trademark of Epoxy Technology Inc. Corporaton 3.2. Cable Preparaton To avod personal njury, ALWAYS wear eye protecton when workng wth optcal fber. NEVER look nto the end of termnated or untermnated fbers. Laser radaton s nvsble but can damage eye tssue. NEVER eat, drnk, or smoke when workng wth fbers. Ths could lead to ngeston of glass partcles. BE VERY CAREFUL to dspose of fber ends properly. The fbers create slvers that can easly puncture the skn and cause rrtaton. 1. Slde the crmp sleeve (small dameter end frst) onto the cable. 2. Usng the ruler, aramd shears, jacket strpper, and strp tool, strp the cable to the dmensons gvennfgure3. Note: Not to Scale Strppng Dmensons A C B Small Dameter End of Crmp Sleeve CONNECTOR DIMENSION TERMINUS A B C ML MT 27-30 [1.06-1.18] 25-28 [.98-1.10] Fgure 3 15-16 [.59-.63] 13-14 [.51-.55] 2.5-3.5 [.10-.14] 3. Usng the alcohol pad or lnt -free cloth dampened wth sopropyl alcohol, clean the glass claddng to remove any coatng resdue. NEVER clean the buffer or fbers wth a dry cloth. 3.3. Prepare and Apply Epoxy A. Prepare the Epoxy and Injector 1. Remove the separatng clp from the bag of epoxy. Mx the epoxy nsde the bag thoroughly for 2 mnutes. When mxed properly, the epoxy wll have a unform, translucent, amber color. 2 of 6 Tyco Electroncs Corporaton
LuxCs Fber Optc Connector Termnus Kts 1828199-1 and 1828200-1 2. Cut the epoxy bag dagonally at one corner, and squeeze the mxed epoxy nto the epoxy dsh. 3. Make sure the ferrule resn njector (syrnge) counter s set to poston 0.26 (equvalent to 2.6 ml). If t s not, turn the knob untl t s. 4. Obtan a new pston and capllary, and press the njector push -button untl t stops. 3. Unformly dstrbute the cable strength members around the back of the termnus. See Fgure 4, Detal B. 4. Slde the crmp sleeve over the cable strength members untl the end of the crmp sleeve bottoms aganst the termnus. See Fgure 4, Detal C. Use a new pston and capllary for each new batch of epoxy. Detal A MT Connector 5. Frmly nsert the pston nto the njector mandrel untl t stops, then release the njector push -button. Ferrule 6. Thread the capllary over the pston and lock t onto the njector. B. Apply the Epoxy 1. Depress the njector push -button, and ntroduce the end of the capllary nto the epoxy dsh contanng the epoxy. ML Connector Back Porton of Termnus Under Cable Jacket Strength Members Do Not Enter Termnus 2. Gently release the njector push -button to lft the epoxy. If ar bubbles are lfted, leave the capllary n the epoxy, push out half of the amount lfted, then pump t agan untl the pston s fully extended. Strength Members Do Not Enter Termnus 3. Clean the capllary, and remove the drop of epoxy. Detal B 4. Poston the capllary on the ferrule. 5. Gently press the njector push -button to nject the epoxy nsde the ferrule. Inject all of the epoxy. 6. Wth the njector push -button depressed, remove the capllary from the ferrule. Then release the push -button. Strength Members Dstrbuted Evenly 3.4. Termnate the Connector Detal C 1. Remove the protectve cover from the termnus. Retan the protectve cover. 2. Carefully nsert the fber nto the back of the termnus untl the buffer bottoms on the base of the ferrule. DO NOT allow the cable strength members to enter the termnus. See Fgure 4, Detal A. For the ML connector, the back porton of the termnus should slde under the cable jacket. Fgure 4 Crmp Sleeve Aganst Termnus Tyco Electroncs Corporaton 3 of 6
LuxCs Fber Optc Connector Termnus Kts 1828199-1 and 1828200-1 5. Usng the ferrule resn njector, apply a drop of epoxy to the back part of the termnus. See Fgure Fgure 5, Detal A. Detal A 6. Place the end of the crmp sleeve nto the de assembly of the hand tool. Algn the back of the termnus wth the edge of the de. See Fgure 5, Detal B. Epoxy 7. Hold the termnus n place, and actuate the tool. The cable strength members should be retaned. Back of Termnus 8. Remove the assembly from the tool, and nspect the crmp sleeve for a straght and even crmp. 3.5. Cure the Epoxy 1. Remove any excess epoxy from the assembly. Detal B End of Crmp Sleeve n Crmpng Chamber Hand Tool Excess epoxy wll be dffcult to remove after curng. 2. Place the connector assembly onto the curng oven block; then, place the curng oven block n the heat cure oven accordng to the nstructons ncluded wth the oven. Cure the epoxy between 115_C and 120_C [239_F and 257_F] for a mnmum of 15 mnutes. Back of Termnus Algned wth Edge of De To avod damage to the assembly, DO NOT expose assembly to excessve temperatures. Fgure 5 3. After curng, grasp the cable and gently lft the assembly out of the oven. The assembly wll be HOT allow suffcent tme for the assembly to cool before proceedng. After Scorng, Pull Fber Straght Away 3.6. Cleave the Fber To avod damage to the assembly, allow the assembly to cool. To avod personal njury, ALWAYS wear eye protecton when workng wth optcal fber. BE VERY CAREFUL to dspose of fber ends properly. The fbers create slvers that can easly puncture the skn and cause rrtaton. Epoxy End Face of Ferrule Fber Fgure 6 Scrbe Tool 1. Frmly support the assembly, and place the blade of the scrbe tool drectly above the epoxy. DO NOT allow the blade to make contact wth the epoxy. See Fgure 6. Allowng the blade to touch the epoxy could damage, chp, or crack the cuttng tp of the blade. 4 of 6 Tyco Electroncs Corporaton
LuxCs Fber Optc Connector Termnus Kts 1828199-1 and 1828200-1 2. Lghtly draw the beveled edge of the blade across the fber parallel to the tp of the ferrule. After scorng the fber, pull t straght away from the ferrule. The fber should shear cleanly at the scrbed pont. Polshng Bushng Fgure-8 Pattern 3.7. Polsh the Fber It s recommended polshng the fber usng a polshng machne. Machne polshng produces the best results. Polsh the fber accordng to the machne manufacturer s nstructons. If machne polshng s not possble, hand polsh the fber accordng to the followng: 1. Usng a small pece of the 5 -mm (lght grey) polshng flm, lghtly polsh the endface of the ferrule n a small crcular moton to remove the fber stub down to the level of the epoxy and untl the fber stops leavng a trace on the flm. For optmum results, keep the polshng flms clean. 2. Install the termnus onto the polshng bushng. 3. Place the polshng pad on the polshng plate. Place the 9 -mm polshng flm on the polshng pad. Always place the polshng bushng on a clean area of the polshng flm. NEVER start polshng across a drty area of the polshng flm. 4. Holdng the polshng bushng and termnus, place the polshng bushng on the flm. Usng lght pressure on the ferrule, polsh n an elongated fgure -8 pattern (approxmately 50.8 [2.0] long). See Fgure 7. Make 15 fgure -8 patterns. 5. Clean the endface of the ferrule and the polshng bushng wth the alcohol pad or alcohol -dampened lnt -free cloth. 6. Remove the 9 -mm polshng flm from the polshng pad, and place the fne damond (green or lavender) polshng flm on the polshng pad. 7. Hold the assembly and, usng very lght pressure, polsh the tp of the fber n an elongated fgure -8 pattern (approxmately 50.8 [2.0] long). Make 6 fgure -8 patterns. 8. Inspect the fber accordng to Paragraph 3.8. If small perpheral chps are evdent n the fber, contnue polshng the fber wth the fne damond flm. Inspect the fber agan. If the fber s not acceptable, t mght be necessary to use the 9 -mm polshng flm and then use the fne damond polshng flm to remove small perpheral chps. Fgure 7 9. Clean the endface of the ferrule and the polshng bushng wth the alcohol pad or alcohol -dampened lnt -free cloth. 10. Remove the fne damond polshng flm from the polshng pad, and place the.3 -mm (whte) polshng flm on the polshng pad. 11. Holdng the polshng bushng and termnus, place the polshng bushng on the flm, and usng lght pressure on the ferrule, polsh n an elongated fgure -8 pattern (approxmately 50.8 [2.0] long). Make 3 fgure -8 patterns. 12. Clean the endface of the ferrule and the polshng bushng wth the alcohol pad or alcohol -dampened lnt -free cloth. 3.8. Clean the Ferrule TO AVOID PERSONAL INJURY, compressed ar used for cleanng must be reduced to less than 207 kpa [30 ps], and effectve chp guardng and personal protectve equpment (ncludng eye protecton) must be used. 1. Wpe completely around the ferrule of the termnus usng the alcohol pad or sopropyl -alcohol dampened lnt -free cloth. Then wpe around the ferrule usng a dry lnt -free cloth. 2. Place the dry lnt -free cloth on a smooth, flat surface. Holdng the termnus perpendcular, wpe the ferrule endface across the cloth. 3. Blow compressed ar across the endface of the ferrule. 4. Usng the mcroscope (wth the 1.25 -mm adapter), examne the endface of the ferrule for debrs accordng to Secton 4. If debrs s present, repeat Steps 1 through 3. Tyco Electroncs Corporaton 5 of 6
LuxCs Fber Optc Connector Termnus Kts 1828199-1 and 1828200-1 Ths s the fnal step pror to connector connecton. DO NOT wpe the ferrule or allow t to touch anythng before connectng the connector. Endface of Ferrule Acceptable Fber Small Perpheral Chps 4. INSPECTION 1. Usng the mcroscope (wth the 1.25 -mm adapter), nspect the ferrule and fber accordng to thefollowngcrtera(refertofgure8): Make sure that any epoxy s removed from the ferrule Fne Polshng Lnes Use a sharp blade to remove epoxy from the chamfered edge of the ferrule. DO NOT allow the blade to touch the fber. Drt may be mstaken for small pts; f drt s evdent on the ferrule or fber, clean wth the alcohol pad or sopropyl -alcohol dampened lnt -free cloth, then dry Fne polshng lnes are acceptable Endface of Ferrule Unacceptable Dark Scratches Fber Large Chps Small perpheral chps (at the outer rm) on the fber are acceptable Large chps n the center of the fber and dark scratches are unacceptable, and the fber must be re -termnated Fgure 8 2. If not nstallng the connector mmedately, nstall the protectve cover onto termnus to prevent contamnaton to the endface of the ferrule. 5. REPLACEMENT AND REPAIR Kt components are not reparable. Replace any damaged components. DO NOT re -use termnated connectors by removng the cable. 6. REVISION SUMMARY S Intal release of nstructon sheet 6 of 6 Tyco Electroncs Corporaton