InstructonSheet LghtCrmp*XTC/NeXTC 408-9860 FberOptcConnectorKts 21APR11 RevL For Procedure on Inspectng the Fber, Refer to Secton 6 VerfythatInstructonSheet(408-Seres) PertanstoConnectorKtBengTermnated ToVerfy,RefertoProductDrawngfor ApplcableInstructonSheetat: www.te.com (SearchbyConnectorKtPartNumber, ClckonthePartNumber,ClckonProductDrawng) Plunger BareFber CableBoot Crmp Sleeve Push-On CableBoot Connector Body LargeDameter FlexblePlastcTubng Dust Cover SmallDameterPolyester Elastomer(GreyorWhte) Tubng(Usedwth250-mm CoatedFberOnly) LargeDameterPVC(Black) Tubng(UsedwthCables HavngJacketDameter LessThan2.30mm[.090n.]) 1. INTRODUCTION LghtCrmp XTC/NeXTC fber optc connector kts are desgned to be used wth cable havng snglemode 125--mm outsde dameter fber (ceramc ferrule connector), multmode 125--mm fber (ceramc, stanless steel, or polymer ferrule connectors), or 140--mm outsde dameter fber (stanless steel connector). Read these nstructons carefully before applyng any connectors. LghtCrmp XTC/NeXTC fber optc connectors, whle beng fully compatble wth OPTIMATE* 2.5mm bayonet connectors and other ST style snglemode and multmode connectors, do not requre epoxy durng assembly of the connector. Fgure 1 2. DESCRIPTION (Fgure1) The connector kt conssts of two cable boots (ether one may be requred), acrmp sleeve, plunger, connector body,larger dameter flexble plastc tubng, large dameter PVC tubng, small dameter polyester elastomer tubng, and adust cover. These connectors accommodate buffer szes of 250 mm and 900 mm. Jacketed fbers must be no larger than 3.10 mm [.122 n.] n dameter for proper jacket captvaton. UseofthesenstructonsonLghtCrmp XTC/NeXTCfberoptcconnectorswthother bufferdametersorlargerjacketdametersmay resultnmproperfberand/orcablecaptvaton. Dmensonsonthssheetarenmetrcunts [wthu.s.customaryuntsnbrackets].fgures arenotdrawntoscale. Reasons for ressue of ths nstructon sheet are provded n Secton 7, REVISION SUMMARY. 3. REQUIREDTOOLSANDMATERIALS 3.1. Tools Mcro--Strp Strpper 492109--2 (203 mm [.008 n.]) Fber Optc Combnaton Strp Tool 1278947--1 (408--4577) 1 of8 LOCB
Cable Strpper 501198--1 (408--9394) Scssors 501014--1 Cable Preparaton Template 503574--1 LghtCrmp Plus* ST De Set wth Crmpng Tool 492623--1 (conssts of De Set 492622--1 and PRO--CRIMPER* III Hand Tool 2064431--1) Unversal Cleave Tool 503705--1 Polshng Bushng 503337--1 (metal) or Polshng Bushng 503304--1 (plastc black) or Polshng Bushng 503304--2 (plastc bege) Polshng Plate 501197--1 Polshng Pad 504584--1 (black) Reslent Polshng Pad 501523--1 (whte woven) 200 Mcroscope Kt 1754767--1 (ncludes 2.5--mm adapter) 3.2. ConsumableItems TermnatonKt503330-1contansthe preparatontoolsrequredtoapplythese connectors. 5--mm Polshng Flm 228433--8.3--mm Polshng Flm 228433--5 lnt--free tssues sopropyl alcohol 4. FIBERPREPARATION 4.1. UnjacketedFbers Thesenstructonsareapplcableonlyto LghtCrmpXTC/NeXTCfberoptcconnectors whenusedwthunjacketedfbers,jacketed fbers,bufferedfbers,orcoatedfbers. Toavodpersonalnjury,ALWAYSwearsafety glasseswhenworkngwthoptcalfbers. BEVERYCAREFULtodsposeoffberends properly.thefberscreateslversthatcaneasly puncturesknandcauserrtaton. 1. If termnatng unjacketed buffered fber wthout usng the breakout kt, slde the bare fber boot onto the fber. See Fgure 2. 2. For 900--mm buffered fber, slde the push--on boot onto the fber; then slde the large dameter flexble plastc tubng onto the fber so that the tubng fts nsde the boot. See Fgure 2. Unjacketed Buffered Fber (Wthout Breakout Kt) Fber BareFber Boot 900-mmBufferedFber 25mm [1.0n.] Fber Fgure 2 20mm [.80n.] Fgure 3 Push-On Boot LargeDameter FlexblePlastcTubng StrppngDmensonsforUnjacketedFbers BareGlass Markngon Coatng Note: NottoScale Usng the mcro--strp strpper, remove 25 mm [1.0 n.] of the buffer and coatng from the fber. Several strps mght be requred to remove all of the buffer and coatng. 3. For 250--mm coated fber, usng the combnaton strp tool, remove 25 mm [1.0 n.] of the coatng from the fber. Then, mark the coatng 20 mm [.80 n.] behnd the end of the buffer as shown n Fgure 3. Makesurethecombnatonstrptoolremovesthe clearcoatngfromthefber.ifthecoatngremans onthefber,thepreparedfberwllstubnthe connectorandwllnotpassthrough. 4. Remove debrs from the fber by wpng the strpped fber wth alnt--free tssue dampened wth sopropyl alcohol. 4.2. JacketedFbers 1. Slde the push--on boot onto the cable as shown n Fgure 4. 2. If the jacket dameter of the cable s less than 2.30 mm [.090 n.], slde the PVC tubng over the cable jacket. See Fgure 4. 2 of8
Iftheexactjacketdametersunknown,usethe PVCtubngftsldeseaslyoverthejacket. ForJacketedFber Push-OnBoot 3. Usng the cable strpper, remove the cable jacket to the dmenson gven n Fgure 5or use the cable preparaton template. 4. Usng the scssors (makng sure that t s sharp), trm the strength members to the dmenson gven n Fgure 5. 5. Usng the mcro--strp strpper, remove the buffer and the coatng from the fber to the dmenson gven n Fgure 5. Several strps mght be requred to remove all of the buffer and coatng. Makesurethemcro-strpstrpperremovesthe clearcoatngfromthefber.ifthecoatngremans onthefber,thepreparedfberwllstubnthe connectorandwllnotpassthrough. 6. Slde the crmp sleeve onto the cable and poston the sleeve so that t captures the strength members n a bent--back poston. See Fgure 6. ForCableHavngJacketDameter Lessthan2.30mm[.090n.] PVCTubng 25mm[1.0n.] Bufferand Coatng Fgure 4 StrppngDmensonsforJacketedFbers 12.7mm[.50n.] StrengthMembers 5. ASSEMBLY 5.1. TermnatonProcedure 1. For 250--mm coated fber, nsert the small dameter tubng (grey or whte) nto the back of the plunger. See Fgure 7. The tubng s properly seated when approxmately 6.0 mm [.24 n.] of the tubng remans outsde of the plunger. Note: NottoScale Fgure 5 17.5mm[.69n.] JacketRemoved 2. Insert the plunger nto the rear of the connector body untl t stops. See Fgure 8, Detal A. 3. Feed the prepared fber (jacketed or unjacketed) through the rear of the plunger (and connector body) untl t stops. Tonsert the fber easly,hold the fber at the buffer/fber nterface, and rotate the connector slowly whle nsertng the fber. See Fgure 8, Detal B. Payspecalattentontocableswthloosejacket materal.itsmportantthatthebufferstrplength smantaneddurngthefeedandnotbepushed backntothecablejacket. Thebarefbershouldprotrudefromtheconnector ferrulenotmorethan12.7mm[.50n.].ifthe fberdoesnotprotrude,tbrokeorwas mproperlyprepared.preparethefberagan, makngsurethatanybrokenfberpecesare removedfromtheconnector. Strength Members For250-mmCoatedFber 6.0mm[.24n.] Fgure 6 Fgure 7 CrmpSleeve Plunger SmallDameterTubng 3 of8
4. Open the des of the tool fully.if the ratchet s engaged, squeeze the handles together untl they release. DetalA Rearof ConnectorBody Thecrmpngtoolsmarkedwth XTC/NeXTC andhastwohexagonalcrmpngchambers. DetalB Plunger 5. Gently close the des of the tool untl you hear one clck from the ratchet. Poston the connector assembly n the des so that the shoulder of the de s located between the plunger and the folded-- back strength members. Make sure that the connector assembly s algned wth the drecton of the arrow on the des, and the eyelet and strength members are postoned n the large--wdth pocket. See Fgure 9. Plunger Buffer/Fber Interface BECAREFULnottobreakthefberwhle nsertngtheconnectorntothetool. For900-mmbufferedfber,makesurethatthe fbersfullynsertedntotheconnectordurng crmpng. For250-mmcoatedfber,makesurethatthe markonthebuffer(seeparagraph4.1,step3)s vsbleattheedgeofthesmalldametertubng beforecrmpng. Fgure 8 EyeletandStrength Membersn Large-WdthPocket ConnectorAssembly Algnedwth ArrowonDes 6. Slowly squeeze the tool handles together untl the ratchet releases, then release the tool handles and allow them to open fully. 7. Carefully remove the crmped connector from the tool. BECAREFULnottobreaktheprotrudngfber whleremovngtheconnectorfromthetool. 8. For jacketed fbers, perform the followng steps: DONOTperformthefollowngstepsfor unjacketedfbers. Fgure 9 a. Whle holdng the connector, carefully slde the crmp sleeve away from the connector body to release the strength members. See Fgure 10. ForJacketedFber b. Slde the crmp sleeve over the back end of the connector, coverng the evenly--spread strength members. For cable wth ajacket dameter of less than 2.30 mm [.090 n.], slde the PVC tubng under the crmp eyelet untl the tubng bottoms. Fgure 10 CrmpSleeve 4 of8
c. Usng the crmpng tool, place the larger cavty around the larger dameter (closest to the connector body) of the crmp sleeve. See Fgure 11. d. Squeeze the tool handles together untl they release. e. Move the crmpng tool to the smaller dameter of the crmp sleeve and, usng the smaller cavty of the tool, squeeze the tool handles together untl they release. See Fgure 12. f. Slde the cable boot over the crmp sleeve to complete the connector assembly.see Fgure 13. 5.2. CleavetheFber ALWAYSwearsafetyglasseswhenworkngwth optcalfbers.beverycarefultodsposeof fberendsproperly.thefberscreateslversthat easlypuncturethesknandcauserrtaton. 1. Insert the connector nto the sde of the cleave tool so that the protrudng fber s guded through the slot n the tool. See Fgure 14. Makesurethatthefberextendsbeyondtheedge ofthecleavetool.iftdoesnot,proceedas follows: 1. UsngSapphreScrbeTool504064-1or smlarscrbetool,gentlybrushthetoolblade acrossthefberata3to5_ angle(aboutthe dameterofonefberfromtheferrulesurface). SeeFgure15.Donotapplyforceonthefber wththebladewhlescrbngsnceexcessve forcemayfracturethefbermakngtheconnector useless. 2. Grasptheprotrudngfberlghtlybetweenthe thumbandforefnger,thengentlypulltnlne wththeconnector.thefbershouldcleave cleanlyatthescrbeproducngamrror-lke surface.ifthefberdoesnotcleaveeasly, re-scrbethefber,andtryagan.aproper cleave,closetotheferrulesurface,sessental forobtanngasuccessfulfberpolsh. 3. Push the ferrule nto the bore untl the connector stops at the screw. Toavodpossblenjury,holdtheconnectoraway fromyourfacewhenpushngtheactuatorbutton. LargerDameter ofcrmpsleeve SmallerDameter ofcrmpsleeve Fgure 11 Fgure 12 Smaller Cavty Larger Cavty Holdthecleavngtoolandconnectornverted overacontanerorapeceofmaskngtapewth thestckysdefacngup.thsmethodholdsthe cleavedfberendandanyfberdebrsforsafe dsposal. Fgure 13 CableBoot 5 of8
4. Gently depress the actuator button to cleave the fber. Allscrewsarefactorypresetonthecleavetool. DONOTADJUSTTHESCREWS;otherwse, poorcleaveswllresult. Fber 5. If not polshng the connector mmedately,place the dust cover on the connector. 5.3. PolshtheFber 1. Cut asmall pece (50 50 mm [2 2 n.]) of the 5--mm polshng flm. 2. Whle holdng the polshng flm n the ar, form a concave shape and ar polsh the connector tp by gently rubbng the tp of the connector n small crcles or fgure--8 patterns untl the protrudng stub of the cleaved fber s flush wth the ferrule surface. Refer to Fgure 16. Analternatemethodofarpolshngstohold oneendofthepolshngflmbetweenthendex andmddlefngersandholdtheotherendofthe flmbetweenthethumbandtherngfngerwth theabrasvesurfaceoftheflmup.pulltheflm taut,andarpolshtheconnectortpasdescrbed nstep2untlnotracesarevsbleontheflm. SeeFgure17. For stanless steel ferrule connectors, brush the cleaved fber stub lghtly n acrcular moton on a hand--held pece of 5--mm polshng flm to take off any sharp edges. Connector Fgure 14 CleaveTool AfterScorng,PullFberStraghtAway Epoxy EndFace offerrule Fber Fgure 15 ScrbeTool 3. Clean the polshng plate wth water or an approprate wndow cleanng soluton. Dry the polshng plate thoroughly. 4. For polymer ferrule connectors, remove the adhesve backng from the whte woven reslent polshng pad, then place the pad on the polshng plate. See Fgure 18. For the stanless steel and ceramc ferrule connectors, remove the adhesve backng from the black polshng pad, then place the pad on the polshng plate. See Fgure 18. 5. Place apece of the.3--mm polshng flm on the polshng pad. 6. For polymer ferrule connectors, place the end of the metal or bege plastc polshng bushng onto the polshng flm. For the stanless steel and ceramc ferrule connectors, place the end of the metal or black plastc polshng bushng onto the polshng flm. RubnSmallCrcles RubnFgure-8Pattern Fgure 16 or 6 of8
7. Gently nsert the connector nto the polshng bushng, and move the bushng n afgure--8 pattern, supportng the weght of the connector for the frst three fgure--8 patterns to prevent the fber from breakng or scorng the flm. See Fgure 18. AlternateMethodof HoldngPolshngFlm DONOTwetthepolshngflmwthwater.These connectorsrequreadrypolsh.usngwateror otherlquddurngpolshngwllcausedebrs buld-upwthntheconnectorwhchmay adverselyeffecttheconnectoroptcal performance. Fgure 17 Replacescoredflmtoavodfberbreakage. 8. Contnue polshng from 15 to 20 more fgure--8 patterns allowng the full weght of the polshng bushng to rest on the polshng flm. Aprotrudngfber(PF)polshoftenprovdes superorconnectorperformance.therefore,ts recommendedtoleavethefberprotrudng slghtlyfromtheferrulesurface. For stanless steel ferrule connectors, remove the crcular machne marks on the ferrule tp (from the edge toward the center) untl acrcle between 0.5 and 0.7 mm [.020 and.028 n.] (stll vsble) of machne marks remans. Ths wll leave the fber protrudng slghtly from the ferrule face as recommended for optmum performance (refer to Fgure 20). Other relevant crtera for nspectng the fber descrbed n Secton 6preval. BlackPolshngPad (StanlessSteelorCeramcFerruleConnectors) or WhteWovenReslentPolshngPad (PolymerFerruleConnectors) Polshng Plate Polshng Bushng Polshng Flm Neverremovethefberholechamfer.DONOT over-polsh. Fgure 18 Another method of approxmatng the correct fnshed dameter s to see f the dameter of the machne marks s fve tmes the dameter of the fber; however, actually measurng the fnshed dameter s the preferred method. See Fgure 19. ForStanlessSteelFerruleConnectors 9. For stanless steel ferrule connectors, clean the ferrule face wth adry,lnt--free tssue, and/or dab the ferrule face on areslent pece of tape to remove any stubborn polshng grt. 10. Clean the connector tp and polshng tool face wth alnt--free tssue to remove any resdue. 11. Mate the connector wth the receptacle or, f not matng the connector mmedately,place the dust cover on the connector. Fber Dameter Fgure 19 0.5-0.7mm [.020-.028n.] 7 of8
6. INSPECTING THE FIBER (SeeFgure20) DISCONNECTthecablefromthesourcebefore nspectng.thenfraredlghtused,althought cannotbeseen,cancausenjurytotheeye. 1. Remove the connector from the polshng bushng, and clean the ferrule face wth alnt--free tssue. The ferrule face may also be cleaned by dabbng the ferrule face on areslent pece of tape to remove stubborn polshng grt. 2. Inspect the connector wth the mcroscope. If possble, place the far end of the fber near abrght lght. Compare the fber end to Fgure 20, and take any recommended acton. 3. Verfy that the fber s flush (or s protrudng only afew mcrons) wth the ferrule surface by movng the mcroscope focus control. If the fber and ferrule surface come nto focus together, the fber s flush. If the fber comes nto focus before the ferrule surface (when movng toward the endface), then the fber s protrudng, and addtonal polshng may be requred. :NeverVewActveFberSgnals 7. REVISIONSUMMARY Revsons to ths nstructon sheet nclude: S Changed company logo Ideal Lghtscratches Polshmoreon.3-mmflm Heavyscorng orscratches Tryrepolshng Chpoutsde fbercore Tryrepolshng Chppedcore Unacceptable Reject Roughsurface Tryrepolshng Drtordebrs Tryre-cleanng Tryrepolshng Chppedface Unacceptable Reject Crackedfber Unacceptable Reject Brokenfber Unacceptable Reject Fgure 20 8 of8