OpticalCon Field Repair Instruction Fiber Optic Connection System Neutrik AG Im alten Riet 143 9494 Schaan Liechtenstein 2006-08 NEUTRIK AG 1
Table of contents 1. OpticalCon Repair Options... 3 2. Cable Connector Field Repair... 3 3. Corning UniCam Connectors... 4 4. Cable Connector Field Repair using the Corning UniCam... 5 4.1. Safety Precaution... 5 4.2. General... 6 4.3. Components... 6 4.4. Continuity Test System (CTS)... 7 4.5. Installation tool and UniCam connector preparation... 8 4.6. Cable pre-preparation... 12 4.7. Fiber preparation - 900 µm Tight-buffered Fibers (Neutriks 2-pole fiber cables)... 13 4.8. Fiber Preparation - 2.0 mm Single-fiber Cables (Neutrik Hybrid, / SMPTE cables)... 16 4.9. Fiber Cleaving... 18 4.10. Connector installation... 20 4.11. Installation of Neutrik 2-pole fiber cables... 26 4.12. Installation of Neutrik Hybrid / SMPTE cables... 26 5. Cable Field Repair using the Corning CamSplice TM... 27 5.1. General... 27 5.2. Features / Benefits... 28 5.3. Assembly... 28 6. Ordering Info... 29 NEUTRIK AG 2
1. OpticalCon Repair Options The OpticalCon fiber optic connection system offers ruggedized connectors and cables optimized for demanding environments and high mating cycles. The probability of damage to connectors or cables may by disregarded. If, however, such damage should occur against all expectations, Neutrik is prepared to offer repair options. Time matters? Damaged cable NO YES Field repair Return to Neutrik dealer Temporary operation Repair Neutrik AG 2. Cable Connector Field Repair Most robust fiber optic connection systems are proprietary and can't be repaired on site when having a problem and time matters. The OpticalCon connection system is based on regular LC connectors, so it is possible to use conventional field installable LC connectors to fix your connection in case of an emergency. Neutrik has tested various systems and suggests the usage of Corning UniCam LC connectors. NEUTRIK AG 3
3. Corning UniCam Connectors The patented Corning UniCam connector is a mini-pigtail housed in a connector body. There is a fiber stub already bonded into the ferrule in the factory, where the end face of the ferrule is polished to a PC finish. The other end of the fiber is cleaved and resides inside the connector. The field fiber is cleaved and inserted into the connector until it butts up against the fiber stub. A simple rotating cam actuation process completes the connector with no epoxy or polishing required. After strain relieving the fiber to the connector, it is ready to be mated to another connector inside an adapter. Field installable LC connector No Epoxy / No Polish Factory polished fiber stub Performs a mechanical splice to the factory-installed fiber stub Contains index matching gel for reliable, consistent results Over 30 million UniCam connectors installed Continuity Test Set available to provide immediate visual feedback of the installation quality during assembly Attenuation values < 0,75 db Factory Polish Fiber Stube Mechanical Splice with Index Matching Gel Field Fiber The most significant advantages of the UniCam connector are clear when using it for installation at the outlet. The only tools required are a stripper, a cleaver, the installation tool, and an alcohol pad. As a result, assembly space can be kept to a minimum, set-up is quick, and assembly is relatively fast and easy with no consumables. NEUTRIK AG 4
4. Cable Connector Field Repair using the Corning UniCam 4.1. Safety Precaution Safety Glasses WARNING: The wearing of safety glasses to protect the eyes from accidental injury is strongly recommended when handling chemicals and cutting fiber. Pieces of glass fiber are very sharp and can easily damage the cornea of the eye. Chemical Precautions Isopropyl Alcohol Isopropyl Alcohol is Flammable. WARNING: Flashpoint = 54 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. Fiber Precautions 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 to tape kept for that purpose alone. Good housekeeping is very important. Cable Handling Precautions CAUTION: Fiber optic cable is sensitive to excessive pulling, bending and crushing forces. Consult the cable specification sheet for the cable you are installing. Do not bend cable more sharply than the minimum recommended bend radius. Do not apply more pulling force to the cable than specified. Do not crush the cable or allow it to kink. Doing so may cause damage that can alter the transmission characteristics of the cable. The cable may have to be replaced. Laser Handling Precautions WARNING: Laser light can damage your eyes. Laser light is invisible. Viewing it directly does not cause pain. The iris of the eye will not close involuntarily as when viewing a bright light. Consequently, serious damage to the retina of the eye is possible. Never look into the end of a fiber which may have a laser coupled to it. Should accidental eye exposure to laser light be suspected, arrange for an eye examination immediately. WARNING: DO NOT use magnifiers in the presence of laser radiation. Diffused laser light can cause eye damage if focused with optical instruments. Should accidental eye exposure to laser light be suspected, arrange for an eye examination immediately. NEUTRIK AG 5
4.2. General In this chapter you will learn how to assemble a field-installable Corning Cable Systems LC UniCam multimode or single mode connector. This chapter describes how to install UniCam LC connectors on 900 µm tight-buffered fibers (Neutriks 2-pole fiber cables) or 2.0 mm cables (Neutriks Hybrid and SMPTE cables). 4.3. Components Each LC UniCam connector package contains the parts like shown. Note: Do not remove the dust caps from the connector until instructed to do so. The dust caps provide vital protection against damage and contamination. NEUTRIK AG 6
4.4. Continuity Test System (CTS) The CTS system includes: o SC-ST jumper o ST-LC jumper o SC duplex to pinned MT-RJ jumper o SC duplex to non-pinned MT-RJ jumper o Couplers for use with MT-RJ, SC, LC, and ST-compatible connectors. The CTS jumpers can be used for both single-mode and multimode connectors. The VFL-350 is the recommended light source for the system, although any Visual Fault Locator that accepts 2.5 mm ferruled connectors may be used. VFL-350 Visual Fault Locator: The Corning Cable Systems VFL-350 emits either continuous or 3 Hz flashing visible laser light at a wavelength of approximately 635 nm to perform continuity checks and locate faults in both multi- and single mode fibers optical fibers and components. The VFL-350 makes use of a Class 2 laser with a power output of less than 1mW. Under normal operations, the laser light is not dangerous. NEUTRIK AG 7
4.5. Installation tool and UniCam connector preparation The UniCam installation tool is designed to position the fiber into the connector, rotate the cam that aligns the fibers, and crimp the buffered fiber in place. The tool makes connector assembly easy and accurate. NEUTRIK AG 8
Flip the crimp handle open and rotate the wrench so the handle is up. For installation of the CTS system, rotate the slider to the CTS position by pulling the slider handler fully back, and while holding it, rotating the slider to the orientation like shown on the inset. Remove the connector components from the bag. Remove and discard the cap from the rear of the connector. NEUTRIK AG 9
Examine the connector to make sure it is in its open position. On LC connectors the cam is in its open position when the central groove on the cam is 90 from the latch which secures the front dust cap. Remove the front dust cap from the connector and plug the connector into either side of the LC CTS coupler. NEUTRIK AG 10
With the slider in its CTS position, load the coupler and connector as follows: o o o o Guide the CTS jumper through the arms of the crimp handle and plug the CTS jumper into the front of the CTS coupler. Make sure that the jumper s connector is secured into the coupler. Pull back and hold the slider at the the end of its travel. Insert the CTS coupler and the UniCam connector into the tool and guide the UniCam through the wrench until the crimp tube rests on the crimp platform. Slowly release the slider handle and carefully guide the CTS adapter into the slider. The tabs on the CTS adapter should rest against the slider. Do not attempt to place the CTS adapter tabs within the slider. Critical Step: The crimp tube must rest on the crimp platform as shown in the inset. If the connector does not slide into the tool when gently pushed, check to make sure the connector is in the open position described before, the wrench handle is up, and you are inserting the connector with its proper side up. NEUTRIK AG 11
Insert the ST connector on the end of the ST-LC jumper into The light source (VFL 350). The final setup looks like shown in the picture. 4.6. Cable pre-preparation Remove about 200mm of the cable jacket. You will require a Sharp knife or cable jacket removal tool since the PUR jacket is very hard to cut. 200 mm Cut off the aramid yarn using the aramid scissor. NEUTRIK AG 12
4.7. Fiber preparation - 900 µm Tight-buffered Fibers (Neutrik 2-pole fiber cable) Slide the 900 µm boot (small end first) and then the trigger down the fiber until they are out of the way. Measure and mark 40 mm from the end of the buffered fiber Remove this 40-mm section of the buffer with the 203 µm No-Nik tool in 6mm steps! Hold the No-Nik tool in your right hand so that the directional arrow is visible and pointing to the right. Open the tool with its handles. Note the actual location of the blades in the blade housing NEUTRIK AG 13
Place the fiber in the V-grooves in the blade housing so that no more than 2 mm (0.08 in.) of coated fiber extends beyond the housing. This positioning will provide a total strip length of 6 mm (0.25 in). Place your right thumb along the left side of the tool. Push the No-Nik tool along the fiber axis in a smooth, straight stroke to slide the severed piece of coating off of the fiber Repeat the steps removing additional 6 mm lengths until the 40mm length of glass fiber has been exposed. NEUTRIK AG 14
Mark the buffer 7 mm back from the strip point with a permanent ink marker. This mark must be made on the buffer. It is a visual aid to indicate when the field fiber contacts the fiber stub. Remove rests of the fiber coating using the Corning stripping tool. Position the fiber where the jacket stops in the V-notch, tilt the stripper about 45 and slide to the fiber end. It is important that all rests of coating are removed. Clean finally the bare fiber with two passes of an alcohol wipe. Do not touch the bare fiber after cleaning it. Do not remove the 7 mm mark. NEUTRIK AG 15
4.8. Fiber Preparation - 2.0 mm Single-fiber Cables (Neutrik Hybrid, / SMPTE cable) Slide the required boot (segmented end first) and then the trigger down the cable until they are out of the way Measure and mark 40 mm from the end of the cable s outer jacket Strip off the 40-mm section of outer jacket with the buffer stripping tool Use scissors to trim the aramid yarn flush to the end of the outer jacket. Measure and mark 11 mm from the end of the outer jacket NEUTRIK AG 16
Strip off the 11-mm section of outer jacket. You should have 11 mm of aramid yarn showing. Fold the aramid yarn back over the cable jacket and slide the crimp ring about 5 mm down the yarn to hold it out of the way Measure and mark the 900 µm buffer coating 9 mm from the end of the cable jacket. Place an additional mark on the buffer 2 mm from the the edge of the jacket. This mark is a visual aid to indicate when the field fiber contacts the fiber stub. After this follow the instructions of 4.7 (Fiber preparation - 900 µm Tight-buffered Fibers) NEUTRIK AG 17
4.9. Fiber Cleaving Press down on the handle to open the cleaver's fiber clamp With your other hand, place the fiber(s) in the fiber guide so that the end of the fiber is under the fiber clamp and the end of the fiber coating lines up with the stop. DO NOT FLEX THE FIBER GUIDE AT THIS TIME. NEUTRIK AG 18
Press down the cleaver arm until it just touches the fiber and guide. This will apply enough pressure to properly score the fiber(s). CRITICAL STEP: Gently release the cleaver arm. Flex the fiber guide to snap the fiber(s). The fiber is now ready for splicing. Press down on the cleaver's handle to once again lift the fiber clamp. Remove the end piece of fiber with tweezers and place the fiber on a loop of tape for proper disposal NEUTRIK AG 19
4.10. Connector installation Turn on the VFL light source. A glow should be visible in the area of the cam when the CTS system is on. Press in the release button on the UniCam tool s fiber index, and place the fiber between the rollers. Make sure the fiber is fully seated between the rollers before removing your finger from the button. NEUTRIK AG 20
While pulling the fiber through the rollers, insert the fiber into the connector s crimp tube until you feel it firmly stop against the connector s fiber stub. The index rollers will rotate, allowing the fiber to pull through. Guide the fiber in straight. Do not bend or angle it. If you feel resistance at the entry funnel, pull the fiber back out a short distance and re-insert. Notes: If you have stripped and cleaved the fiber to the correct length, the buffer mark should stop within 2 mm of the lead-in tube. If this mark is not visible, the fiber may have been broken. Remove the connector, re-strip and recleave the fiber, and begin with a new connector. For jacketed fibers, the buffer mark must be visible between the lead-in tube and the aramid yarn to assure that the fibers butt together. If you don t see the mark, pull the fiber out of the connector, and start over again with new cable preparation. NEUTRIK AG 21
For installations on 900um fiber lightly pinch the index rollers on the fiber, and slowly rotate the rollers until a 12 mm (0.5 in.) bow forms in the fiber between the connector and the index rollers. Note that you may chose to maintain inward pressure by hand instead of using the fiber index rollers. For installation on 2.0mm cables - lightly pinch the index rollers on the fiber, and slowly rotate the rollers until the cable jacket just begins to bow between the connector and the index rollers. Note that you may chose to maintain inward pressure by hand instead of using the fiber index rollers. NEUTRIK AG 22
Rotate the wrench down until it stops. It is normal for the wrench to rotate beyond 90. DO NOT ROTATE THE WRENCH BACK UP. The glow from the connector s cam should noticeably dim after the wrench is rotated fully down. If the glow is not significantly dimmed, rotate the wrench up, remove the fiber from the connector, and repeat the installation. Carefully flip the crimp handle 180 until it contacts the crimp tube. Push down firmly to crimp. The tool cannot over-crimp the connector NEUTRIK AG 23
Flip the crimp handle back. You should see a flat impression in the crimp tube, indicating a proper crimp Remove the fiber from the index rollers by pressing the release button and lifting it out Remove the connector from the CTS coupler and replace the front dust cap. NEUTRIK AG 24
2.0 mm Single-fiber Cables (Neutrik Hybrid or SMPTE cable): Hold the cable and slide the crimp ring back along the cable jacket to free the aramid yarn. Flare the yarn around the buffered fiber. The ends of the yarn should be within 1 mm of the back of the Square cam If the yarn is too long, trim it now. Hold the connector and push the crimp ring over the aramid yarn and against the back of the connector s cam. Place the connector crimp ring into the opening of the crimp tool Jaws. Squeeze the handles shut until they automatically release to crimp the crimp ring onto the connector. Remove the connector and cable from the tool. NEUTRIK AG 25
4.11. Installation of Neutrik 2-pole fiber cables The usage of UniCam LC connectors for OpticalCon repair is intended as a temporary installation. We recommend to return the OpticalCon cable to your Neutrik dealer for certified repair after usage. Fasten cable ties acting as strain relief to avoid stress of the unprotected LC connectors (not included in the toolkit!). Connect the UniCam LC's with the OpticalCon chassis connector for temporary use and fasten the strain relief. 4.12. Installation of Neutrik Hybrid / SMPTE cables Neutriks hybrid and SMTE cables consist of fibers and also copper wires. Note: Use an adaption chassis connector when working with hybrid cables to wire the copper contacts, in addition you need a short OpticalCon patch cable (has to be ordered separately). OpticalCon chassis connector + short OpticalCon patch cable NEUTRIK AG 26
Strip the copper wires after the UniCam assembly. Connect the UniCam LC`s with the rear of an OpticalCon chassis connector (has to be ordered separately). Solder the copper wires. Use a shrinking tube and two cable ties to build a simplified cable retention / protection (not included in the toolkit). Solder copper contacts Shrinking tube Cable tie 5. Cable Field Repair using the Corning CamSplice TM 5.1. General Corning Cable Systems CamSplice Mechanical Splice is simple and craftfriendly for both multimode and single-mode fibers. It features a cam locking mechanism, which requires no adhesive. The CamSplice Mechanical Splice incorporates a unique, patented fiber alignment method that self-centers the fibers and provides extremely accurate alignment. Average blind (non-tuned) splice loss for the CamSplice Mechanical Splice is specified at 0.15 db with a minimum loss less than 0.3 db. There is only one part for 250/250 µm, 250/900 µm or 900/900 µm applications (one size fits all). The CamSplice Mechanical Splice requires as the UniCam an initial training and few accessories to assemble. The assembly process involves stripping and cleaving fibers, inserting the fibers into the splice part until they touch and turning the cams to secure the fibers. The process does not involve any adhesives or special tools, although an optional assembly fixture is recommended. NEUTRIK AG 27
5.2. Features / Benefits No adhesive or epoxy required Universal, one-part-fits-all fiber coatings Rematable, tunable No polishing required Self-centering fiber alignment mechanism Optional lead-in tubes for securing 900 µm fibers Index-matching gel pre-inserted No stress on fiber in alignment area Small assembly fixture recommended, but optional Fits in industry-standard splice trays 5.3. Assembly Requires the same cable preparation tools as the Corning UniCam (Toolkit TKS) * In addition an optional assembly fixture is available *...see also ordering info chapter 6; The assembly procedure is similar to the Corning UniCam connector. Find detailed info on the assembly instruction from Corning Cabling Systems which you can download at www.neutrik.com in the OpticalCon accessory section. NEUTRIK AG 28
6. Ordering Info UniCam and Camsplice are products and trademarks of Corning Cable Systems. The field repair toolkit, the field installable UniCam LC connectors as well as the mechanical splice Camsplice can be ordered at: - Corning Cable systems - Anixter (World wide Corning Distributer) http://www.corningcablesystems.com http://www.anixter.com/ http://onlinecatalog.anixter.com Field Repair Toolkit Unicam Singlemode Camsplice Camsplice assembly fixture Corning Anixter Field Repair Toolkit TKT-UNICAM-CTS-SF 309616 Unicam LC Multimode 95-050-99 280092 Unicam Singlemode 95-200-99 280090 Camsplice (6 pc.) 95-000-04 129467 Camsplice assembly fixture (optional) 2104040-01 129469 Please note: We strongly recommend an initial training lesson on the assembly of UniCam and Camsplice which can be requested from Corning or Anixter when purchasing the field repair toolkit. NEUTRIK AG 29
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