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AZ1500-2-2 Assembly Instructions    [1500 Series] 

3mm Tight Buffered Fiber Instructions (13 Steps)

Specifications:

Type:  ST*, Field Installable, ST*II Compatible

Mode:  Singlemode

Ferrule Material:  All Zirconia ferrule

Curing Type:  Anaerobic & Epoxy   

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Step 1

Slide tapered end of 3mm flame retardant boot onto 3mm cable approx. 6".  Starting with the small side of the crimp ring, slide the crimp ring onto the 3mm Cable.

[Diagram]

 

Step 2

Place 3mm jacketed cable over Template.  Mark 1.505 dimension, as per template.  Strip.

[Diagram] [Template]

 

Step 3

Trim Kevlar whiskers approx. 1/2".

[Diagram]

 

Step 4

Place .9mm buffered tube over template.  Mark .74" dimension, as per template.  Strip buffer tube off in front of 3mm cable with No Nik stripper.

[Diagram] [Template]

 

Step 5

Now the 3mm jacketed cable will appear as shown in diagram.  

[Diagram]

 

Step 6

This step is very important.  Clean stripped fiber with isopropyl alcohol soaked lint free cloth or a dry lint free cloth.  To clean fold cloth in half over fiber and gently squeeze on the fiber and pull it through the cloth.  This will clean the fiber of debris.  Set aside carefully.

[Diagram]

 

Step 7 - Gluing the Fiber (Anaerobic and Epoxy)

Anaerobic Instructions

  1. Take Loctite RC680 adhesive with flat end needle and insert into the back end of the connector ferrule holder. When it bottoms out, gently squeeze adhesive until a green dot forms in front of the ferrule. Then slowly withdraw adhesive (while maintaining pressure to allow some adhesive to coat the inside of the ferrule and ferrule holder.)

  2. Brush the stripped part of the fiber approx. .615" of the fiber from in front of the buffer (leaving 1/8" (.125") from the front end of the stripped part of the fiber uncoated) and 1/4" of the buffer with Loctite 7649 primer.  Wait 15 seconds to allow primer to dry.

  3. Thread the fiber through the back end of the ferrule holder until it bottoms out.  [Diagram]

  4. Slide the crimp ring over Kevlar whiskers until flush with back of connector.  Using the Sargent 2165 CT crimp tool, crimp back portion of larger diameter crimp ring w/.178 die.  Next, crimp small portion of crimp ring w/.128 die.  [Diagram]

  5. Slide flame retardant boot over crimp ring.  [Diagram]

  6. Proceed to Step 8.

Epoxy Instructions

  1. Mix Epo Tek 353ND epoxy (recommended).

  2. After mixing epoxy, fill a syringe with epoxy. Place needle tip over syringe and insert into back end of ferrule holder. When needle tip bottoms out, inject epoxy until a yellow dot forms in front of the ferrule. Slowly withdraw syringe (while continuing to inject epoxy to allow some epoxy to coat the inside of the ferrule holder).

  3. Thread the fiber through the back end of the ferrule holder until it bottoms out.  [Diagram]

  4. Slide the crimp ring over Kevlar whiskers until flush with back of connector.  Using the Sargent 2165 CT crimp tool, crimp back portion of larger diameter crimp ring w/.178 die.  Next, crimp small portion of crimp ring w/.128 die.  [Diagram]

  5. Slide flame retardant boot over crimp ring.  [Diagram]

  6. Place in fiber optic curing oven at 120° C or more for 3 minutes to accelerate and reduce chemical bond time. Remove from oven and allow to cool. (PVP curing oven recommended.)

  7. Proceed to Step 8.

Step 8

Cleave fiber on two sides. Pull straight up.  Carefully dispose of cleaved fiber.  (After cleaving, until the fiber stub is flush with the ferrule, if too much force is applied to the fiber it will easily chip and leave pits or toenails that go into the ferrule.)

[Diagram]

   

Step 9

Take 15 micron lapping film and roll up and air polish using small circular motions (not figure 8's) and do not proceed to the next step until the air polish as only .002" of the fiber extended above the ferrule face.  Otherwise, there is a chance of snapping the fiber when proceeding to polish.  Blow off with air duster.

 

Note for Steps 10 thru 12: 

Be sure to blow off connector and puck after each lapping sequence to prevent contamination scratching of core. 

 

Step 10

Place 5 micron lapping film on PVP plastic lapping plate.  Insert connector into singlemode polishing puck and do 7 light laps an 8 regular figure 8 patterns (wet or dry polishing).  PVP recommends wet polishing.  Wet polishing is more forgiving at this stage than dry polishing. Once you master the sensitivity, you may want to just dry polish to reduce the necessity of blowing off ferrule and puck after every lapping stage.

[Diagram]

 

Step 11

Place 1 micron lapping film on PVP plastic lapping plate.  Insert connector into singlemode polishing puck and do 7 light laps and 8 regular figure 8 patterns (wet or dry polishing).  PVP recommends wet polishing.

[Diagram]

 

Step 12

Place .3 micron lapping film on PVP plastic lapping plate.  Insert connector into singlemode polishing puck and do 7 light laps and 8 regular figure 8 patterns (wet or dry polishing).  PVP recommends wet polishing.

[Diagram]

 

Step 13

For best results, inspect with interferometer.  Pleaser refer to Model 2000 Operators Manual (coming soon to the website) for detailed instructions.  Check apex offset 50um maximum and that fiber end is not polished flat.  Check to see if fiber core and cladding area are free of scratches, chips, and pits.

[Diagram]

 

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       2008 Pine Valley Precision, Inc.
       Last modified: 02/27/08