Instruction Sheet
SC- and FC-Type Singlemode
and Multimode Simplex and 408-8674
LOC B
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of 12
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
29 OCT 08 Rev F
Duplex Connector Kits
Figure 1
Protective
Cover
Duplex Clip
Buffer Boot
Crimp
Eyelets
Connector
Subassemblies
Heat Shrink Assembly
Bend Limiting
Boot
Boots
Connector
Subassembly
Housing
Protective
Cover
Protective Cover
Housing
Housing
Simplex Connector Kit
Duplex Connector Kit
1. INTRODUCTION
This instruction sheet covers the application of all
SC– and FC–type Singlemode, Multimode, Simplex,
and Duplex Connector Kits. See Figure 1.
These connectors are used in telephone company
central offices, CATV head–ends, inter–building
backbones and customer premise applications. This
instruction sheet covers the termination of the
connector kits (shown in Figure 1) to fiber optic cable.
These connector kits are available for termination to
250–
m
m coated and 900–
m
m buffered fiber, 1.6– to
2.4–mm and 3.0–mm jacketed cable. With the use of
a field–installable clip, all simplex connectors can be
joined into a duplex form.
Throughout this instruction sheet, references
made to connectors will include both the SC- and
FC-type connectors, unless otherwise specified.
Read these instructions thoroughly before starting
assembly.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.
2. DESCRIPTION
(Figure 1)
Each SC–type connector kit consists of a housing, a
protective cover, a connector subassembly, and either
a crimp eyelet and boot or a buffer boot.
Each FC–type connector kit consists of a housing,
protective cover, a connector subassembly, and either
a crimp eyelet and boot or a buffer boot.
Refer to Figure 1 for component descriptions and
related connector kit information.
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3. ASSEMBLY PROCEDURE
3.1. Required Tools and Consumables
The following tools and consumables are required for
assembling the connector kits (the 408 numbers in
parentheses indicate the related instruction sheet).
Kits are provided with a protective cover installed
onto the connector subassembly. Keep the cover
in place until ready for installation.
A. Tools
Combination Strip Tool 1754708–1 or
1278947–1 (408–4577)
Aramid Shears 1278637–1
Cable Preparation Template 1754636–1
SC Fiber Protector 502656–1
FC Fiber Protector 502862–1
Fiber Optic Sapphire Scribe Tool 504064–1
(408–4293)
LC/ SC/FC 1.6–2.4–mm Jacket Die Set
1588175–1
SC/FC 3.0–mm Long Eyelet Die
Set 492025–1
SC/FC 3.0–mm Short Eyelet Die
Set 492131–1
PRO–CRIMPER* II Hand Tool Frame Assembly
58532–1 (408–4020)
Heat Cure Oven 502134–1 (120V) or 502134–2
(240V) (408–9460)
Oven Block Assembly 1457628–1
Epoxy Mixer 501202–1
Fiber Optic Inspection Microscope 1754767–1
(adapter included)
SC Polishing Bushing 502631–1
FC Polishing Bushing 504862–1
Polishing Plate 501197–1
Polishing Pad 501858–1 (Green Pad)
B. Consumables
Epoxy, EPO–TEK
t
353–ND 504035–1, or
anaerobic adhesive and anaerobic primer
(LOCTITE 648
t
Anaerobic Adhesive and
LOCTITEActivator 7649 are recommended,
respectively, replacing the
manufacturer–obsoleted 3405 LOCTITE
OPTILOC Anaerobic Adhesive Primer)
EPO–TEK is a trademark of Epoxy Technology Inc.
LOCTITE and OPTILOC are trademarks of Henkel
Corporation
Refer to manufacturers Material Safety Data
Sheet (MSDS) for characteristics, reactivity data,
and handling of the epoxy.
Epoxy Applicator Kit 501473–3
Alcohol pads or isopropyl alcohol and
lint–free cloths
—5
m
m Polishing Film 228433–8
—1
m
m Polishing Film 503887–1
0.3–
m
m Polishing Film 228433–5
3.2. Fiber Preparation (Strip and Dip)
To avoid personal injury, ALWAYS wear eye
protection when working with optical fibers.
NEVER look into the end of terminated or
unterminated fibers. Laser radiation is invisible
but can damage eye tissue. Never eat, drink, or
smoke when working with fibers. This could lead
to ingestion of glass particles.
BE VERY CAREFUL to dispose of fiber ends
properly. The fibers create slivers that can easily
puncture the skin and cause irritation.
A. 250-
m
m Coated Fiber and 900-
m
m Buffered Fiber
1. Slide the buffer boot (small diameter end first)
onto the fiber buffer. See Figure 2, Detail A.
2. Using the combination strip tool, strip the coated
or buffered fiber according to the dimensions
shown in Figure 3.
This operation will expose the glass cladding.
3. Clean the glass cladding using the alcohol pad
or lint–free cloth dampened with alcohol to remove
any coating residue.
NEVER clean buffer or fiber with a dry cloth.
For best results, the primer must be applied
properly and allowed to dry.
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Figure 2
Detail A: Preparing Coated/Buffered Fiber
Detail B: Preparing 1.6-mm
to 2.4-mm Jacketed Cable
Buffer Boot
Fiber
Cable
Bend Limiting Boot
Heat Shrink
Boot
Cable
Crimp
Eyelet
Detail C: Preparing
3.0-mm Jacketed
Cable
4. If terminating with anaerobic adhesive, dip the
fiber and buffer into the primer or apply to the
buffer and fiber with a brush. Allow 30 seconds for
the primer to dry.
Figure 3
NOTE:
Not to scale. Dimensions are in millimeters.
A
B. 1.6- to 2.4-mm and 3.0-mm Jacketed Cable
1. Slide the boot (small diameter end first) onto the
cable. Then slide the heat shrink assembly (heat
shrink end first) or crimp eyelet onto the cable.
S
Refer to Figure 2, Detail B for heat–shrink
installation.
S
Refer to Figure 2, Detail C for crimp eyelet
installation
If duplex cord is used, unzip the jacket into
separate cords at least 230 mm [9.0 in.] from the
cable end.
2. Using the combination strip tool and Aramid
shears, strip the cable according to the dimensions
shown in Figure 4.
Figure 4
NOTE:
Not to scale. Dimensions are in millimeters.
A
This operation will expose the glass cladding.
3. Clean the glass cladding using the alcohol pad
or lint–free cloth dampened with alcohol to remove
any coating residue.
NEVER clean buffer or fiber with a dry cloth.
4. If terminating with anaerobic adhesive, dip the
fiber and buffer into the primer or apply with the
brush, allowing 30 seconds for the primer to dry.
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For best results, the primer must be applied
properly and allowed to dry.
3.3. Selection, Preparation, and Application of
Adhesive/Epoxy
A. Selection
S
The recommended anaerobic adhesive is easy
to use and is packaged in two bottles ––
adhesive and primer. It will cure at 22° C
[71.6° F] in approximately three minutes.
S
The recommended epoxy is easy to work with
and is packaged in pre–measured components.
It will cure in approximately 30 minutes at
120°C [248° F].
B. Preparation of Anaerobic Adhesive
1. Install the needles on the two applicators,
making sure they are secure.
2. Remove the plunger from one of the applicators
and load adhesive into the back.
3. Replace the plunger.
4. Holding the applicator vertically (needle
upward), allow the adhesive to drain away from the
needle and slowly push the air out of the applicator
until a bead of adhesive appears at the tip of the
needle.
5. Using the second applicator for primer (with the
plunger fully forward), draw a small amount
(approximately three–to–five ml) of primer into the
applicator.
C. Preparation of Epoxy
1. Remove the separating clip from the epoxy bag
and, using the epoxy mixer, mix the epoxy inside
the bag thoroughly for two minutes.
When mixed properly, the epoxy should have a
uniform, translucent, amber color.
2. Using the epoxy applicator kit, install the needle
tip onto the epoxy applicator. Make sure that the tip
is secure. Remove the plunger.
3. Cut the epoxy bag diagonally at one corner.
Squeeze the epoxy into the back of the applicator.
Reassemble the plunger. Loosen, but do not
remove, the cap. Hold the applicator vertically
(needle tip upward), and slowly push the plunger
until the entrapped air escapes and a bead of
epoxy appears at the tip. Remove the cap.
4. Clean the tip of the applicator needle using the
alcohol pad or alcohol–dampened lint–free cloth.
D. Application of Adhesive/Epoxy
A 20 gage syringe is recommended for epoxy
application.
1. Remove the protective cover and attach the
appropriate cure protector, as shown in Figure 5,
for buffer or jumper connector subassemblies.
Cure protectors are not required for use with
anaerobic adhesive.
2. Hold the connector subassembly in an upright
position. Insert the needle tip into the rear body
and support tube until the needle tip touches the
bottom of the ferrule. See Figure 6.
3. Keeping the base of the ferrule against the
needle tip,
slowly
inject adhesive/epoxy into the
connector subassembly until a small bead of
adhesive/epoxy exits from the endface of the
ferrule at the front of the connector.
Figure 5
FC-Type Connector
SC-Type Connector
4. Retract the applicator slightly (approximately
1.0 mm [.04 in.]). Hold for one second, then
withdraw the applicator needle quickly without
injecting more adhesive/epoxy into the connector
subassembly.
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Figure 6
Applying Adhesive/Epoxy
Endface
of Ferrule
Applicator
Needle
Ferrule
Support
Tube
Rear Body
of Connector
Front of
Connector
If too much epoxy is injected into the connector
subassembly, the connector subassembly will not
function properly.
3.4. Termination of the Fiber
A. 250-
m
m Coated Fiber and 900-
m
m Buffered Fiber
1. While holding the connector between the thumb
and forefinger (with the ferrule facing away), look
into the back, where the fiber is to be placed.
2. Carefully insert the fiber into the support tube
(which is recessed inside the connector
subassembly) and rear body until the buffer
bottoms on the base of the ferrule. The fiber
should extend approximately 6.4 mm [.25 in.] from
the ferrule endface.
3. For parts terminated with anaerobic adhesive,
dispense a drop of primer from the applicator onto
the tip of the ferrule over the adhesive bead, and
set the part aside to allow the adhesive to finish
curing (approximately one to three minutes).
Proceed to Paragraph 3.6.
For best results, the adhesive must be applied
correctly and allowed to dry.
B. 1.6- to 2.4-mm Jacketed Cable
1. While holding the connector between the thumb
and forefinger (with the ferrule facing away), look
into the back, where the fiber is to be placed.
2. Carefully insert the fiber into the rear body and
support tube (which is recessed inside the
connector subassembly) until the buffer bottoms on
the base of the ferrule. With the buffer bottomed,
the cable jacket should be just short of the rear
body. The fiber should extend approximately
6.4 mm [.25 in.] from the ferrule endface.
DO NOT allow the cable strength members to
enter the connector.
3. Uniformly distribute the cable strength members
around the rear body of the connector. See
Figure 7, Detail A.
4. Slide the heat shrink assembly forward over the
cable strength members until the crimp eyelet
bottoms against the connector. See
Figure 7, Detail B.
5. Place the crimp eyelet of the heat shrink
assembly into the crimping chamber of the die
assembly. Align the back of the connector with the
edge of the die as shown in Figure 8.
6. Hold the connector subassembly in place and
actuate the tool handle. This operation retains the
strength members.
7. Remove the assembly from the hand tool and
inspect it for a straight and even crimp. Be sure the
crimp is centered on the crimp eyelet.
8. For parts terminated with anaerobic adhesive,
dispense a drop of primer from the applicator onto
the tip of the ferrule over the adhesive bead and
set the parts aside to allow the adhesive to finish
curing (approximately one to three minutes) Heat
the shrink tubing evenly and shrink it into place.
Overheating can cause fiber bending, breakage,
and high insertion loss.
For best results, the adhesive must be applied
correctly and allowed to dry.
9. Proceed to Paragraph 3.6.
CAUTION
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Figure 7
Detail A
Detail B
Heat Shrink Assembly
Cable Strength
Members Uniformly Distributed
Crimp Eyelet
Detail C
Figure 8
Crimping Heat Shrink Assembly
Crimp Eyelet in
Crimping Chamber
Heat Shrink
Assembly
Back of Connector
Aligned with
Edge of Die
C. 3.0-mm Jacketed Cable
1. While holding the connector between the thumb
and forefinger (with the ferrule facing away), look
into the back, where the fiber is to be placed.
2. Carefully insert the fiber into the rear body and
support tube (which is recessed inside the
connector subassembly) until the buffer bottoms on
the base of the ferrule. With the buffer bottomed,
the cable jacket should be just short of the rear
body. The fiber should extend approximately
6.4 mm [.25 in.] from the ferrule endface.
Do NOT allow the strength members to enter the
connector.
3. Uniformly distribute the cable strength members
around the rear body of the connector.
See Figure 7, Detail A.
4. Slide the crimp eyelet forward over the cable
strength members until it bottoms against the
connector. See Figure 7, Detail C.
Be SURE to use the proper crimp die-set with
the appropriate eyelet. See Figure 9.
5. Place the crimp eyelet into the appropriate
crimping chamber of the die assembly. Align the
edge of the large diameter end of the crimp eyelet
with the edge of the die, as shown in Figure 10.
6. Hold the connector in place and actuate the tool
handle. This operation retains the strength
members.
Figure 9
Long Eyelet
Short Eyelet
Use Die-Set
492026-1 Use Die-Set
492131-1
7. For parts terminated with anaerobic adhesive,
dispense a drop of primer from the applicator onto
the tip of the ferrule over the adhesive bead.
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Figure 10
Hand Tool Frame with Die Assembly
Large Diameter
End of Crimp
Eyelet Aligned
with Edge of Die
NOTE:
SC-type connector shown. Crimp procedure is the
same for FC-type connectors.
8. Set the parts aside to allow the adhesive to
finish curing (approximately one to three minutes).
Proceed to Paragraph 3.6.
For best results, the adhesive must be applied
correctly and allowed to dry.
3.5. Curing Epoxy Terminated Parts
BEFORE CURING, make sure all excess epoxy
is removed from the connector subassembly; it
will be difficult to remove epoxy after curing.
1. Insert the connector subassembly (with attached
cure protector) into the cure oven as shown in
Figure 11. Heat cure the epoxy at 115
_
to 120
_
C
[239
_
to 257
_
F] for a minimum of 15 minutes. For
jumper connector kits, this operation will shrink the
heat shrink assembly.
To avoid damage to the assembly, DO NOT
expose assembly to excessive temperatures.
2. After curing, use the cable to gently lift the
assembly out of the oven.
Upon removal from the cure oven, the assembly
will be HOT. Allow sufficient time for cooling.
Figure 11
Cable Holder
Oven Block Assembly
NOTE:
Simplex Jumper
Connector Kit shown.
Heat Cure
Oven
Figure 12
Tool Tip
Connector Tip
Epoxy/Adhesive
Bead
Excess Fiber
Pull
After
Cleave
Cleave Tool
3.6. Cleaving the Fiber
ALWAYS wear safety glasses when cleaving
optical fibers. CAREFULLY DISPOSE OF FIBER
ENDS. The fibers create slivers that can easily
puncture the skin and cause irritation.
1. If using a fiber protector, rotate it to remove it,
then hold the connector subassembly firmly in one
hand.
2. Place the sapphire cutting tip just above the
epoxy/adhesive, as shown in Figure 12.
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Do NOT allow the sapphire cutting tip to make
contact with the epoxy or adhesive, as they may
damage, chip, or crack the sapphire cutting tip.
3. Gently score the fiber by drawing the beveled
edge of the sapphire blade across the fiber.
4. After lightly scoring the fiber, pull the fiber
straight away from the connector to finish the
cleave process. The fiber should shear cleanly at
the scribe point.
3.7. Assembly of the Connector
1. Slide the boot forward until it touches the rear of
the connector body.
Avoid twisting the boot while sliding it over the
crimp eyelet. Permanent damage could result.
See Figure 13. (The FC type connector is
complete. Proceed to Section 4, POLISHING
PROCEDURES.)
2. For SC–type connectors, slide the connector
housing over the connector assembly until it clips
into place. The chamfer must be aligned as shown
in Figure 14, Detail A. For duplex SC–type
connectors, identify the channel “A” connector.
If the polarity is undetermined, light up one fiber
path. One of the two connectors should be
illuminated. Designate the lit channel as
Channel A" and the other as Channel B."
3. Install the duplex housings accordingly. Be sure
to orient the resilient beam and retention plate
housings as shown in Figure 14, Detail B.
Do NOT join the two halves together at this time.
For buffer fiber applications, the SC-type duplex
insertion tool must be used to assemble the
connector housing and the connector
subassembly.
4. POLISHING PROCEDURES
4.1. Hand Polishing
For best results, the polishing films MUST be
kept clean.
1. To level the fiber, lightly polish the end face with
hand–held 5–
m
m polishing film (air polish). Use a
small circular motion to remove the fiber stub down
to the level of the epoxy/adhesive and until the
fiber stops leaving a trace on the film.
2. Install the connector into polishing bushing. See
Figure 15.
3. Place the polishing pad on the polishing plate.
The remainder of the polishing procedure is
performed on this pad and plate.
Figure 13
1.6- to 2.4-mm Jumper
Connector Kit
(Simplex Shown)
Buffer Boot
Against Rear Body
Buffer Connector Kit
(Simplex Shown)
Boot Against
Rear Body
Bend-Limiting Boot
Against Rear Body
3.0-mm Jumper Connector Kit
(Simplex Shown)
CAUTION
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CAUTION
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Figure 14
Key
Chamfer
Retention Plate
Housing
Resilient Beam
Housing
Connector
Subassembly
Connector
Housing
Plug Body
Chamfer Must
be Aligned
Detail A
Detail B
Figure 15
Polishing
Bushing
4. Place the 5–
m
m polishing film on the polishing
pad.
Always place the polishing bushing on a clean
area of the polishing film. Never start polishing on
or across a dirty section of the film.
5. Holding the polishing bushing and connector,
start polishing very lightly. Polish in an elongated
figure–8 pattern. See Figure 16. Initially, a small
amount of exposed fiber will be worn away. This is
indicated by a narrow white trace on the film. As
the exposed fiber wears away, the trace will widen
and darken, indicating that adhesive/epoxy is being
removed. At this point, a slight downward force
may be applied while polishing. Check the tip often
and stop polishing on the 5–
m
m film when the
adhesive/epoxy is medium red–pink and about
one–third the ceramic ferrule diameter in size.
When polishing ceramic ferrule connectors, it is
essential that not all of the adhesive/epoxy is
removed when using the 5-
m
m film.
6. Clean the polishing bushing and connector
assembly with an alcohol pad.
Figure 16
Figure-8
Pattern
7. Remove the 5–
m
m film from the polishing pad
and replace it with the 1–
m
m film.
8. Holding the connector and polishing bushing,
polish on the 1–
m
m film for about 20 seconds.
9. Clean the polishing bushing and connector
assembly with an alcohol pad.
10. Remove the 1–
m
m film from the polishing pad
and replace it with the 0.3–
m
m film.
11. Hold the connector and polishing bushing.
Using light force, polish on the 0.3–
m
m film until the
adhesive/epoxy is gone. Do not overpolish.
12. Clean the polishing bushing and connector
assembly with an alcohol pad.
4.2. Machine Polishing
Refer to the polishing machine manufacturer for
recommended polishing process.
CAUTION
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5. INSPECTING THE FIBER
Using the microscope, inspect the fiber for the
following criteria (refer to Figure 17):
Disconnect cable from any power signal source
before inspecting. The light used can cause injury
to the eye.
S
Be sure all epoxy/adhesive is removed from
the ferrule. Use a sharp blade to remove
epoxy/adhesive from the chamfered edge of
the ferrule. DO NOT touch the fiber.
S
Dirt may be mistaken for small pits. If dirt is
evident, clean with an alcohol pad or
alcohol–dampened lint–free cloth, and then dry.
S
Fine polishing lines are acceptable.
S
Small chips at the outer rim of the fiber are
acceptable. Large chips in the center of the
fiber render the polish unacceptable, and the
fiber must be re–terminated.
If not installing the connector immediately, place
the protective cover over the ferrule.
Damaged components must not be used. They
must be replaced with new components.
Figure 17
Acceptable
Unacceptable
Ferrule Endface Fiber
Fine Polishing Lines
Small Peripheral
Chips Permissible
Scratches
Large Pits
6. DUPLEX CONNECTOR ASSEMBLY
6.1. Duplex Housings
Once joined, the resilient beam and retention
plate housings are NOT separable.
1. The retention plate housing will retain the
resilient beam housing when the two are joined.
Figure 18
Join the two housings by holding the resilient beam
housing and sliding the retention plate housing
over the beams until they latch in place. See
Figure 18.
2. Figure 19 shows a completely assembled
multimode duplex connector.
Figure 19
6.2. Duplex Clip (For Use with Simplex Connector
Housing Only)
1. Place the simplex connector housings in one
half of the duplex clip. See Figure 20.
2. Place the other half of the duplex clip over the
housings and snap the two clips together. See
Figure 20.
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Figure 20
7. CLEANING PROCEDURES
To avoid personal injury, compressed air used for
cleaning must be reduced to less than 207 kPa
[30 psi], and effective chip guarding and personal
protective equipment (including eye protection)
must be used.
7.1. Connector
1. Wipe completely around the ferrule with an
alcohol pad or lint–free cloth dampened with
isopropyl alcohol.
2. Wipe completely around the ferrule using a dry
lint–free cloth.
3. Place the dry lint–free cloth on a smooth, flat
surface. Holding the connector perpendicular, wipe
the ferrule endface across the cloth.
4. Blow compressed air across the endface of the
ferrule.
5. Examine the endface for debris, using the
microscope. If debris is present, repeat Steps 1
through 4.
This is the final step prior to connector insertion.
DO NOT wipe the ferrule or allow it to touch
anything before mating the connector.
6. Mate the connector to the receptacle.
7. If the attenuation is too high, unmate both
connectors (if applicable), repeat Steps 1 through
5, and follow procedures in Paragraph 7.2,
Receptacle.
7.2. Receptacle
1. Blow compressed air through the receptacle.
If both connectors are not removed, blow
compressed air into the open end of the
receptacle.
2. Re–mate the connector(s) to the receptacle
following the procedures in Paragraph 7.1.
Steps 7.1 and 7.2 may have to be repeated if the
connector loss is still too high.
8. RECOMMENDED TUNING PROCEDURES
Tuning Tool 1693383–1 is used to rotate the ferrule
into the position of lowest loss. The tool has
numbered flats, spaced every 60 degrees that are
used to identify the position of the ferrule. The end of
the tool has a machined key that will engage into the
ferrule in only one position. The corresponding
number that matches up with the key on the
connector identifies the the current tuning position.
8.1. Setup
Before testing a connector, insert the tuning tool into
the front of the connector, to obtain the “initial tuning
position.” Note this position.
Inspect the ferrule for dirt and debris.
NEVER look into the end of terminated or
unterminated optical fibers. Laser radiation is
invisible, but can damage the eye.
Damage will occur to the ferrule if the tool is
rotated without the tool being bottomed all the
way toward the connector.
Damage may occur to the cable assembly if the
ferrule is rotated more than 180 degrees (three
tuning positions) in either the clockwise or the
counterclockwise direction.
8.2. Tuning Operation
1. Mate the offset end of the tuned launch lead to
the connector to be tuned using a ceramic sleeve
adapter.
2. Record the power level of the detector.
3. Unmate the connector and insert the tuning tool
to the previously noted (initial tuning) position.
4. Press the tuning tool axially toward the
connector until it bottoms and rotate it clockwise
one numerical position, or 60 degrees.
DANGER
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5. Release the tool and remove it.
6. Repeat steps one through five, for a total of
three tuning positions.
7. After the third tuning measurement is taken,
tune the connector counterclockwise five positions.
8. Repeat steps one through five for the other
three tuning positions.
9. Tune the connector as described in steps two
through five to the position of greatest power
(lowest loss), going in the direction of least
rotation.
Be sure not to exceed 180 degrees of rotation
from the original position.
9. REVISION SUMMARY
Revisions to instruction sheet 408–8674 include:
S
Updated document to corporate requirements
S
New format
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