The following step-by-step guide describes how to terminate plastic fiber optic cable. It is ideal for both field and factory installation. Connectors can be easily installed on cable ends with wire strippers, cutters and a crimping tool.
Finishing the cable is accomplished with the Broadloom AFBR-4594Z Polishing Kit, consisting of a Polishing Fixture, 600 grit abrasive paper and 3 µm pink lapping film (3M Company, OC3-14). The connector can be used immediately after polishing.
Materials needed for plastic fiber termination are:
1. Broadcom Plastic Optical Fiber Cable (Example: HFBRRUS500Z, HFBR-RUD500Z, HFBR-EUS500Z, or HFBREUD500Z)
2. Industrial Razor Blade or Wire Cutters
3. 16 Gauge Latching Wire Strippers (Example: Ideal StripmasterTM type 45-092).
4. HFBR-4597Z Crimping Tool
5. AFBR-4594Z Polishing Kit
6. One of the following connectors:
a) HFBR-4501Z/4503Z Gray Simplex/Simplex Latching Connector and HFBR-4525Z Simplex Crimp Ring
b) HFBR-4511Z/4513Z Blue Simplex/Simplex Latching Connector and HFBR-4525Z Simplex Crimp Ring
c) HFBR-4506Z Parchment (off-white) Duplex Connector and HFBR-4526Z Duplex Crimp Ring
d) HFBR-4516Z Gray Latching Duplex Connector and HFBR-4526Z Duplex Crimp Ring
Step 1
The zip cord structure of the duplex cable permits easy separation of the channels. The channels should be separated a minimum of 100 mm (4 in) to a maximum of 150 mm (6 in) back from the ends to permit connectoring and polishing.
After cutting the cable to the desired length, strip off approximately 7 mm (0.3 in.) of the outer jacket with the 16 gauge wire strippers. Excess webbing on the duplex cable may have to be trimmed to allow the simplex or simplex latching connector to slide over the cable.
When using the duplex connector and duplex cable, the separated duplex cable must be stripped to equal lengths on each cable. This allows easy and proper seating of the cable into the duplex connector.
Step 2
Place the crimp ring and connector over the end of the cable; the fiber should protrude about 3 mm (0.12 in.) through the end of the connector. Carefully position the ring so that it is entirely on the connector with the rim of the crimp ring flush with the connector, leaving a small space between the crimp ring and the flange. Then crimp the ring in place with the crimping tool. One crimp tool is used for all POF connector crimping requirements.
For applications with extreme temperature operation or frequent temperature cycling, improved connector to cable attachment can be achieved with the use of an
RTV (GE Company, RTV-128 or Dow Corning 3145-RTV) adhesive. The RTV is placed into the connector prior to insertion of the fiber and the fiber is crimped normally.
The connector can be polished after the RTV has cured and is then ready for use.
Note: By convention, place the gray connector on the transmitter cable end and the blue connector on the receiver cable end to maintain color coding (different color connectors are
mechanically identical).
Simplex connector crimp rings cannot be used with duplex connectors and duplex connector crimp rings cannot be used with simplex connectors because of size differences.
The simplex crimp has a dull luster appearance; the duplex ring is glossy and has a thinner wall.
Step 3
Any excess fiber protruding from the connector end may be cut off; however, the trimmed fiber should extend at least 1.5 mm (0.06 in) from the connector end.
Insert the connector fully into the polishing fixture with the trimmed fiber protruding from the bottom of the fixture. This plastic polishing fixture can be used to polish two simplex connectors or simplex latching connectors simultaneously, or one duplex connector.
Note: The four dots on the bottom of the polishing fixture are wear indicators. Replace the polishing fixture when any dot is no longer visible. Typically, the polishing fixture can be used 10 times; 10 duplex connectors or 20 simplex connectors, two at a time. Place the 600 grit abrasive paper on a flat smooth surface, pressing down on the connector, polish the fiber and the connector using a figure eight pattern of strokes until the connector is flush with the bottom of the polishing fixture. Wipe the connector and fixture with a clean cloth or tissue.
Step 4
Place the flush connector and polishing fixture on the dull side of the 3 µm pink lapping film and continue to polish the fiber and connector for approximately 25 strokes. The fiber end should be flat, smooth and clean.
This cable is now ready for use.
Note: Use of the pink lapping film fine polishing step results in approximately 2 dB improvement in coupling performance of either a transmitter-receiver link or a bulkhead/splice over a 600 grit polish alone. This fine polish is comparable to the Broad com factory polish. The fine polishing step may be omitted where an extra 2 dB of optical power is not essential, as with short link lengths. Proper polishing of the tip of the fiber/connector face results in a tip diameter between 2.5 mm (0.098 in.) minimum and 3.2 mm (0.126 in.) maximum..
AFBR-4594Z Polishing Kit
