3-5504566-1 - Tyco Electronics

Instruction Sheet

OPTIMATE* FSMA

Fiber Optic Connector 408-9863

LOC B

of 7

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

06 OCT 08 Rev E

Types 905 and 906

Figure 1

Full Ferrule

Sleeve

Half Ferrule

Sleeve

Heat Shrink

Tubing

Type 905 Connector

Dust

Cap

Crimp

Sleeve

Strain Relief

(3.10 [.122])

Strain Relief

(4.30 [.169])

Crimp

Sleeve

Connector

Body

Type 906 Connector

Connector

Body

Dust

Cap

1. INTRODUCTION

This instruction sheet covers the application of

OPTIMATE FSMA Fiber Optic Connector Types 905

and 906 for data and telecommunications

applications. Base part numbers which apply to each

type are listed in Figure 1.

Read this material thoroughly before starting

assembly.

All numerical values are in metric units [with U.S.

customary units in brackets]. Dimensions are in

millimeters [and inches], unless otherwise

specified. Figures are for reference only, and are

not drawn to scale.

Reasons for reissue are in Section 6, REVISION

SUMMARY.

2. DESCRIPTION

Figure 1 shows the components of each FSMA

connector type. Connector Type 905 contains a

connector body, crimp sleeve, strain relief, and dust

cover. Connector Type 906 contains a full ferrule

sleeve and a half ferrule sleeve in addition to a

connector body, crimp sleeve, strain relief, and dust

cover.

If an o-ring is desired, use part number

986799-2. The o-ring must slide over the ferrule

and into the connector body groove.

If terminating to 2.2 [.087] diameter plastic fiber,

use tubing part number 5501275-6 to build up

the cable diameter.

Both FSMA connector types provide essentially the

same mechanical and optical performance. Both use

the close fit of a precision plug (the ferrule) in a

precision bore (the coupling bushing) to radially align

the optical fibers of mated connectors. With these

connectors, the ferrule tips of mated connectors do

not touch, but are separated by a small air gap. The

correct air gap is established by finishing the

connector to the correct length by polishing.

The difference between the types is that Type 906

has a stepped ferrule which requires the use of a

ferrule sleeve over it for alignment. The half sleeve is

used in ADM (active device mount) applications and

the full sleeve is used with a coupling bushing. Since

the optical and mechanical performance of both

connector types is comparable, it is suggested that

Type 905 connectors be used where possible.

NOTE

408-9863

OPTIMATE FSMA Fiber Optic Connector Types 905 and 906

Rev

of 7 Tyco Electronics Corporation

Type 905 connectors cannot be mated with Type

906 connectors in a coupling bushing. Type 905

can only mate with Type 905, and Type 906 can

only mate with Type 906. Also, the use of a full

sleeve in an ADM application will damage the

active device.

3. PREPARATION

3.1. Required Tools and Materials

The following tools and materials should be on hand

to perform FSMA fiber optic connector terminations

according to these instructions. The number in

parentheses indicates the corresponding Tyco

Electronics instruction sheet.

A. Tools

— PRO–CRIMPER* II Hand Tool Assembly 58551–1

with Die Assembly 58552–1 (408–4090)

— KEVLAR

}

Shears 1278637–1

— Polishing Plate 501197–1

— Cable Stripper 501198–1 (408–9394)

— Epoxy Mixer 501202–1 (used with BIPAX

{

epoxy)

— Heat Cure Oven 502134–1 when using heat

curing epoxies (408–9460)

— Curing Sleeve 502248–2

— Inspection Microscope Kit 1754767–1

— Fiber Stripper 504024–1 (203

m [.008 in.], red

handle) (408–9485)

— Fiber Stripper 504024–3 (305

m [.012 in.], white

handle) (408–9485)

— Cleave Tool 504064–1 (408–4293)

— Polishing Bushing 228025–1

— Template 501813–1

— SMA Microscope Adapter 1985040–1

— Microscope Coupling Adapter 1985041–1

B. Consumables

— .3–

m Polishing Film 228433–5

—1–

m Polishing Film 228433–7

—5–

m Polishing Film 228433–8

— 15–

m Polishing Film 228433–9

— Epoxy Applicator Kit 501473–3

— Alcohol Fiber Wipe 501857–2

— BIPAX Epoxy 1918652–1, General Purpose

C. Termination Kits

The tools and consumables listed are included (with

exceptions) in the following kits.

— FSMA Termination Kit 503746–2 (does not include

epoxy mixer, epoxy cure oven, microscope kit, alcohol

fiber wipe, and epoxy)

}

Trademark of E.I. Du Pont De Nemours and Company Corporation

{

Trademark of TRA-CON, Inc.

3.2. Preparing Strain Relief

1. For cable having an outer diameter less than

2.54 [.100], use the strain relief as supplied.

2. For cable having an outer diameter between

2.54 [.100] and 4.32 [.170], cut strain relief, using

the KEVLAR shears, at the appropriate segments

shown in Figure 2.

3. For cable having an outer diameter larger than

4.32 [.170], use the heat shrink tubing instead of

the strain relief.

Figure 2

3.56 [.140]

4.32 [.170]

4.06 [.160]

3.3. Preparing Fibers

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.

1. Slide the strain relief (small end first) or the heat

shrink tubing over the cable. Refer to Figure 1.

2. Slide the crimp sleeve (if cable has strength

members) over the cable. Refer to Figure 1.

Do NOT use the crimp sleeve if the cable has no

strength members. Crimping is not required when

cable has no strength members.

Then proceed as follows:

A. For Jacketed Cable With Strength Members

1. Use the template or refer to Figure 3, Detail A,

and mark the outer jacket at 38.1 [1.500] and at

7.87 [.310] from the first outer jacket mark.

2. Strip the outer jacket to 7.87 [.310] using the

cable stripper.

CAUTION

DANGER

NOTE

408-9863

OPTIMATE FSMA Fiber Optic Connector Types 905 and 906

of 7Rev

Tyco Electronics Corporation

The cable stripper must be adjusted to the

appropriate cable jacket diameter; otherwise

damage to the fiber will occur. Refer to

Instruction Sheet 408-9394 for adjustment

instructions.

3. Trim the strength members even with the outer

jacket using the KEVLAR Shears.

4. Strip the outer jacket at the 38.1 [1.500] mark

using the cable stripper.

5. Mark the fiber buffer at 28.0 [1.100] from the

cable jacket.

6. Strip the fiber buffer using the fiber stripper

(red handle) for fiber having a diameter less than

150

m or the fiber stripper (white handle) for fiber

having a diameter less than 231

m and greater

than 151

m. Remove no more than 6.35 [.250] of

buffer at a time.

Fiber strippers are available to accommodate

cable up to 1000-

m diameter.

7. Clean the fiber using an alcohol fiber wipe.

B. For Jacketed Cable Without Strength Members

1. Use the template or refer to Figure 3, Detail B,

and mark the outer jacket at 38.1 [1.500].

2. Strip the outer jacket using the cable stripper.

The cable stripper must be adjusted to the

appropriate cable jacket diameter; otherwise

damage to the fiber will occur. Refer to

Instruction Sheet 408-9394 for adjustment

instructions.

3. Mark the fiber buffer at 28.0 [1.100] from the

cable jacket.

4. Strip the fiber buffer using the fiber stripper

(red handle) for fiber having a diameter less than

150

m or the fiber stripper (white handle) for fiber

having a diameter less than 231

m and greater

than 151

m. Remove no more than 6.35 [.250] of

buffer at a time.

5. Clean the fiber using an alcohol fiber wipe.

C. For Bare Buffered Fiber

1. Use the template or refer to Figure 3, Detail C,

and mark the fiber buffer at 38.1 [1.500].

Figure 3

Detail A

Jacketed Cable With Strength Members

7.9

[.310]

28.0

[1.100]

Detail B

Jacketed Cable Without Strength Members

Detail C

Bare Buffered Fiber or Plastic

28.0

[1.100]

38.1 [1.500]

2. Strip the fiber buffer using the fiber stripper

(red handle) for fiber less than 150–

m diameter or

the fiber stripper (white handle) for fiber less

231–

m and greater than 151–

m diameter.

Remove no more than 6.4 [.250] of buffer at a

time.

3. Clean the fiber using an alcohol fiber wipe.

D. For Plastic Fiber

1. Use the template or refer to Figure 3, Detail C,

and mark the outer jacket at 38.1 [1.500].

2. Strip the outer jacket using the cable stripper.

The cable stripper must be adjusted to the

appropriate cable jacket diameter; otherwise

damage to the fiber will occur. Refer to

Instruction Sheet 408-9394 for adjustment

instructions.

3. Clean the fiber using an alcohol fiber wipe.

3.4. Preparing BIPAX Epoxy

BIPAX Epoxy, General Purpose

Pot Life: 30 minutes

Ambient Cure Time: 24 hours at 25

C [77

F] or

Oven Cure Time: 2 hours at 65

C [149

CAUTION

NOTE

CAUTION

408-9863

OPTIMATE FSMA Fiber Optic Connector Types 905 and 906

Rev

of 7 Tyco Electronics Corporation

1. Install the needle tip of the epoxy applicator.

Make sure it is secure; then remove the plunger.

2. Remove the separating clip from the epoxy

package.

3. Mix the epoxy thoroughly for 20 to 30 seconds.

Use of the epoxy mixer is recommended for

thorough mixing of epoxy.

4. Cut the epoxy pack open and squeeze the

epoxy into the back of the applicator.

5. Reassemble the plunger and hold the applicator

needle tip up. Slowly push the plunger until the

entrapped air escapes and a bead of epoxy

appears at the tip.

3.5. Applying Epoxy

A. For Jacketed Cable With Strength Members

1. Hold the connector with the knurled end up.

2. Insert the tip of the epoxy applicator until it

bottoms against the ferrule. See Figure 4, Detail A.

3. Inject epoxy until a small bead, approximately

0.76 [.030] in diameter, appears at the ferrule. Do

not let the bead smear or get too large.

4. Withdraw the applicator while simultaneously

injecting epoxy in the connector until it is

approximately half full.

5. Apply a small drop of epoxy to the outside of

the knurled end of the connector. See Figure 4,

Detail B.

Do not get any epoxy on or inside the nut area.

6. Fan out the strength members.

7. Carefully insert the fiber into the connector until

it bottoms. Use a twisting motion while inserting the

fiber. Make sure the strength members are outside

the knurled end of the connector. The fiber must

extend out the front of the connector.

Do not force the fiber. The fiber could break if

forced. If the fiber does break, remove the broken

fiber from the connector and repeat Paragraph

3.3,A.

Figure 4

Epoxy

Knurled

End

FSMA

Connector

Detail A

Epoxy

Applicator

Detail B

Ferrule

8. Slide crimp sleeve over the strength members

until it bottoms on the connector shoulder.

B. For Jacketed Cable Without Strength Members,

For Bare Buffered Fiber, and For Plastic Fiber

1. Hold the connector with the knurled end up.

2. Insert the tip of the epoxy applicator until it

bottoms against the ferrule. See Figure 4, Detail A.

3. Inject epoxy until a small bead, approximately

0.76 [.030] in diameter, appears at the ferrule. Do

not let the bead smear or get too large.

4. Withdraw the applicator while simultaneously

injecting epoxy in the connector until it is

approximately half full.

5. Carefully insert the fiber into the connector until

it bottoms. Use a twisting motion while inserting the

fiber. The fiber must extend out the front of the

connector.

Do not force the fiber. The fiber could break if

forced. If the fiber does break, remove the broken

fiber from the connector and prepare the fiber

according to Paragraph 3.3,B, 3.3,C, or 3.3,D.

6. Apply a piece of masking tape to the nut and the

cable. This will hold the connector onto the cable

while the epoxy cures.

For cable without strength members, skip to

Paragraph 4.2. for cable protection assembly.

Crimping is not required.

4. ASSEMBLY PROCEDURE

4.1. Crimping Fiber

For detailed information concerning the hand tool

assembly, refer to 408-4090.

CAUTION

NOTE

408-9863

OPTIMATE FSMA Fiber Optic Connector Types 905 and 906

of 7Rev

Tyco Electronics Corporation

1. Squeeze the tool handles until the ratchet

releases. Allow the handles to open fully.

2. Place the connector body into the first crimp

cavity according to Figure 5. Make sure that the

connector body rests against the side of the die.

This will crimp the sleeve toward the mating end.

3. Squeeze the handles until the ratchet releases.

4. Reposition the connector into the second crimp

cavity according to Figure 5. Push connector

forward so that uncrimped portion of sleeve is now

inside the cavity. This will crimp the sleeve toward

the cable end.

5. Squeeze the tool handles until the ratchet

releases; then remove the connector from the tool.

Crimp Cavity

A" (Ref)

Crimp

Sleeve

CABLE OD (Max) 1ST CRIMP

CAVITY 2ND CRIMP

CAVITY

3.1 [.12] A A

4.3 [.17] C C

5.3 [.21] D D

Figure 5

4.2. Cable Protection

A. Heat Shrink Tubing

1. Slide the heat shrink tubing over the crimped

sleeve as far as possible.

2. Using the heat gun, apply heat until tubing is

snug around connector and cable.

Refer to the instructions packaged with the heat

gun for important safety precautions.

B. Strain Relief

If applicable, slide the strain relief over the crimped

sleeve.

4.3. Curing Connectors

1. Screw the curing sleeve onto the connector to

protect the fiber during curing.

2. Hang the connector vertically with the tip down,

making sure the masking tape is in place to hold

the connector during curing.

3. Cure assembly according to Paragraph 3.4. Use

the cure oven if epoxy requires temperature

elevation.

It is NOT recommended to cure plastic fiber at a

temperature above 65

C [149

F]; elevated

temperatures can damage plastic fiber.

When using cure oven, connector assemblies will

be hot. Make sure assemblies have properly

cooled before continuing.

4.4. Cleaving Fiber

A. For Jacketed Cable and Bare Buffered Cable

DO NOT saw or cut the fiber off with cleave tool.

This could fracture the fiber, making the

connector unusable. Also, DO NOT contact the

epoxy with the blade. This could chip or dull the

blade.

Be very careful to dispose of the fiber ends

properly. The fibers create slivers that can easily

puncture the skin and cause irritation.

1. Remove the curing sleeve.

2. Attach a piece of masking tape to the

workbench for use of easy disposal of the fiber

ends.

3. Hold the connector firmly in an upright position.

4. Place the cleave tool directly above the epoxy.

See Figure 6. Lightly draw the beveled edge

across the fiber parallel to the tip of the connector.

5. Gently pull the fiber straight away from

connector. If the fiber does not easily pull off,

recleave the fiber and try again.

DANGER

CAUTION

DANGER

408-9863

OPTIMATE FSMA Fiber Optic Connector Types 905 and 906

Rev

of 7 Tyco Electronics Corporation

Figure 6

Tool

Tip

Connector

Tip

Epoxy

Bead

Excess

Fiber

Cleave

Tool

Pull Straight Away

After Cleaving

B. For Plastic Fiber

1. Remove the curing sleeve.

2. Cut the plastic fiber above the epoxy bead using

a sharp utility knife.

DO NOT cut the fiber flush to the end of the

connector. Leave a small amount of fiber

protruding to be removed during polishing.

4.5. Polishing Fiber

Cut a small piece (50x50 mm [2x2 in.]) of 15–

polishing film. While holding the film in the air, form a

concave shape, and air polish the connector tip by

gently rubbing the tip of the connector in small circles

or figure–8 motions. Repeat several times until the

fiber is smooth. Then proceed as follows:

1. Screw the polishing bushing onto threaded end

of connector. See Figure 7. Make sure connector is

bottomed inside the polishing bushing.

Figure 7

Polishing

Bushing (Ref)

End of

Connector

2. Place a sheet of 15–

m polishing film on the

polishing plate. See Figure 8.

A few drops of water can be applied to the

polishing film to allow for easier polishing.

BE CAREFUL with the first few strokes.

Protruding rough fiber can easily shatter with too

much pressure.

Figure 8

Polishing

Film

Polishing

Plate

3. Hold connector and bushing firmly between

thumb and forefinger; lightly polish in an elongated

figure–8 motion to a length of approximately

9.837 [.3873]. See Figure 9.

Figure 9

4. Clean the connector face with an alcohol

fiber wipe. This prevents heavy debris from

contaminating the finer polishing films.

5. Change to 5–

m polishing film.

6. Polish connector in an elongated figure–8

pattern to a length of approximately 9.817 [.3865].

7. Clean the connector face.

8. Change to 1–

m polishing film

NOTE

CAUTION

408-9863

OPTIMATE FSMA Fiber Optic Connector Types 905 and 906

of 7Rev

Tyco Electronics Corporation

9. Polish connector in an elongated figure–8

pattern to a finished length of 9.812–9.799

[.3863–.3858].

DO NOT overpolish. Check the fiber tip

frequently.

10. If an exceptional polish is required, polish

again using .3–

m polishing film.

5. INSPECTION

Never inspect or look into the end of a fiber when

optical power is applied to the fiber. The infrared

light used, although it can not be seen, can cause

injury to the eyes or blindness.

Make sure the ferrule length is within the

polishing length of 9.812-9.799 [.3863-.3858].

The fiber or an ADM could be damaged if

polishing length is too long.

1. Remove polishing bushing from connector.

2. Clean the connector face with an alcohol fiber

wipe.

3. Inspect the polished ferrule tip using the

inspection microscope kit. Compare fiber end to

examples shown in Figure 10 and take any

recommended action.

4. Place the dust cover over the connector if the

connector is not going to be used immediately.

6. REVISION SUMMARY

Revisions to this document include:

Updated document to corporate requirements

Deleted and added part numbers in Figure 1

and Paragraphs 3.1.A and B

Deleted text in Paragraph 3.1.C

Figure 10

Ideal Fine scratches

Polish more with

fine diamond film

Heavy scoring

or scratches

Try repolishing

Chip outside

fiber core

Try repolishing

Chipped core

Unacceptable

Reject

Rough surface

Try repolishing Dirt or debris

Try re-cleaning

Try repolishing

Chipped face

Unacceptable

Reject

Cracked fiber

Unacceptable

Reject

Broken fiber

Unacceptable

Reject

ÏÏ

NOTE

DANGER

CAUTION