FIBER OPTIC CONNECTORS HE-2000 CROCODILE FUSION FOR ZEUS D50 HE - ASSEMBLY INSTRUCTION
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ASSEMBLY INSTRUCTION FIBER OPTIC CONNECTORS HE-2000 CROCODILE FUSION FOR ZEUS D50 HE Part No. 1951590 - Version 07.05.2019
Index 0 INDEX Page 1 INTRODUCTION ______________________________________________________________________ 2 1.1 Tooling fusion field termination system _____________________________________________________________ 2 1.2 Equipment and material used ______________________________________________________________ 2 2 HE-2000 CONNECTOR SET _____________________________________________________________ 6 3 SAFETY REQUIREMENTS______________________________________________________________ 10 4 CABLE PREPARATION_________________________________________________________________11 5 MEASUREMENT METHOD IL____________________________________________________________29 HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 1
Introduction 1
1 INTRODUCTION
This document describes the preparation of cable after splicing the alberino fusion.
Cables that can be spliced to the connectors must have the following characteristics:
- cables with ø 250μm primary coating and 900μm secondary coating
- cables with ø 1.6 to 8.0mm jacket.
1.1 TOOLING FUSION FIELD TERMINATION SYSTEM
1.2 EQUIPMENT AND MATERIAL USED
P.N. Description Image
1049775 Jokari
1040186 Stripping pliers Jonard 3 holes
1020713 Kevlar Cutter
Side cutters
1020483
160 mm
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 2
Introduction 1
P.N. Description Image
1075632 Crimping pliers HE E.2000
Crimping pliers AF8 with
1081071
adapter (Positioner) UH2-5
1056892 FTTH Crimping Pliers
1073457 T-Stripper
1073458 Kevlar Scissor
1060309 V-groove protection
1059637 Fusion Alberino Holder
1069263 Fiberholder special outdoor
1020681 Mixing plate
1020358 Mixing sticks
1047068 Hysol Glue 608
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 3
Introduction 1
P.N. Description Image
1020822 Cleaning - cloth Kimwipes 11x21cm
1073654 Stickler connector cleaner
1020588 Tweezers 120 mm Typ 00
1049773 Wrench 12 mm
1072536 Wrench 19 mm
1074651 Ferrule extractor
Hollow pin guide
1074744
mounting/demounting tool
1074654 Termini extractor
1074680 Termini assembler
1900109 Marker Pen
1900216 Marker Pen Edding 780
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 4
Introduction 1
P.N. Description Image
1020537 Ruler L=150mm
Tube Stripper
1071976
3-5.5 mm
1066753 Protection sleeve insertion tool
1075931 Crimping sleeve device
Adapter FBPT E-2000
APC/PC for ferrule inspection HE-2000
1073321
with JDSU P5000i digital
inspection probe
IBC-M250 for ferrule
000-001-785C000
front face cleaning HE-2000
1074744 Ferrule puncher
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 5
Connector Set 2
2 HE-2000 MINI BREAKOUT CONNECTOR SET
2.5mm Crocodile Fusion Alberino HE
Optical/Electrical termini
DM 4
HE-2000 Connector and bulkhead
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 6
Connector Set 2
Item Quantity Description
10 1 Cable boot
20 1 External Nut
30 1 O-Ring
40 1 Brass Ring
50 1 Ring
60 1 Crimping Ring
100 1 Internal Nut
110 1 Spacer
120 1 Bush
140 1 Spring
150 1 DM 4
160 1 HE-2000 Body
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 7
Connector Set 2
DM 4 ADAPTER INSERT FUSION VERSION
Item Quantity Description
10 1 Cable boot
20 1 Protection sleeve
30 1 Crimping sleeve
40* 1 Fusion alberino
50 1 Assembled Termini
60 1 Termini Housing
70 1 Termini Cap
80 1 DM 4 adapter
90 1 Hollow pin guide
100 1 Ceramic sleeve holder
110 1 Electrical contact protection
120 - Female Electrical contact
130 - Male Electrical contact
SM/PC Crocodile Alberino
Item Quantity Description
40* 4 E-2000™ Crocodile SM PC/APC
MM/PC Crocodile Alberino
Item Quantity Description
40* 4 E-2000™ Crocodile MM 50µm PC
40* 4 E-2000™ Crocodile MM 62.5µm PC
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 8
Connector Set 2
HE-2000 BULKHEAD
Item Quantity Description
10 1 Nut
20 1 Inox Washer
30 1 Plastic Washer
40 1 Channel Connector
50 1 O-Ring
60 1 HE-2000 Bulkhead
70 1 Bronz Ring
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 9Safety requirements 3
3 SAFETY REQUIREMENTS
Safety glasses for eye protection are required when using epoxy, care should be taken not to get any residue on your
skin and avoid touching your eyes.
CAUTION: when using razor blades handle with extreme care.
CAUTION: Never look directly into a laser light when handling a fault finder or optical equipment.
During the preparation determine which type of cable will be used SM or MM in order to prepare the fiber and the
material correctly.
FIBER OPTIC BREAKOUT CABLE TYPE
Dimensions (µm) Material Color
D1 8.3 Glass Transparent
D2 125 Glass Transparent
D3 500 Acryl Transparent
D4 900 Hard Elastomeric Various
D5 5500 PUR Black
D6
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 10Cable preparation 4
4 CABLE PREPARATION
Insert all the components along the cable before beginning
with the preparation.
Attention: the brass ring (40) must be positioned so that the
groove remains directed towards to the inner nut (100).
The ring (120) must be placed with the larger internal diameter
directed towards also the crimping ring (60) must be inserted
with the larger internal diameter directed towards the ring (50)
so that it enters in the crimping ring (60).
60 120
50
Strip about ~50mm cm with a Jokari stripper.
Open the outer jacket about an additional ~80mm using the
internal ripcord.
Cut the first ~20 mm cable stripped with the side cutter this
to prevent using part of eventually damaged fibers you should
be left with ~110 mm of stripped Jacket.
At the end of the ripcord cut around the cable watching to
ensure the blade does not cut past the jacket.
Be careful not to cut yourself!
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 11Cable preparation 4
If you prefer use the tube or a knipex stripper to cut the outer
jacket.
Remove the outer jacket and start the stripping procedure.
Cut the two plastic traction white sheaths.
Cut the cable according to the
measurement indicated on the
drawing.
Use the Felt Tip Pen to mark the 900 μm fibers to a length of
49mm 0 /+1 mm.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 12Cable preparation 4
Place the fiber into the fiber holder, make sure to place the
49mm marking at the groove of the fiber holder.
6±0.3
49mm fiber holder mark.
Place the fiber holder into the thermal stripper to strip the fiber.
The stripped fibre must be cleaned with a tissue dampened with
99% Isopropyl alcohol or with the Stickler Connector Cleaner.
A properly cleaned fiber is necessary for a successful cleave
and splice.
Place the outdoor fiber holder into the cutting device close
the cover slowly, firmly pressing the “pusher-pin” the cutting
is performed by the movement of the circular blade.
Remove the fiber holder with the cleaved fibre from the device.
Place the fiber holder into the splicer.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 13Cable preparation 4
To fit the Alberino in the universal holder make sure to match
Picture A Picture B
the point 1 with the point 2 (see picture A/B): Point 2
- After, push down the functional cup (see picture C).
Point 1
Universal holder for Alberino
Alberino + functional cap
Picture C
Place the universal holder in the splicer and proceed with the
splicing procedure.
Place the two fibres equally distant from the central reference Marks on the screen
line of the screen;
please refer to the marks on the screen to obtain the desired
distance (see a screenshot below). Then check the state of
the fibres.
This is the ideal case.
Clean fibers with a good cutting angle (fibers perpendicular
to the splicing axis).
Approx. 1.5 x fiber diameter
In case of slightly dirty fibers, press “PREFUSE" to clean them.
Press several times if necessary until the fibers are OK. In case
of too dirty fibers, the cleaning procedure must be repeated
by removing the fiber holders from the fusion splicer.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 14Cable preparation 4
If the fiber of the Fusion alberino (the fiber on the left side of
the display) is not OK, the Fusion alberino must be replaced.
If the fiber to be spliced (the fiber on the right side of the
display) is not OK, please repeat the fiber preparation and
check your tools.
If the fibers look OK, place the fibers for splicing and
proceed as described.
Move the fiber to be spliced by rotating the knob on
the right clockwise until the cleaved end of the fiber is
positioned as close as possible to the reference line in the
center of the display.
Move the Fusion alberino by rotating the left disc in the
direction indicated on the picture until the cleaved end of the
fiber touches the end of the other fiber. Be sure not to put
any pressure on the fibers.
Move the fiber to be spliced by turning the right knob by 2
clicks in the direction shown on the picture. Pressure is exercised
on the two fibers.
Splice the two fibers by pushing the “SPLICE” button then
check the splice quality. If the splicing is OK, the cladding
surface is regular. If the splicing shows deformed areas as
shown on the right, there could be the following causes of
the incorrect splicing:
-Insufficient quality of fiber surface.
-unsuitable program number was chosen.
-Dirt on the fiber surface.
-Excessive or insufficient pressure on the fibers.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 15Cable preparation 4
After performing the splicing, perform the following operations:
open the protection cover then press the mobile electrode
support down, until it engages and make sure that it stays
in this position.
Place a protection layer over the electrodes so they are protected
from eventual epoxy falling down.
Mix a small amount of epoxy, mix the epoxy well with a
mixing stick.
The special quick epoxy foil pack H.G.608 is split in two parts.
Place the resin in one syringe and the hardener in another. In
this way you may use the necessary quantity and the package
will last longer.
Proportion resin / hardener: 1/1
2 ml syringe p/n1020616
Needle EFD 5118 p/n1020622
Spread a drop of glue over the bare fibre and part
of the 900µm with a metal wire.
Correct
It is important that the part of 900µm coating which is then
covered by the outer shells are spread evenly with a coating
of glue.
Not correct
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 16Cable preparation 4
Gently close the back parts of the alberino beginning from left.
Finishing to the right.
Close the two outer shells with help of a tweezers.
With a light force the shells will snap lock together and stay
securely closed.
Unblock the fiber/cable by opening the support blocking
level (see 1).
Unblock the two supports (24+28) of the two locks in the
resting position (see 2).
Remove the alberino support from the splicer and pull out the
spliced Alberino from the universal holder.
Remove the alberino support from the splicer and pull out the
spliced Alberino from the universal holder.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 17Cable preparation 4
With the help of tweezers extract the kevlar from the ring.
Cut the Kevlar at +/- 6mm, from the outside of cable jacket.
6
Clean the cable with alcohol, apply a layer of glue on the
cable jacket surface.
Position the ring (110) true to the cable jacket.
Apply a layer of glue under and on the surface of the ring (110)
then slide the ring (90) at the beginning of the cable sheath.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 18Cable preparation 4
Place the cable on the device. Crimp the sleeve.
Important
After crimping the lenght from the front face of the ferrule to
the end of the sleeve should be 89 - 90mm.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 19Cable preparation 4
DM 4 ADAPTER INSERT ASSEMBLY
Prepare the ferrules to be mounted into their termini (150).
Take the termini assembler (1074680) with the red point Key
facing up.
Press the lever and insert the termini by lining up the key with
the red dot.
Once the termini is half way in, release the lever and push the
termini all the way till it clicks.
Remove the cap from one ferrule .
Hold the fibre about 1,5 inches from the ferrule’s front face and
rotate it so that the key faces up. Carefully insert the ferrule
into the termini until it clicks.
When inserting, be very careful not to bump the front face into
the termini edges and damage it.
If ferrule is aligned properly, the ferrule slides in and gets
locked easily.
Put back the protective cap onto the ferrule.
Repeat sequence for all 4 ferrules.
At this point your ferrules should look like this.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 20Cable preparation 4
To remove the ferrules from the termini (150) proceed as follows:
Take the ferrule extractor (1074651).
Slide the fiber in the instrument’s slit.
Push the instrument into the termini until it clicks.
Hold the fiber and pull the termini out as shown in the picture.
As soon as you have pulled out the ferrule protect it with the
cap.
Notch Key
Remove the cap from termini being very careful not to bump
its front face.
Align the notch on the DM 4 (150) and the key of the
termini as shown on the drawing and slide in the latter till it clicks.
Be careful that the fiber number matches the letter engraved
on the connector body. The mapping order is as follows:
Green fibre => pos. A
Orange fibre => pos. B
Blue fibre => pos. C
Brown fibre => pos. D
To avoid damaging the fiber, do not push the termini by
applying forces to the fiber; hold the backside of the termini
instead:
Put back the protective cap onto the ferrule.
Keep the fibers nice and straight, do not twine them.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 21Cable preparation 4
Gently move forward the Ring (120), the spring, the preassembled
backshell (110) and the nut (100).
Align the DM 4 with the notch facing upwards the alignment
Notch
will be guaranteed by the pin inserted in the preassembled
interface (160).
Key
This is what it should look like when the body assembly are
installed.
Insert the assembled parts in the HE-2000 body . The two
wings of the spacer (110) will snap into the appropriate seats
of the Body.
Lock the inner nut (100) with a 12mm wrench, the nut must be
secured. The flat surface should be facing upwards.
Place the brass ring (40) and the rubber ring (30) in abutment,
tighten using a 19mm wrench the outside nut (20) on the HE-
2000 body.
Put the cable boot (10) in position.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 22Cable preparation 4
Insert the hollow pin guide (100) in the corresponding mounting/
demounting tool (1074744).
Remove ferrule protective caps.
Insert the assembled ceramic sleeve in the DM 4 (150).
These termini are inserted only in slots “D” and “B”.
Turn clockwise (90°) to fasten it into the body.
Check that the wing of the termini are oriented horizontally
parallel to the axis of the DM insert.
To remove the termini from the DM (Diamond Insert) use the
termini extractor (1074654).
Hold it with its hook facing downwards. Slide the extractor in
the slot above the termini until the front end can't go no further.
To avoid breaking the extractor move it straight in and out and
not up or down.
Pull the extractor gently out while holding the termini.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 23Cable preparation 4
BULKHEAD ASSEMBLY CABLE OR FIBER
VERSION
Insert all the components along the cable before beginning
with the preparation.
For cable version insert crimping ring (30).
For fiber version insert cable boot (10).
Cut cable jacket according to the measurement indicated in
the drawing.
Bend the cable cover (Kevlar) backwards.
Insert the protection sleeve (20) between the secondary coating
and the cable jacket as shown on the drawing, until the end 20
is placed flush with the cable jacket.
This is to prevent the secondary coating from being damaged
(micro-bending) caused by crimping the sleeve(30) on the
cable jacket.
The tool (1066753) makes insertion of the protection sleeve
easier Insert the protection tube (20) into the insertion.
First step:
Insert the sleeve as far as it will go.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 24Cable preparation 4
Second step:
Twist the tool around and complete the insertion.
Place the prepared cable into the appropriate Fiberholder and
proceed with the stripping and splicing procedure as described
on section cable preparation once finished continue the
procedure as described on section channel connector.
To conclude short the Kevlar about 5mm and put the crimping
ring (30) into the right position, by using the crimping pliers
(1056892) crimp the sleeve in three steps with Hexagon slot
1-2 and 3.
At this point your ferrules should look like this.
Repeat sequence for all 4 ferrules.
Insert the nut (10) the ring (70) the metal washer (20) and
rubber washer (30) over the termini.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 25Cable preparation 4
Insert the assembled termini in their respective seats of the DM
4 adapter making sure at the right channel position.
Green fibre => pos. A
Orange fibre => pos. B
Blue fibre => pos. C
Brown fibre => pos. D
Pull forward washers (20-30).
Insert the hollow pin guide (100) in the corresponding tool.
The assembled ceramic sleeve are inserted only in slots “A”
and “C”.
Turn counterclockwise (90°) to fasten it into the body.
Check
Check that the wing of the termini are oriented horizontally
parallel to the axis of the DM insert.
Pin
Fresatura
Align the termini with the notches facing upwards the Notch
Nasello
interno
alignment will be guaranteed by the pin inserted in the 60
preassembled interface (60).
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 26Cable preparation 4
Tighten using a 21mm wrench the outside nut (10) on the
HE-2000 bulkhead.
Only for fiber version:
Put the cable boots in position.
PREPARATION OF THE ELECTRICAL CABLE
a) Insert the heat shrink tube and protection.
b) Strip la cable jacket of the cable approx. 4mm.
(P.N Crimping pliers AF8 with adapter (Positioner) UH2-5: 1081071)
Insert the wire in the contact and crimp with the special crimp pliers. Pay attention that the selector is on
AWG corresponding to the correct cable to be crimped.
Hysol 0151
Spread a drop of Hysol 0151 adhesive on the electrical contact.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 27Cable preparation 4
Male contact
Place the plastic protection over the contact.
Protection Female contact
Place the heat shrink tube on the protection as shown and fix
it with an air gun,
min. : Tmin = 175°C
Mount the electrical cord in the contact and insert it into the
assembled body taking care to the orientation.
Mount the electrical cord into the termini (150) taking care to
the orientation.
Align the notch on the DM 4 and the key of the
Cartridge. Then slide till it clicks.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 28Measurement Method IL 5
5. MEASUREMENT METHOD IL MEASUREMENT METHOD IL
21. Measurement fanout and patchcords MIL
Measurement method for MIL 38999 and HE-2000 components
21.1 Measurement instruments
21.1.1 Light source
Components SM: Light source Laser or LED
Components MM: Light source LED
21.1.2 Mode Filter
Components SM: Not defined (the ca. 3 m fiber of the reference patchcord is sufficient)
Components MM: ‘Mode conditioner’ already present at the MM measurement station
21.1.3 Receiver (Power Meter)
Set wavelength as light source.
21.1.4 Wavelength
Components SM: 1310 nm and/or 1550 nm
Components MM: 850 nm and/or 1310 nm
21.1.5 Reference patchcords
Use the reference patchcords as indicated in paragraph 6. For so called reference
connectors and bulkheads MIL 38999 / HE-2000, see details in paragraph 21.1.6.
21.1.6 Technical abbreviations and symbols
Abbreviations Symbols Definitions
REF Reference connector MIL 38999 / HE-2000 1)
DUT Connectors MIL 38999 / HE-2000 under test
REF Reference Bulkhead MIL 38999 / HE-2000 1)
DUT Bulkhead MIL 38999 / HE-2000 under test
REF Generic connector on reference fanout 2)
DUT Generic connector on fanout under test
1) The so-called MIL 38999 / HE-2000 reference connectors and
bulkheads on fanout are to be assembled in the best possible way
and stored as reference patchcords.
2) IReference connectors on the exit side of the fanout, mentioned
in point 1) are to be assembled as 0.1 dB. This way the
attenuation caused by the above mentioned will be reduced to the
minimum.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 29MEASUREMENT METHOD
Measurement 5
Method IL IL
21.2 Measurement method
21.2.1 Measurement method for fanout with MIL 38999 / HE-2000 connector
a) Reference measurement:
LS PM
b) DUT measurement:
1) 1)
LS PM
1) For simplicity, only one side of the fanout is represented.
21.2.2 Measurement method for fanout with MIL 38999 / HE-2000 bulkhead
a) Reference measurement:
LS PM
b) DUT measurement:
1) 1)
LS PM
1) For simplicity, only one side of the fanout is represented.
21.2.3 Measurement method for patchcords with MIL 38999 / HE-2000 connectors
a) Reference measurement:
LS PM
b) DUT measurement:
1) 1)
LS PM
1) For simplicity, only one side of the fanout is represented.
HE-2000 Crocodile Fusion for Zeus D50 Outdoor_e 30You can also read
