FIBER OPTIC CONNECTORS MIL 83526 CROCODILE FUSION FOR ZEUS D50 OUTDOOR - ASSEMBLY INSTRUCTION
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ASSEMBLY INSTRUCTION FIBER OPTIC CONNECTORS MIL 83526 CROCODILE FUSION FOR ZEUS D50 OUTDOOR Part. No. 1902624 - Version 08.05.2019 MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 1
Index 0 INDEX Page 1 INTRODUCTION ______________________________________________________________________2 1.1 Equipment and material used ______________________________________________________________ 2 2 HE-2000 CONNECTOR SET _____________________________________________________________6 3 SAFETY REQUIREMENTS______________________________________________________________ 10 4 CABLE PREPARATION_________________________________________________________________ 11 5 MEASUREMENT METHOD IL____________________________________________________________ 33 MIL83526 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 EQUIPMENT AND MATERIAL USED P.N. Description Image 1049775 Jokari 1040186 Stripping pliers Jonard 3 holes 1020713 Kevlar Cutter Side cutter Futuro 1020483 160 mm 1073457 T-Stripper 1073458 Kevlar scissors 1056892 FTTH Crimping Pliers 1075632 Crimpring Pliers HE Crimping pliers AF8 with 1081071 adapter (Positioner) UH2-5 MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 2
Introduction 1 P.N. Description Image 1060309 V-groove protection 1059637 Fusion Alberino Holder 1056423 Fiber holder 900-3000μm 1069263 Fiberholder special outdoor 1020681 Mixing plate 1020358 Mixing sticks 1047068 Hysol Glue 608 1020822 Cleaning - cloth Kimwipes 11x21cm 1073654 Stickler connector cleaner 1020588 Tweezers 120 mm Typ 00 MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 3
Introduction 1 P.N. Description Image 1071974 Wrench 15mm 1051781 Wrench 16mm 1020495 Wrench 17mm 1051782 Wrench 20mm 1074651 Ferrule extractor Hollow pin guide 1074744 mounting/demounting tool 1074654 Termini extractor 1074680 Termini assembler Ferrule puncher for pushing ferrule 1075858 out of the body 1066753 Protection sleeve insertion tool Adapter FBPT E-2000 APC/PC for ferrule inspection HE-2000 1073321 with JDSU P5000i digital inspection probe MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 4
Introduction 1 P.N. Description Image 1900109 Marker Permanent, thin, black 1900216 Marker Pen Edding 780 1020537 Ruler L=150mm 13x0.3 1071976 Tube Stripper 3-5.5 mm 1075931 Crimping sleeve device 1051761 Insert extractor OLB/OLC 1020494 Allen Key SW 2mm MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 5
Connector Set 2 2 MIL 83526 BREAKOUT CONNECTOR SET 2.5mm Crocodile Fusion Alberino HE 1. INTRODUZIONE In questo documento vengono descritte le varie fasi di montaggio del connettore MIL 83526 DM. Questo documento per principio è valido per le seguenti versioni: Optical/Electrical termini No documento Denominazione DM4ST 0235 Componenti MIL – 83526 DM ST 0214 Componenti Inserto DM 4X Outdoor 1.1 COMPONENTI MIL-83526 DM Item 1.2 COMPONENTI Quantity BULKHEAD MIL-83526 DM Description 10 1 Cable boot OLC 20 1 Connector cup OLC 30 1 Ring Ø 5,5/13,50 x 4,5 40 1 Washer Ø 6,2/17,0 x 1,5 50 1 Outer shell grip ass. OLC 60 1 Nut OLC 70 1 Body connector OLC 80 1 Cylinder OLC 90 1 Inox spring 1.3 COMPONENTI BULKHEAD MIL-83526 DM SHORT 100 1 Spacer OLC 110 1 Small ring 120 1 Big sleeve 130 1 DM insert 140 1 Body assembly OLC MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 6
Connector Set 2 2.1 CHANNEL CONNECTOR 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 Channel Connector 90 1 Hollow pin guide 100 1 Ceramic sleeve holder 110 1 Electrical contact protection 120 1 Female Electrical contact 130 1 Male Electrical contact 140 1 Heat-Shrink SM/PC Crocodile Alberino Item Quantity Description 40* 4 Crocodile fusion SM PC MM/PC Crocodile Alberino Item Quantity Description 40* 4 Crocodile fusion MM 50µm PC MM/PC Crocodile Alberino Item Quantity Description 40* 4 Crocodile fusion MM 62.5µm PC MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 7
Connector Set 2 2.2 MIL 83526 BULKHEAD 1.2 COMPONENTI BULKHEAD MIL-83526 DM 1.3 COMPONENTI BULKHEAD MIL-83526 DM SHORT Item Quantity Description 10 1 Allen screw M4 20 1 Nut OLB 30 1 flange OLB 40 1 Outer shell OLB 50 1 Spacer 60 1 Cylinder OLB 70 1 Inox spring 80 1 Spacer OLB DF-174.a 2 90 1 Small ring 100 1 Big sleeve 110 1 DM4 120 1 Connector cup OLB 130 1 Body assembly OLB MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 8
Connector Set 2 2.3 MIL 83526 SHORT BULKHEAD 1.3 COMPONENTI BULKHEAD MIL-83526 DM SHORT Item Quantity Description DF-174.a 2 10 1 Nut 20 1 Inox spring 30 1 Ring OLB 40 1 Inox spacer 50 1 Short outer shell OLB 60 1 DM4 70 1 Connector cup OLB 80 1 Short body assembly OLB MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 9
Safety requirements 3 3 SAFETY REQUIREMENTS Safety glasses for eye protection are required when using epoxy and stickler cleaner, 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 in order to prepare the fiber and the material correctly. DISTRIBUTION FIBER OPTIC CABLE 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 MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 10
No documento Denominazione ST 0235 Componenti MIL – 83526 DM ST 0214 Componenti Inserto DM 4X Outdoor Cable preparation 4 1.1 COMPONENTI MIL-83526 DM 4 CABLE PREPARATION Insert1.2 all COMPONENTI BULKHEAD the components along MIL-83526 the cable DM before beginning with the preparation. Attention: The cylinder (80) must be placed with the larger internal diameter directed towards to the front, also the spacer (100) must be inserted with the larger internal diameter directed towards the cylinder (80). 1.3 COMPONENTI BULKHEAD MIL-83526 DM SHORT Strip about ~50 mm with a Jokari stripper. DF-174.a 2 Open the outer jacket about ~80 mm using the internal ripcord. Cut the first ~20 mm cable stripped with the Jokari stripper this to prevent using part of eventually damaged fibers. You should be left with ~110mm of stripped Jacket MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 11
Cable preparation 4 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! If you prefer use the tube stripper to cut the outer jacket. Remove the outer jacket and start the stripping procedure. Cut the cable according to the measurement indicated on the drawing. 80mm MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 12
Cable preparation 4 Use the Felt Tip Pen to mark the 900 μm fibres to a length of 49mm 0 /+1 mm. 49mm Place the fiber into the fiber holder, make sure to place the 49mm marking at the groove of the fiber holder. Fiber holder mark Place the fiber holder into the thermal stripper to strip the fiber. The stripped fiber 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. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 13
Cable preparation 4 Place the fiber holder into the splicer. Fit the Alberino in the universal holder. To fit the Alberino in the universal holder make sure to match the point 1 with the point 2 (see picture A/B) - After, push down the functional cup (see picture C). Place the universal holder in the splicer and proceed with the splicing procedure. Marks on the screen Place the two fibers equally distant from the central reference 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 fibers. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 14
Cable preparation 4 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. 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. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 15
Cable preparation 4 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. 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 glue pack Loctite 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 MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 16
Cable preparation 4 Spread a drop of glue over the bare fibre and part of the 900µm with a metal wire. 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. Correct Not correct Gently close the back parts of the alberino beginning from left. Finishing to the right. Finally close the wings with tweezers until they click. So that the fibers and the splice are protected. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 17
Cable preparation 4 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. With the help of tweezers extract the kevlar from the ring. Cut the Kevlar at +/- 6mm, from the outside of cable jacket. 6 Thin out the kevlar if necessary. Clean the cable with alcohol, apply a layer of glue (loctite 608) on the cable jacket surface. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 18
Cable preparation 4 Position the ring (110) true to the cable jacket. Apply a layer of glue on the surface of the ring (110) and slide the ring (120) at the beginning of the cable sheath. Place the cable on the crimping sleeve device and verify the right position to crimp the sleeve . Important After crimping the length from the front face of the ferrule to the end of the sleeve should be 90±1mm. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 19
Cable preparation 4 Prepare the ferrules to be mounted into their termini. Take the termini assembler (1074680) with the red point 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 being very careful not to bump its front face into the termini edges and damage it. Hold the fiber about 1,5 inches from the ferrule’s front and rotate it so that the key faces up. Carefully insert the ferrule into the termini until it clicks. If all the parts are properly aligned, the ferrule slides in and gets locked effortlessly. Push the termini assembler lever to release termini and fiber and pull them out. Put back the protective cap onto the ferrule. Repeat sequence for all 4 ferrules. At this point your ferrules should look like this. To remove the ferrules from the termini 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. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 20
Cable preparation 4 Notch Key Remove the cap from termini being very careful not to bump its front face. Align the notch on the DM 4 adapter and the key of the termini as shown on the drawing and slide in 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. Insert the Ch. Connector Termini in the DM 4 adapter insert. These hollow pin guide inserted only in slots “D” and “B”. Turn the hallow pin guide counterclockwise (90°) to fasten it into the body. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 21
Cable preparation 4 To remove the termini from the DM4: Take instrument (1075644) and hold it with its hook facing downwards slide the instrument in the slot above the termini until the front end can’t go no farther. To avoid breaking the instrument be careful to move it straight in and out and not up or down. Pull the instrument while holding the termini. Notch Align the DM 4 adapter insert with the notch facing upwards the alignment will be guaranteed by the pin inserted in the preassembled interface. Key This is what it should look like when the body assembly are assembled. Fit the OLC extractor tool over the OLC body assy module. With a 15mm wrench close the nut by holding the OLC assembly tool. Danger! Fiber twisting. The cable should not turn while tightening the compression nut. A pen mark will help. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 22
Cable preparation 4 Place the washer (40) and the ring (30) in position. Screw the outer orange shell grip on (50). Put the compression cup (20) on. Use a 17mm wrench to tighten the compression cap nut. Again make sure that the cable does not turn while tighting. Put the cable boot (10) on. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 23
Cable preparation 4 Close the connector with the dust protection cup. The MIL 83526 Plug is now complete. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 24
Cable preparation 4 MIL 83526 BULKHEAD LONG VERSION PREPARATION Insert all the components along the cable before beginning with the preparation. 1.2 COMPONENTI BULKHEAD MIL-83526 DM Long version with 5500 cable. 1.3 COMPONENTI BULKHEAD MIL-83526 DM SHORT Proceed with the preparation of the cable as previously described at page 14 to page 15. DF-174.a 2 Cut the cable according to the measurement indicated on the drawing. Place the fiber into the fiber holder, make sure to place the 36mm marking at the groove of the fiber holder. 36mm Fiber holder mark. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 25
Cable preparation 4 Continuous the preparation of the cable as described at page 16 to page 21, at this point your ferrules should look like this. Repeat sequence for all 4 ferrules. With the help of tweezers extract the kevlar from the ring. Cut the Kevlar at +/- 6mm, from the outside of cable jacket. 6 Thin out the Kevlar if necessary. Clean the cable with alcohol, apply a layer of loctite 608 glue on the cable jacket surface. Position the ring (90) at beginning of the cable jacket. Apply a layer of glue on the surface of the ring (90) and slide the crimping ring (110) along as far as it will go. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 26
Cable preparation 4 Place the cable on the crimping sleeve device and verify the right position to crimp the sleeve (100). 77+-1mm Important After crimping the length from the front face of the ferrule to the end of the sleeve should be 77±1mm. 77±1mm Continuous the preparation of the cable as described at page 23. 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 These hallow pin guides are inserted only in slots “A” and “C” Turn hallow pin counterclockwise (90°) to fasten it into the body. For the bulkhead version long pull forward the components; tighten using a 20mm wrench the inside nut. Spread a little grease on the O-rings MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 27
Cable preparation 4 Close the bulkhead with the dust protection cup. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 28
Cable preparation 4 MIL 83526 BULKHEAD SHORT VERSION PREPARATION Insert all the components along the cable before beginning with the preparation. Short version with 900µm fiber BULKHEAD 1.3 COMPONENTI or 3mm cable. MIL-83526 DM SHORT Insert all the components along the cable before beginning with the preparation. For cable version insert crimping ring (30). DF-174.a 2 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 tube (20) between the secondary coating and the cable jacket as shown on the drawing, until the ending is placed flush with the cable jacket. 20 This is to prevent damage (micro-bending) caused by crimping of the ring (30) on the cable jacket. The tool (1066753) makes insertion of the protection sleeve easier Insert the protection tube (20) into the insertion. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 29
Cable preparation 4 First step: Insert the sleeve as far as it will go. 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. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 30
Cable preparation 4 Insert the assembled termini in their respective seats of the channel connector making sure at the right channel position. The mapping order is as follows: Green fibre => pos. A Orange fibre => pos. B Blue fibre => pos. C Brown fibre => pos. D Insert the Ch. Connector Termini in the DM4 These termini are inserted only in slots “A” and “C” Turn counterclockwise (90°) to fasten it into the body. For the short bulkhead long pull forward the outside nut, tighten using a 16mm wrench the nut, and fix the security screw with an 2mm Allen screwdriver. Spread a little grease on the O-rings. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 31
Cable preparation 4 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. Place the plastic protection over the contact. Male 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 Insert the electrical contact taking care of the orientation into the termini until it clicks. Push the termini assembler lever to release the termini and pull them out. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 32
Cable preparation 4 Align the notch on the DM4 and the key of the termini. Then slide till it clicks. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 33
MEASUREMENT METHOD Measurement IL IL Method 5 21. Measurement fanout and patchcords MIL Measurement method for MIL 38999, MIL 83526 and HE-2000 t 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. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 34
MEASUREMENT METHOD IL 5 Measurement Method 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. MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 35
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