Termination Procedure
LC 1.6mm & 2.0mm Connectors:
1060XX Series
Connector Piece Parts
LC Simplex Connector
Boot
LC Duplex Connector
LC Connector
86001-0110, Rev. B
CriMp Tulolng
Clip
USN30MFO/5/2010
LC Duplex
Boot
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
1060XX Series
Procedure Chart
Procedure
Tool Required
Tool Part Number
Fiber Preparation & Fiber Cleaning
Cable Preparation Template
Jacket Stripper-Splitter (1.6mm)
Jacket Stripper-Splitter (2.0mm)
Buffer Stripping Tool
Kevlar and Jacket Cutter
Crimp Tool
Duplex Assembly Tool
*Tissue
91% Isopropyl Alcohol
86744-1025
86744-1000
86744-1100
86710-0002
86710-0005
86744-5000
86744-0050
86710-0022
see note
Fiber-To-Ceramic Contact Bonding
*Syringe
*Needle
*Epoxy
Oven, 110 V
Protective Tubing
*Tissue
LC Curing Fixture
91% Isopropyl Alcohol
86710-0035
86951-0006
86710-0024
86710-4000
86773-0011
86710-0022
86744-1023
see note
Fiber Cleaving
Cleaving Tool
86773-2000
Hand Polishing
LC Polishing Tool
Blue Rubber Pad
Polishing Plate
*Bottle with Polishing Liquid
*Lapping Film #1 (3x8) Dark Grey w/ Adhesive
*Lapping Film #9 (3x8) Yellow w/ Adhesive
*Lapping Film #11 (3x8) Pink No Adhesive
*Lapping Film (3x4) Purple w/ Adhesive
*Foam Sheet
86024-1000
86710-0149
86710-0040
86710-0160
86710-0025
86710-6158
86710-6166
86930-0011
86710-6167
Final Inspection
100X Microscope
86730-0030
Machine Polishing
Use your internal procedure
Not available from Molex
*Included in consumable kit p/n 86719-7000.
NOTE: Alcohol must be supplied locally, it is not included with consumable kit. 91% Isopropyl alcohol required.
PLEASE READ THROUGH THE ENTIRE PROCEDURE BEFORE STARTING TO ASSEMBLE A CONNECTOR.
86001-0110, Rev. B
USN30MFO/5/2010
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
1060XX Series
1. Slide the boot and crimp tubing onto the cable (Figure 1).
Figure 1
Crimp Tubing
Boot
2. Using the cable preparation template (p/n 86744-1025), precisely stripsplit the cable jacket with appropriate jacket stripper-splitter tool (p/n
867744-1000 for 1.6 mm cable or p/n 86744-1100 for
2.0 mm cable) to the correct length. Trim the kevlar using the kevlar cutter
(p/n 86710-0005). Using the buffer stripping tool
(p/n 86710-0002), precisely strip the buffered fiber. Ensure the tool is free
of any debris during this operation. A clogged tool may result in fiber
breakage. See the owners manual for the proper operation of this tool. The
proper lengths are indicated in the template
(Figure 2).
NOTE:
• While holding firmly onto the buffer, it is recommended you strip
small lengths (approximately 118 inch) of buffer at a time.
• Verify strip lengths with the template. Snip off any excess fiber
with the kevlar cutter (p/n 86710-0005).
• The cable manufacturer recommends cleaning the fiber and buffer
using a lint-free tissue (p/n 86710-0022) that has been moistened
with 91% isopropyl alcohol. Cleanliness of the fiber is essential to
the performance and reliability of the connector.
3. Prepare epoxy (p/n 86710-0024) according to the manufacturer's
instructions. Fill the syringe (p/n 86710-0035) with epoxy and remove any
air bubbles. Wipe the needle with a clean lint-free tissue (p/n 86710-0022).
Do not exceed the pot life of the epoxy (2 hours).
Figure 3
LC Connector
• Remove the dust cap from the connector and check the ferrule hole
for any obstructions by holding it up to a light source.
4. Ensure the nylon tube is fully inserted by pressing it down into the
connector. Fully insert the needle of the syringe
(p/n 86710-0035) into the nylon tube of the connector until it stops.
Keeping the needle at this position, slowly inject epoxy until it appears on
the end face of the ferrule. Release pressure on the plunger, hold
position for 5 seconds, then remove the needle from the connector
(Figure 3).
Figure 4
Wipe end face of the ferrule
Connector Back
Remove Nylon Tubing
86001-0110, Rev. B
5. With one quick motion, remove the nylon tube from the connector and
discard it. With a lint-free tissue (p/n 86710-0022), wipe all the epoxy off
the end-face of the ferrule (Figure 4).
IMPORTANT: No epoxy should be present on the side of the
ferrule or at the back of the connector.
USN30MF0/5/2010
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
1060XX Series
Figure 5
6. Fold the kevlar and jacket halves back towards the cable
(Figure 5).
Figure 6
7. Slowly insert the cable into the connector until the fiber is flush
with the end-face of the ferrule (Figure 6). It often helps to rotate
the connector of the fiber to help find the hole of the ferrule.
• Clean the excess epoxy from the face of the ferrule with a lint free tissue (p/n 86710-0022) and 91 % isopropyl alcohol.
• The ferrule end-face must be completely free of epoxy.
• Fully slide the protective tubing (p/n 86773-0011) over the ferrule,
then fully insert the fiber into the connector (Figure 7).
IMPORTANT: To avoid microbending, do not force the fiber into
the connector after the buffer has bottomed out.
8. Carefully position the kevlar and jacket halves forward onto the
connector end so that the jacket halves are aligned with the
connector clip (Figure 7). Slide the crimp tubing over the kevlar and
jacket halves up to stop. Place the connector into the bottom die of
the crimp tool. Be sure to position the connector so that the pins of
the crimp die are aligned with the clip of the connector (Figure 7).
IMPORTANT:
• Ensure rectangle dies are located to the rear of the termini crimp
sleeve as shown in figure 7 & 10.
IMPORTANT:
• Surface A of the bottom crimp die must be in contact with surface
B of the connector. Proceed to crimp.
Figure 8
Crimp Tubing
• It is extremely important that the crimp tubing covers the jacket
split (Figure 8).
Jacket Split
86001-0110, Rev. B
USN30MFO/5/2010
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
1060XX Series
Figure 9
Curing Cavity
9. Place the connector with protective tubing into one of the curing
oven cavities after the oven has reached its operating temperature
140°C. A beep indicates the start of the curing cycle (Figure 9).
IMPORTANT: During the curing cycle, the cable should be
maintained vertically to avoid any bending which can cause
microbend losses after assembly.
Each cavity of the oven is independently controlled. An LED and a
beep will indicate the end of the curing cycle (15 minutes). After the
epoxy is cured, remove the connector from the oven and allow it to
cool.
Figure 10
10. Repeat the crimping operation of step 8 so the pins of the crimp
die are oriented 90° from the clip of the connector. Precisely hold this
position and crimp (Figure 10).
IMPORTANT: For the LC Simplex Connector, proceed to step
11. For the LC Duplex Connector, proceed to step 12.
SECTION A-A
11. For the LC simplex connector, slide the boot onto the connector
until it snaps on (Figure 11).
Figure 11
Boot
Figure 12
86001-0110, Rev. B
12. For the LC duplex connector, carefully remove the protective
tubing from the connector (Figure 12).
USN30MFO/5/2010
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
1060XX Series
Figure 13
Slot
13. Holding the cleaving tool (p/n 86773-2000), with the trigger
upwards, slowly insert the protruding fiber into the slot of the cleaving
tool, then push the connector until the ferrule comes in contact with
the stop plate (Figure 13).
Connector Clip
IMPORTANT: The connector clip should be aligned with the slot
of the cleaving tool.
14. When cleaving, position the connector and cleaving tool
(p/n 86773-2000) over the debris container. Release the connector and
gently press the trigger to cleave the fiber. Remove the connector from
the tool. Be sure to dispose of the cleaved fiber properly.
Hand Polishing:
Figure 14
15. Begin to hand polish the face of the connector with lapping film #1
(p/n 86710-0025) (Figure 14). The circular motions should be
approximately two inches in diameter. The lapping film is held by hand
and virtually no pressure is applied on the protruding glass fiber. Perform
five-to-ten circular motions on the contact.
16. Carefully and gently clean the ferrule with a lint-free tissue (p/n
86710-0022) and 91% isopropyl alcohol.
17. Carefully mount the connector into the polishing tool (p/n
86024-1000).
NOTE:
Before using lapping film in steps #1 and #4, remove paper
backing to expose adhesive and press the lapping film on the
rubber polishing pad (p/n 86710-0149). Use polishing plate (p/n
86710-0040) as base for rubber polishing pad (Figure 15).
Figure "a"
Figure 15
Rubber Polishing
Polishing Plate
86001-0110, Rev. B
USN30MFO/5/2010
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
860XX Series
Figure 16
Step Lapping Film
Polishing Fluid
Number of Figure "8" Motions
1
p/n 86710-6158
91 % Isopropyl Alcohol
15-20
2
p/n 86710-6166
91 % Isopropyl Alcohol
15
3
p/n 86930-0011
Polishinq Liquid (86710-0160)
10
4
(Foam Sheet)
p/n 86710-6167
Polishinq Liquid (86710-0160)
2-3
NOTE:
Gently clean the contact with a lint-free tissue (p/n 86710-0022) and
91% isopropyl alcohol between each polishing step. For best results,
replace the film every four terminations.
Figure 17
Chip or crack
STEP #1: Using the rubber polishing pad (p/n 86710-0149),
mount a sheet of #9 lapping film (p/n 86710-6158). Liberally apply a
layer of 91 % isopropyl alcohol on the surface of the lapping
film and perform figure "8" motions over the entire length of the
lapping film according to the table (Figure 16). Virtually no pressure
should be applied on the tool at the beginning of the procedure. If
epoxy is still visible after this step, perform two-to-three additional
figure "8" motions.
Scratch
STEP #2: Using the rubber polishing pad (p/n 86710-0149), mount a
sheet of #11 lapping film (p/n 86710-6166). Liberally apply a layer of
91 % isopropyl alcohol on the surface of the lapping film and perform
figure "8" motions over the entire length of the film according to the
table (Figure 16).
STEP #3: Using the rubber polishing pad (p/n 86710-0149), mount a
sheet of lapping film (1 mm diamond p/n 86930-0011). Use the bottle
with polishing liquid (p/n 86710-0160) and liberally apply a layer of
polishing liquid on the surface of the lapping film. Perform figure "8"
motions over the entire length of the film according to the table (Figure
16). Be sure to avoid and remove any air pockets under the film
before polishing.
Good
STEP #4: Using the rubber pad (p/n 86710-0149), mount a foam
sheet (p/n 86710-6167). Use the bottle with polishing liquid
(p/n 86710-0160) and liberally apply a layer of polishing liquid on the
surface of foam sheet. Perform figure "8" motions over the entire
length of the polishing pad.
No good
18. Remove the connector from the polishing tool. Thoroughly clean the
ferrule with a lint-free tissue (p/n 86710-0022) and 91% isopropyl alcohol.
Using the 100X microscope (p/n 86730-0030), inspect the quality of the
polish. No scratches or cracks should be visible (Figure 17).
Figure 18
Endface Geometry
Fiber extension
Ferrule endface radius
Apex offset
Requirements
-0.05 urn < x < 0.05~m
7mm
"R" 25mm
NOTE:
The microscope should be stored in the closed position when not in
use. This will ensure longer battery life.
Less than 50~m
19. Check the ferrule endface geometry using Zoom Interferometer ZX-1
(from Direct Optical Research Company). Use figure 18 to determine if the
ferrule endface geometry is within required specifications. If it is not, return
the cable to the line for re-work.
Figure 19
20. If tuning is required, refer to the tuning procedure (p/n
86001-0109).
NOTE:
If tuning is not required:
• For the LC Simplex Connector proceed to step 21.
• For the LC Duplex Connector, proceed to step 22.
21. Carefully and thoroughly clean the optical contact with a lint free tissue
(p/n 86710-0022) and 91 % isopropyl alcohol. Cover the connector with
the dust cap (Figure 19).
86001-0110, Rev. B
USN30MF0/5/2010
©1999, Molex Fiber Optics, Inc.
Termination Procedure
LC 1.6mm & 2.0mm Connectors:
860XX Series
Figure 20
22. Pre-assemble the LC Duplex clip with the connectors
(Figure 20), and position this subassembly into the Duplex Assembly
Tool (p/n 86744-0050). Carefully squeeze the handles of the Duplex
Assembly Tool until the Duplex clip snaps in. Remove the duplex
connector from the assembly tool.
Duplex Clip LC Duplex Connector
Figure 21
23. Slide the boots over the crimp tubing until they snap in
(Figure 21).
Figure 22
24. Carefully and thoroughly clean the ferrules with a lint-free
tissue (p/n 86710-0022) and 91% isopropyl alcohol. Cover the
connectors with the dust caps (Figure 22).
Rev
A
B
Description
Initial Release
Added note regarding rectangle die orientation after step 8
86001-0110, Rev. B
USN30MFO/5/2010
Revised By
G. Genchanok
G. Genchanok
Date
11/1/1999
5/10/2010
Approvals
GG
GG
©1999, Molex Fiber Optics, Inc.
