Fusion Splicing

EQUIPMENT USE WARNINGS  Do not attempt to use or operate this equipment before reading the instruction 

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manual. Read and follow all safety instructions and cautions contained in the manual and those set forth by your company. This splicer is designed to fusion splice telecommunications optical fiber (glass). Do not attempt to splice any material other than telecommunications optical fibers (glass). Safety glasses should always be worn during fiber preparation and splicing process. A glass fiber fragment can be extremely dangerous, if it comes into contact with the eye or skin. Spilled solvents or alcohol based liquids present a fire hazard. Never operate splicer in an environment where flammable liquids or vapors exist. An extremely dangerous fire and explosion could result from the splicers electrical are in such an environment. Dangerous electrical voltages are present during the operation of this equipment. Failure to properly maintain the equipment can result in personal injury or equipment damage. The splicer cover panels and or any electrically operated accessories should never be opened or removed except by factory personnel. Maintenance should only be performed by factory personnel, except the replacement of electrodes and fuse. Only authorized replacement parts should be used on this equipment. Never use a canned air type cleaner to remove dust or clean the splicer. The splicer’s electrical arc can ignite any remaining gas mixture. During discharging the electrodes generate a very high voltage. Never touch the electrodes. Make sure no water or liquid is present on the splicer. Failure to observe and comply with these conditions can result in personal injury and or equipment damage. Turn the power switch off before installing or removing the power units (battery, AC/DC adopter or battery adapter), or connecting or removing the power cord from the AC/DC adapter. Failure to comply could result in personal injury and or equipment damage. Failure to apply the proper voltages to the machine may result in personal injury or equipment damage. The tube heater generates a high temperature during the “HEAT” cycle. Do not open the cover during the “HEAT” cycle and allow sufficient time for the splice protector sleeve to cool before removing.

1. CAUTIONS  Do not discharge the splicer if the electrodes are not installed.  Use only alcohol to clean the objective lenses, mirrors, and switches and cover panels. Any other chemical may be flame and cause discoloration.  Keep the splicer free from sand or dust. Never clean the V-grooves with hard material or rough object. Doing so will damage the surface and degrade the performance.  Always replace the electrodes as a pair.  Practice adjustment and alignments have been made to all parts of this splicer by factory personnel. Do not loosen any screw or make any modifications to the splicer other than electrode replacements and fuse replacements.  Use the carrying case to transport and store the splicer. The carrying case will prevent damage and provide protection from moisture, vibration and shock during storage and transportation.  Do not store in an area where extreme heat and humidity are present.

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 This splicer requires no lubrication. Doing so will degrade the performance and damage equipment.

2. CLEAVING 2.1 ROUTINE FIBER CLEAVING USING FK11 1. Prepare each fiber for cleaving by stripping all coating materials over a length of 4.5 to 5 cm, then cleaning the exposed fiber using a suitable solvent. A good “wetting” with the solvent also helps to reduce static on the fiber. Allow the fiber to dry fully before attempting to cleave the fiber. N.B. ABSOLUTE CLEANLINESS IS VITAL TO GOOD CLEAVES. FAILURE TO CLEAN CAN CAUSE BLADE DAMAGE. 2. 3.

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Set all levers to the up position. With the levers in these positions, the clamps are open; the blade is back in the START position and the tension clamp to the READY position. Place the prepared fiber into the grooves (insert fiber from the left side of cleaver). Make sure the clean fiber sits well down in both grooves. NOTE: The scale on the left hand clamp is to assist in cleaving at a specified distance from the end of the primary coating. It indicates distance from the diamond blade in millimeters. Lower the right hand clamp lever (2) to the CLOSED position. Now lower the left hand clamp lever (1) fully to LOCKED position, then clamping the fiber. The right hand clamp lever should now be pressed fully down to the locked position, clamping the free end of the fiber. Move the lever labeled “3” smoothly downward to the TENSION ON position. Move the lever labeled “4” smoothly down to release the blade mechanism and cleave the fiber. The green LED will glow for approximately 3 seconds (this is to indicate that the blade is oscillating and the battery is in good condition). Raise level “4 “ to the LOCKED position, open the left hand clamp and remove the cleaved fiber. Return all levers to their START position (up), ready for the next cleave. Remove off cut and store it safely.

Figure 1. FK-11 Cleaver.

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2.2. ADJUSTMENTS 2.2.1. Tension: The Tensioner is used to apply tension to the fiber before it is cleaved. Normal setting of this tensioner is 210 of for 125 um fibers (larger fibers may require more tension). To change the setting, raise the lever “C” to the TENSION OFF position (up), now turn adjuster screw “X” (accessible through the hole in the bottom of the case) using 2 mm screwdriver clock wise to increase the tension and vice versa. NOTE: If correct tension is not known it is best to start with a high tension to ensure cleave and then gradually reduce it until a satisfactory cleave is obtained. This will avoid blade damage caused by failure to cleave. 2.2.2. Blade adjustment: The diamond blade may become worn after many cleaves, in this case it should be raised to a new position. Proceed as follows: using a 2 mm wrench turn the adjuster screw “Y” (accessible through the hole in the rear of the case) clock wise quarter of a turn. The blade cannot be lowered.

3. SPLICING 3.1 3.1.1

GENERAL Outline of FSM-20CSII Optical Fiber Fusion Splicer.

The FSM-20CSII Arc Fusion Splicer is used for splicing SM (Single Mode) optical fiber and MM (Multi Mode) optical fiber. Mutual aligning of both SM and MM optical fibers is performed automatically by image processing microcomputer built into the splicer. The power source applicable for this system is AC85 – 265V (50/60Hz) or DC10-15V. The AC voltage selection is automatic. NEVER USE a cleaning spray on the machine. Spray that includes FREON gas causes abnormally strong discharges. This reduces the life time of the electrodes and may cause damage to the mirrors and lens. 3.2 OPERATION 3.2.1. Keyboard Panel This section gives the key functions of the FSM-20CSII. Fig. 2.1 shows the key layout on the top panel of the splicer. Table 2.1 shows their respective functions.

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Fig 2. Keyboard Layout No. 1

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Table 2.1 Function When the RESET which is pressed, the system stops in any step of operation and the fibers move back to Z axis home position. The splice accepts the RESET with a beeping sound and displays “READY” is displayed on the monitor. SET Key This is used to initiate the gap setting of two fiber end faces and automatic alignment of the fibers. The instructions “GAP SET “ “FIBER OK” and “ALIGNING” are displayed on the monitor at each stage. MODE Key The FSM-20CSII can be preset to 20 different modes for various fibers SM1~SM10, MM1~MM10). This key is used to select the mode. In SM mode, core axis alignment is performed automatically and in the MM mode, fiber axis alignment is performed manually. X/Y Key This is used for the automatic field change operation. When the X/Y key is pressed, the fiber image is changed from (X) to (Y) or (Y) to (X). If this is done after a gap set operation, the fibers are adjusted to the center of the monitor and focused automatically. ARC Key This is used to perform an arc but it will not function while the system is in its automatic splicing operation. No fiber stuffing occurs if this key is operated from the “READY” state or if an arc has already occurred. “**ARC**” is displayed on the monitor just before the discharge is produced. If gap setting has been done, loss estimation automatically follows the discharge operation. This function may be used to re-arc a splice after the automatic process has finished. CND Key This is used to select the menu options. MOTOR Key This is used for controlling the splicer motors manually. (up) Key These are used for moving the ‘*’ cursor wherever applicable in the menus and options. When manual motor control is selected, these keys act as “backward” (down) Key and “Forward” direction controls. ENT Key This is used to select a menu option for discharge conditions or select a motor control. HEAT Key This is used to start the heater process. The heat indicator lamp lights during heating. Condition/Comment These are used for input of the operating parameters or Input keys. the comments. Name RESET Key

3.2.2 Splicing SM Type Optical Fiber 3.2.2.1 Selecting Splice Mode. Confirm “READY” is displayed on the monitor and select SM mode. 3.2.2.2 Setting Optical Fiber 1. Strip, clean and cleave the optical fibers. 2. Open the wind protector.

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Lift the fiber clamps and the sheath clamps. Place the optical fiber in the V-grooves.

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Carefully close the sheath clamp until it clicks. Check that the bare fiber is seated at the bottom of the V-groove. Ensure the fiber end face is positioned between the Vgroove and the discharge electrodes. Repeat for the other fiber. Carefully close the fiber clamps and then the wind protector. Press the “SET” key.

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The mirror is set, “GAP SET” is displayed and the optical fibers move forward to their initial gap. If the CLEANING ARC function is ON, a short discharge now occurs to remove dust from the fiber surface. Press “RESET” and prepare the fibers again if any dust remains after cleaning. If the CLEAVE ANGLE function is ON, the end face angles are checked and an error occurs if either is more than 5 or 3 degrees. Now, the splicer either continues with the splice procedure, or, if the PAUSE function is ON, it stops to allow operator inspection of the fiber images. “FIBER OK” is displayed and a beep is sounded. Press “SET” to continue the splice procedure. CAUTION: The “RESET” key may be pressed at any time to terminate the splice procedure. However, if this is done when the fiber image is not correctly focused or positioned on the monitor, then the image may not be recognized on the next GAP SET. This may lead to collision of the fibers and require them to be prepared again. If the operator is any doubt as to when the “RESET” key was pressed, lift the wind protector and press the “SET” key procedure. However, if this is done when the fiber image is not correctly focused or positioned on the monitor, then the image may not be recognized on the next GAP SET. This may lead to collision of the fibers and require them to be prepared again. If the operator is any doubt as to when the “RESET” key was pressed, lift the wind protector and press the “SET” key Error 3 “TOO DARK” will result and the field and focus motors will move to their correct positions. Lower the wind protector and proceed as normal. 3.2.3 Tube Heater (option) 1. Slide the heat shrink sleeve, through which the fibers are already inserted, to the center of the spliced portion. 2. Open the heater cover. 3. Keep the reinforcing material (steel rod) position downward inside the heat shrink sleeve. Close the heater cover. 4. Press the “HEAT” key and check that the heat indicator lamp is lit. 5. When the sleeve is shrunk completed, the heat indicator lamp is turned off and a beep is sounded. Reinforcing takes approximately 2 and half minutes. 3.3 MAINTENANCE Cleaning the Optical Fiber Guide Unit (V-groove) When the V-groove of the optical fiber guide unit becomes dirty, it causes axial offset of the optical fiber. Ensure the splicer is switched off. Lift the fiber clamp and wipe the V-groove with a cotton stick dipped in alcohol. Alternatively, scour the V-groove with end face of a cleaved fiber. 3.3.1 Cleaning the Objective Lens. If the objective lens is dirty, a bad image may be seen on the monitor and cause abnormal operation of the splicer.

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Ensure the splicer is switched off. Remove the electrode cover, loosen the electrode screws and move the electrode towards the back of the splicer (take care not to damage the tip through any unintentional contact). Wipe the objective lens with a cotton stick dipped in alcohol. Move the electrode back, keeping it firmly pressed into place while tightening the screws lightly. After cleaning, discharge a few time.

Fig.5. Cleaning the Objective Lens.

3.3.2 Cleaning the Mirrors When either of the mirrors is dirty, a bad image may be seen on the monitor and cause abnormal operation of the splicer. Cleaning procedure is as follows. 1. Open the wind protector (the Up/Down mirror is reset automatically) and turn off the splicer. 2. Wipe the mirrors inside the wind protector and in front of the V-grooves with a cotton stick dipped in alcohol. If the mirror has large visible dust, like sand, on its surface, blow it away before wiping (DO NOT use an aerosol gas cleaner for this). 3.3.3 Replacing the Up/Down Mirror. If the mirror has scratches on its, surface, a bad image may be seen on the monitor and cause abnormal operation of the splicer. Replacement procedure is as follows. Note:- Use the hexagonal wrench, tweezers and spare mirror provided in the splicer carrying case. 1. 2. 3. 4. 5.

Press the “SET” key to set the mirror. Press the “RESET” key and turn off the splicer. Open the wind protector, loosen the screws (“D”) fixing the electrodes and remove the electrodes carefully. Remove the screws (“A”) on the mirror attachment using the hexagonal wrench. Remove the mirror attachment (“B”) with the tweezers. Take care not to drop the screw or the mirror attachment inside the splicer. Push the new mirror firmly against the holder (“C”) while tightening the screw. Confirm that no gap is visible between the mirror attachment and the holder. Push both electrodes until the flanges touch the electrode fixture and lightly tighten screws (“D”).

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3.4 CAUTIONS 3.4.1 Notes on Use. 1. 2. 3. 4. 5. 6. 7. 8.

During discharge, the electrode generates a voltage of about 4,000V. Do not touch it. Make sure to ground the splicer main body during use. If there are drops of water on the splicer main body, dry thoroughly before use. Do not discharge while the electrodes are not in place. When alcohol, oil (including hand grease), etc. are adhered to the electrodes, abnormal discharge occurs. However, after discharging several times, such liquids will disappear and a normal discharge will be produced. Turn the power switch off before plugging or unplugging the power cord from the splicer main body. Do not clean the objective lens, switches or panels with any chemical except for alcohol. Such chemicals may cause discoloration or deterioration. Be careful not to get dust or sand on the splicer. Specifically do not rub the Vgrooves with a hard material, such as metals, because they are precisely machined. No lubrication is needed on the splicer. Lubrication may adversely affect operation. Precise adjustments have been made to all parts of the splicer. Do not loosen screws or make any modification (except for mirror, electrode replacement, etc.) If there is something wrong with the splicer, consult the manufacturer.

3.4.2 Notes on Storage and Transportation. 1. 2. 3.

Always use the carrying case of the splicer to prevent moisture, vibration and impact when storing and transporting the splicer. Do not store in a place where high humidity or temperatures can be expected. Clamp is to assist in cleaving at the specified distance from the end of the primary coating. It indicates the distance from the diamond blade in millimeters.

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