fiber optic connectors mil 83526 crocodile...

MIL83526 Crocodile Fusion for Zeus D50 Outdoor- e 1

Part. No. 1902624 - Version 08.05.2019

FIBER OPTIC CONNECTORSMIL 83526 CROCODILE FUSION FOR ZEUS D50 OUTDOOR

ASSEMBLY INSTRUCTION


INDEX

Page

1 INTRODUCTION ______________________________________________________________________21.1 Equipment and material used ______________________________________________________________ 2

2 HE-2000 CONNECTOR SET _____________________________________________________________6

3 SAFETY REQUIREMENTS ______________________________________________________________ 10

4 CABLE PREPARATION _________________________________________________________________ 11

5 MEASUREMENT METHOD IL____________________________________________________________ 33

0Index


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

1020483Side cutter Futuro

160 mm

1073457 T-Stripper

1073458 Kevlar scissors

1056892 FTTH Crimping Pliers

1075632 Crimpring Pliers HE

1081071Crimping pliers AF8 with

adapter (Positioner) UH2-5

1Introduction



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

1Introduction



1071974 Wrench 15mm

1051781 Wrench 16mm

1020495 Wrench 17mm

1051782 Wrench 20mm

1074651 Ferrule extractor

1074744Hollow pin guide

mounting/demounting tool

1074654 Termini extractor

1074680 Termini assembler

1075858Ferrule puncher for pushing ferrule

out of the body

1066753 Protection sleeve insertion tool

1073321

Adapter FBPT E-2000 APC/PC for ferrule inspection HE-2000

with JDSU P5000i digital inspection probe

1Introduction



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

1Introduction


2 MIL 83526 BREAKOUT CONNECTOR SET

Item Quantity 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

100 1 Spacer OLC

110 1 Small ring

120 1 Big sleeve

130 1 DM insert

140 1 Body assembly OLC

2Connector Set

2.5mm Crocodile Fusion Alberino HE

Optical/Electrical termini

DM4

DF-174.a

2

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:

No documento Denominazione ST 0235 Componenti MIL – 83526 DM ST 0214 Componenti Inserto DM 4X Outdoor

1.1 COMPONENTI MIL-83526 DM

1.2 COMPONENTI BULKHEAD MIL-83526 DM

1.3 COMPONENTI BULKHEAD MIL-83526 DM SHORT


2.1 CHANNEL CONNECTOR FUSION VERSION


40* 4 Crocodile fusion SM PC


40* 4 Crocodile fusion MM 50µm PC


40* 4 Crocodile fusion MM 62.5µm PC

SM/PC Crocodile Alberino

MM/PC Crocodile Alberino

MM/PC Crocodile Alberino


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

2Connector Set



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

90 1 Small ring

100 1 Big sleeve

110 1 DM4

120 1 Connector cup OLB

130 1 Body assembly OLB

2.2 MIL 83526 BULKHEAD

2Connector Set

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

2.3 MIL 83526 SHORT BULKHEAD

2Connector Set

DF-174.a

2







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

3Safety requirements

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


4 CABLE PREPARATION

Insert all the components along the cable 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).

Strip about ~50 mm with a Jokari stripper.

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

4Cable preparation

DF-174.a

2







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.

4Cable preparation

80mm


Use the Felt Tip Pen to mark the 900 μm fibres to a length of 49mm 0 /+1 mm.

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.

4Cable preparation

49mm


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.

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.

4Cable preparation

Marks on the screen


This is the ideal case. Clean fibers with a good cutting angle (fibers perpendicular to the splicing axis).

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.

Approx. 1.5 x fiber diameter

4Cable preparation


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/n1020616Needle EFD 5118 p/n1020622

4Cable preparation


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.

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.

Correct

Not correct

4Cable preparation


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.

Thin out the kevlar if necessary.

Clean the cable with alcohol, apply a layer of glue (loctite 608) on the cable jacket surface.

6

4Cable preparation


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 theright 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.

4Cable preparation


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.

4Cable preparation

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.


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. AOrange fibre => pos. BBlue fibre => pos. CBrown 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.

Notch Key

4Cable preparation


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.

Align the DM 4 adapter insert with the notch facing upwards the alignment will be guaranteed by the pin inserted in the preassembled interface.

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 thecompression nut.

A pen mark will help.

4Cable preparation

Key

Notch


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.

4Cable preparation


Close the connector with the dust protection cup.

The MIL 83526 Plug is now complete.

4Cable preparation


MIL 83526 BULKHEAD LONG VERSION PREPARATION


Long version with 5500 cable.

Proceed with the preparation of the cable as previously described at page 14 to page 15.

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.

Fiber holder mark.

4Cable preparation

36mm

DF-174.a

2







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.

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.

4Cable preparation

6


Place the cable on the crimping sleeve device and verify the right position to crimp the sleeve (100).

Important

After crimping the length from the front face of the ferrule to the end of the sleeve should be 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:


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

4Cable preparation

77+-1mm

77±1mm


Close the bulkhead with the dust protection cup.

4Cable preparation


MIL 83526 BULKHEAD SHORT VERSION PREPARATION


Short version with 900µm fiber or 3mm cable.


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 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.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.

4Cable preparation

20

DF-174.a

2







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.

4Cable preparation


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:


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.

4Cable preparation


PREPARATION OF THE ELECTRICAL CABLE

a) Insert the heat shrink tube and protection.

Spread a drop of Hysol 0151 adhesive on the electrical contact.

Place the plastic protection over the 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.

4Cable preparation

(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.

b) Strip la cable jacket of the cable approx. 4mm.

Hysol 0151

Male contact

Female contactProtection


4Cable preparation

Align the notch on the DM4 and the key of the termini. Then slide till it clicks.


5Measurement Method IL

MEASUREMENT METHOD IL

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: Components MM:

Light source Laser or LED Light source LED

21.1.2 Mode Filter

Components SM: Components MM:

Not defined (the ca. 3 m fiber of the reference patchcord is sufficient) ‘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

Reference connector MIL 38999 / HE-2000 1) REF

DUT Connectors MIL 38999 / HE-2000 under test

Reference Bulkhead MIL 38999 / HE-2000 1) REF

DUT Bulkhead MIL 38999 / HE-2000 under test

Generic connector on reference fanout 2) REF

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. 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.

2)


5Measurement Method ILMEASUREMENT 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


LS PM

b) DUT measurement:

1) 1)


21.2.3 Measurement method for patchcords with MIL 38999 / HE-2000 connectors


LS PM

b) DUT measurement:

1) 1)


LS PM

LS PM

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