PRO BEAM Mini* Expanded Beam (EB)
Cable Plug Connectors
Cable Plug Connector Shell Kit
(1828698- 1 Shown)
408-- 10065
29 JUL 09 Rev C
Instruction Sheet
Ferrule Assembly Kit
(1754700- 2 Shown)
O-- Ring
Spring
126--
mm
Ferrule Assembly
Housing
Protective
Cap
Grip Ring
Collet
Sleeve
Collet
Nut
Extension
Wave
Spring
EB Insert Assembly Kit
(1588129- 3 Shown)
EB Insert
Guide Pin
Lens
Figure 1
Dust
Cover
Cable Adapter Kit
(1828700- 2 Shown)
Boot
Washer
Crimp
Sleeve
Crimp
Support
Ferrule Plate
Screw
Cable
Seal
1. INTRODUCTION
PRO BEAM Mini EB cable plug connectors are
designed to be installed onto jacketed fiber optic
cable with aramid strength members.
NOTE
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.
2. DESCRIPTION
Each kit contains the components shown in Figure 1.
The EB insert assembly kit is shipped with a white
protective label on the back (end opposite the lens) of
the EB insert which is installed immediately after final
testing to keep the channel cavities clean. The EB
insert is ready for assembly as shipped.
i
3. HANDLING
DANGER
To avoid personal injury, NEVER look into the
end of terminated or unterminated optical fibers.
Laser radiation is invisible but can damage eye
tissue.
The connector must be assembled using a cable plug
connector shell kit, an EB insert assembly kit, ferrule
assembly kit (one for each fiber or channel), and a
cable adapter kit. Sample part numbers are given in
Figure 1. The combination of the kits selected is
based on the diameter of the cable, the mode and
quantity of fibers, and the operating wavelength of the
system.
CAUTION
To avoid poor optical performance or permanent
damage to the lens of the EB insert, use ONLY
Tyco Electronics ferrule assembly kits. Other
manufacturers’ ferrule assemblies ARE NOT
compatible with the EB insert assembly kit.
S
Do not touch the lens of the EB insert with your
fingers or with any tools
NOTE
If the lens is touched or otherwise contaminated,
clean the lens according to Instruction Sheet
408--8828.
!
i
S
After assembly, re--install the protective cap or
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
mate the connector immediately after the cap
has been removed to prevent contamination to
the EB insert assembly
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2009
Tyco Electronics Corporation, Harrisburg, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
1
of 11
LOC B
PRO BEAM Mini Expanded Beam (EB) Cable Plug Connectors
Collet
Nut
Grip Ring
Washer
Extension
408- 10065
Boot
1m
Cable
Wave
Spring
Collet
Sleeve
Figure 2
Cable Seal
4. TOOLS AND MATERIALS
The following tools and materials are necessary for
preparation, assembly, inspection, and maintenance
of the connector and cable assembly. Follow the
operating instructions packaged with the tools and
safety guidelines packaged with the materials.
NOTE
Items without a part number or supplier are
customer supplied.
— lint--free tissues or cloths
— isopropyl alcohol (99%) or acetone
— Epoxy 504035--1 (4--gram bi--pack)
— Epoxy Applicator Kit 501473--3
For hand polishing only:
— 5--mm Aluminum Oxide Polishing Film
228433--8
— 1mm Rubber Polishing Pad 501858--1
(green)
— Polishing Plate 501197--1 (216¢280 mm)
— 0.3--mm Diamond Polishing Film 228433--5
— Final Polishing Film 502748--2
— lint--free applicator swabs
— Dow Corning Molykote 55 O--ring grease
— Loctite 243 threadlocker
i
4.1. Tools
— cable jacket strip tool
— Aramid Shears 1278637--1
— SDE PEW 12 Hand Tool 91382--1 with Die Set
1673667--1 (408--8795)
— micrometer or vernier, dial, or digital caliper
— Fiber Stripping Tool 504024--1 (125--mm, red
handle) (408--9485)
— Heat Cure Oven Assembly 502134--1 (120 Vac)
or --2 (240 Vac) includes universal heat cure block
or --5 (120 Vac) or --6 (240 Vac) includes FSD heat
cure block (408--9460)
— Curing Fixture 1918023--1 (408--8857)
— Sapphire Scribe Tool 504064--1 (408--4293)
— polishing machine (recommended) or Polishing
Bushing 504862--1 (for hand polishing)
— 200¢ Microscope 1754767--1
— Ferrule Insertion Tool 1693820--1
— 2--mm hex wrench
— EB Insert Installation Tool 1918255--1
— Bench--Mount Assembly Fixture 1918503--1
— 13--mm open--end wrench
— 14--mm open--end wrench
— heat gun
5. ASSEMBLY PROCEDURE
flow table in a clean environment meeting the
requirements of International Organization for
Standardization (ISO) 14644--1 (Class 5),
“Cleanrooms and Associated Controlled
Environments, Part 1.” Make sure that all components
are free from contamination.
Proceed as follows:
IMPORTANT:
Assemble the connector using a laminar
5.1. Prepare the Cable
1. Slide the components shown in Figure 2 onto
the cable allowing 1 m at the end of the cable for
stripping the cable. Make sure to orient each
component as shown.
2. Using the cable jacket strip tool, strip the jacket
to the dimension shown in Figure 3, exposing the
strength members and fiber. Retain the stripped
piece of jacket for later use.
Using the shears, trim the strength members to the
length given in Figure 3.
4.2. Materials
— Loctite 480 Prism instant adhesive
Loctite, 480, Prism, and 243 are trademarks of Henkel Corporation.
Dow Corning and Molykote are registered trademarks of Dow Corning Corporation.
2
of 11
Tyco Electronics Corporation
Rev
C
PRO BEAM Mini Expanded Beam (EB) Cable Plug Connectors
Cable Strip Length
Fiber
Strength
Members
Jacket
408- 10065
11+1 mm
45+5 mm
Note:
Not to Scale
Figure 3
Detail A
NOTE
These instructions are for single--channel
connectors. For multi--channel connectors,
perform the same assembly procedure for each
channel.
Fiber
End of Jacket
4-- 5 mm
Jacket
i
5.2. Terminate the Fiber
1. Apply a continuous bead of the instant adhesive
around the cable jacket between 4 and 5 mm from
the stripped end of the jacket. See Figure 4,
Detail A.
NOTE
Loctite Prism 480 instant adhesive is a
cyanoacrylate which hardens extremely quick.
Detail C
2. Rotate and slide the crimp support (large
diameter end first) over the fiber and strength
members and onto the jacket until it bottoms
(rotating the crimp support between the thumb and
index finger will help feed the strength members
through the crimp support). See Figure 4, Detail B.
3. Apply a thin band of the instant adhesive around
the knurled portion of the crimp support. Make sure
that the band is continuous around the entire
circumference. See Figure 4, Detail C.
4. Slide the piece of cable jacket (stripped from the
jacket in Paragraph 5.1) over the buffered fiber and
into the center of the strength members until it
bottoms against the crimp support and the strength
members are flared away from the fiber. See
Figure 4, Details D and E.
5. Slide the crimp sleeve over the fiber and piece
of cable jacket so that the strength members fold
back evenly around and over the crimp support
and until it bottoms on the rear flange of the crimp
support; then remove the piece of cable jacket.
This step should be performed quickly before the
adhesive begins to harden. See Figure 4, Detail E.
Detail B
Strength
Members
Apply Continuous Beam of
Instant Adhesive Here
Rotate and Slide
Crimp Support to Help Feed
Strength Members Through
i
Crimp Support
Bottomed on Jacket
Apply Thin Band of Instant Adhesive Here
Detail D
Piece of Cable Jacket Used
to Flare Strength Members
Detail E
Piece of Cable Jacket
Against Crimp Support
Strength Members
Flared
Crimp
Sleeve
Figure 4
Rear Flange of
Crimp Support
Rev
C
Tyco Electronics Corporation
3
of 11
PRO BEAM Mini Expanded Beam (EB) Cable Plug Connectors
6. Place the crimp sleeve in the 8.6--mm hex nest
of the hand tool, and crimp the crimp sleeve onto
the crimp support. Make sure to position the crimp
sleeve in the hex nest so that the crimp will locate
from the back of the crimp sleeve to within the
dimension shown in Figure 5, Detail A.
7. Using the micrometer or caliper, measure the
crimp sleeve across the flats of the hex crimp to
make sure that it conforms to the crimp height and
crimp width shown in Figure 5, Detail B.
If necessary, crimp again, and re--measure the
crimp.
8. At the back of the crimp support, apply the
instant adhesive around the circumference of the
crimp support at the junction of the cable and the
crimp support. Then at the front of the crimp
sleeve, apply the instant adhesive over the opening
of the crimp sleeve to encapsulate the strength
members. See Figure 5, Detail C. Remove any
excess adhesive.
9. Mark the fiber at the dimension shown in
Figure 5, Detail D, and using the fiber stripping
tool, strip the buffer to the mark, exposing the bare
fiber. Using a lint--free tissue or cloth dampened
with the isopropyl alcohol or acetone, clean the
bare fiber.
CAUTION
Take care not to break the bare fiber. If any part
of the fiber breaks, the crimp support and crimp
sleeve must be replaced, and the cable must be
re--stripped.
Detail A
408- 10065
Back of
Crimp Sleeve
Crimp Location
Detail B
8.7+0.1 mm
Crimp Height
2+1 mm
5+0.1 mm
Crimp Width
Detail C
Apply Instant Adhesive Here
Opening of Crimp Sleeve
Back of
Crimp Sleeve
Junction of Cable and Crimp Support
Detail D
32.2+1/-- 0 mm
!
Mark and Strip Buffer
Detail E
Spring
10. Slide the spring onto the fiber buffer. See
Figure 5, Detail E.
Bare Fiber
11. Pre--heat the heat cure oven to 100_C.
12. Prepare the epoxy according to the following:
a. Remove the separating clip from the epoxy
package. Using the epoxy mixer, mix the two
components together thoroughly for 20 to 30
seconds.
b. Install the needle tip on the applicator from
the epoxy applicator kit. Make sure it is secure.
Remove the plunger.
c. Cut the epoxy packet open, and squeeze
the epoxy into the back of the applicator.
Re--assemble the plunger. Hold the applicator
vertically, and slowly push on the plunger until
the entrapped air escapes and a bead of epoxy
appears at the needle tip.
d. Using a lint--free tissue or cloth dampened
with the isopropyl alcohol or acetone, clean the
tip of the applicator.
Fiber Buffer
Figure 5
13. Hold the ferrule assembly vertically, and insert
the needle tip into the base of the ferrule assembly
until it is against the back (end closest to the base)
of the ferrule assembly. Refer to Figure 6.
14. While holding the ferrule assembly
firmly
against the needle tip,
slowly
inject the epoxy until
a small bead of epoxy (approximately 0.75 mm in
diameter) forms at the end face of the ferrule
assembly. DO NOT allow the bead to get too large
or smear.
15. Withdraw the needle slightly, and inject an
additional small amount of epoxy so that the cavity
at the base of the ferrule assembly is
approximately one--third to one--half full.
4
of 11
Tyco Electronics Corporation
Rev
C
PRO BEAM Mini Expanded Beam (EB) Cable Plug Connectors
DANGER
To avoid personal injury, remember that epoxy is
a hazardous material, and pay particular attention
to the following:
End Face of
Ferrule Assembly
408- 10065
0.75-- mm Diameter (Approx)
Bead of Epoxy
Base of Ferrule
Assembly
—ALWAYS follow manufacturer’s safety guidelines.
—ALWAYS wear protective gloves when using epoxy.
—ALWAYS use epoxy in a well ventilated area.
—AVOID prolonged and frequent contact with skin.
—AVOID inhaling fumes from epoxy.
16. Place the crimp sleeve and fiber into the curing
fixture according to the instructions included with
the curing fixture.
Carefully insert the fiber into the back of the ferrule
assembly (previously prepared with epoxy).
Simultaneously slide and rotate the ferrule
assembly on the fiber (to prevent any air pockets
from being trapped in the epoxy) until it bottoms.
Make sure that the bare fiber is protruding from the
end face of the ferrule assembly. If it is not, re--strip
and re--terminate the fiber.
Place the ferrule assembly in the curing fixture
according to the instructions included with the
curing fixture.
17. Cure the assembly in the heat cure oven for 20
minutes. Remove the assembly from the oven, and
allow the assembly to cool to room temperature.
18. Measure the assembly to make sure that it
conforms to the dimension given in Figure 7. If it
does not, re--strip and re--terminate the fiber.
NOTE
Although the curing fixture is designed to ensure
that the required functional length is obtained, it
is still important to measure the assembly for this
length after curing.
Applicator Needle
Figure 6
Curing Fixture
Spring
Cable
Fiber
Base and O-- Ring
of Ferrule Assembly
Assembly After Curing
Crimp
Sleeve
42.5+1/-- 0 mm
Required Functional Length
Figure 7
i
5.3. Cleave the Fiber
Firmly support the ferrule assembly, and draw the
beveled edge of the scribe tool across the fiber as
shown in Figure 8. After scoring the fiber, pull the
fiber straight away from the ferrule assembly.
DANGER
Safely dispose of excess fiber.
After Scoring, Pull Fiber Straight Away
Fiber
Epoxy
Scribe Tool
CAUTION
To avoid damage to the tip of the scribe tool,
DO NOT allow the scribe tool to contact the
epoxy.
End Face of
Ferrule Assembly
Figure 8
!
Rev
C
Tyco Electronics Corporation
5
of 11
京公网安备 11010802033920号
EEWORLD
