Assembly Instruction for Fiber Optic Series
FO2-4
Fischer Connectors
Assembly instructions Rev6.0
2
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Table des matières
1 Introduction .............................................................................................................................................................. 3
2 Document history ..................................................................................................................................................... 3
3 Definitions and Acronyms ......................................................................................................................................... 3
4 FO2-4 Plugs & Receptacles with Cable Clamp Set .................................................................................................... 4
5 FO2-4 Plugs & Receptacles with Potting Set ............................................................................................................. 8
6 FO2-4 R01, R03 & R13 Receptacles with Wire Set .................................................................................................. 13
7 Terminus assembly ................................................................................................................................................. 16
8 Polishing .................................................................................................................................................................. 18
9 Appendix ................................................................................................................................................................. 26
Assembly instructions Rev6.0
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This document is the property of Fischer Connectors.
This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
1 Introduction
This document covers :
- The application of Fischer FiberOptic Series electrical contacts and optical termini to electrical and fiber optic
cables (singlemode and multimode fibers)
- The assembly of fiber optic cable with a cladding size of 125 µm and having the cable structure described in
Fischer FiberOptic Series Cable Specifications
- The assembly of Fischer FiberOptic Series electrical contacts and optical termini and Rear Accessory sets
(Wire, Cable Clamp and Potting sets) to Fischer FiberOptic Series 2/4 channel connectors (referred as FO2-4
in the present document)
Please read these instructions thoroughly before starting assembly.
2 Document history
Date
Revision #
Author
Controller
Modification description
15.03.2017
6.0
JGY
SRH/CMI
New Document
3 Definitions and Acronyms
Text
Definition / Acronym
FO
Fischer FiberOptic
FO2/4
Fischer FiberOptic Series two channels or four channels-2/4 fiber
IEC
International Electrotechnical Commission
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
4 FO2-4 Plugs & Receptacles with Cable Clamp Set
Assembly steps
Components list :
A – Sleeve Holder
B – Connector Body
C – Insulator
D – Termini
E – Support Washer
F – O-ring Seal
G – Clamp Set Body
H – Conical Ring
I – Clamp Nut
J – Rear Nut
K – Shrink Tube
L – Bend Relief
Note : the pictures shown in this section represent a P01 Plug.
The following assembly steps are valid for P01 plug, as well as R01, R03, R13 and R50 receptacles, except the final
step (sleeve holder assembly).
Picture
Process
Tools
Slide over the cable :
- the Bend Relief “L”
- the Shrink Tube “K”
- the Rear Nut “J”
- the Clamp Nut “I”
- the Conical Ring “H”
- the Clamp Set Body “G”
- the O-Ring Seal “F”
Strip the cable to the dimensions
as given on the picture.
Ruler, aramid shears,
jacket stripper,
and strip tool
Terminus assembly : See section 7
Polishing: See section 8
Insert all the termini “D” into the
insulator “C”.
When you insert the terminus
”D”, be careful to turn it during
the insertion to not “bend” the
contact O-ring.
A B C
D
E F G H I
J K L
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Pin Layout front view.
Place the Support Washer “E”
around the termini ”D”.
Push the contact bloc (termini
“D” + insulator “C”) with the
Support Washer ”E” until it clips.
Position the O-Ring Seal “F” on
the Clamp Set Body “G” then
slide the Clamp Set Body “G” into
the Connector Body "B".
Receptacle
Plug
Click
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Screw by hand the Rear Nut “J”
on the Connector Body “B”, then
uniformly distribute the cable
strength members around the
back of the Clamp Set Body “G”.
Position the Conical Ring “H”
against the strength members.
Screw by hand the clamp nut “I”
on the back body clamp “G”.
Screw the Rear Nut "J”
Recommended torque : 5.0 Nm
Torque wrench [5Nm]
Size 13
Counter piece:
receptacle FO2/4
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Screw the Clamp Nut ”I”.
Recommended torque : 5.0 Nm
Note : hold the Clamp Set Body
with a wrench while screwing the
Clamp Nut “I”.
Torque wrench [3Nm]
Size 9
Wrench size 10!
Slide the Shrink Tube "K" until the
end of the shrink tube bottoms
against the Back Nut “J” and heat
it.
Heat gun
Shrink tube operating
temperature Range : 55°C to 110°C.
Apply epoxy on the Shrink Tube
"K" and slide the Bend Relief ”L”
until the end of the bend relief
bottoms against the Back Nut “J”.
Epoxy: RT-355
Resintech
Insert Sleeve Holder "A" in the
Connector Body "B".
Note : there is no sleeve holder
for R01, R03,R13 and R50
receptacles. Thus, this final
assembly step is valid only for
P01 plug.
5
6
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
5 FO2-4 Plugs & Receptacles with Potting Set
Assembly steps
Components list :
A – Sleeve Holder
B – Connector Body
C – Insulator
D – Terminus
E – Support Washer
F – O-ring Seal
G – Potting Set Body
H – Rear Nut
I – Shrink Tube
J – Bend Relief
Note : the pictures shown in this section represent a P01 Plug.
The following assembly steps are valid for P01 plug, as well as R01, R03, R13 and R50 receptacles, except the final
step (sleeve holder assembly).
Picture
Process
Tools
Slide over the cable :
- the Bend Relief “J”
- the Shrink Tube “I”
- the Rear Nut “H”
- the Potting Set Body “G”
- the O-Ring Seal “F”
Strip the cable to the dimensions
as given on the picture.
Ruler, aramid shears,
jacket stripper,
and strip tool
Terminus assembly : See section 7
Polishing: See section 8
Insert all the termini “D” into the
insulator “C”.
When you insert the terminus
”D”, be careful to turn it during
the insertion to not “bend” the
contact O-ring.
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Pin Layout front view.
Place the Support Washer “E”
around the termini ”D”.
Push the contact bloc (termini
“D” + insulator “C”) with the
Support Washer ”E” until it clips.
Position the O-Ring Seal “F” on
the Potting Set Body “G” then
slide the Potting Set Body “G”
into the Connector Body "B".
Be careful to the orientation of
the back body.
Receptacle
Plug
Click
Assembly instructions Rev6.0
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Screw by hand the Rear Nut “H”
on the Connector Body “B”.
Screw the Rear Nut "G".
Recommended torque : 5.0 Nm
Torque wrench [5Nm]
Size 13
Counter piece:
receptacle FO2/4
Slide the Shrink Tube "I" until the
end of the shrink tube bottoms
against the Potting Set Body “G”
as shown on the left picture and
heat it.
Heat gun
Shrink tube operating
temperature Range : 55°C to 110°C..
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Slowly inject the epoxy inside the
Potting Set Body “G” using the
filling hole located at the bottom
of the Potting Set Body “G”.
Note : the second hole, smaller
and located above the filling hole,
is an overfilling hole. Stop
injecting epoxy when epoxy starts
to flow from this overfilling hole.
Resin Epoxy RS 851-044
Black
Remove any excess epoxy from
the assembly (if any), apply tape
on both filling and overfilling
holes and place the assembly
onto the curing oven block.
Curing time : 12 hours
@ approx. 23°C.
Apply epoxy on the Shrink Tube
"I" and slide the Bend Relief ”J”
until the end of the Bend Relief
”J” bottoms against the Back Nut
“H”.
Epoxy: RT-355
Resintech
Injection Hole
(2mm)
Overfill hole
Injection
Hole (2mm)
Overfill hole
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Insert Sleeve Holder "A" in the
Connector Body "B".
Note : there is no sleeve holder
for R01, R03,R13 and R50
receptacles. Thus, this final
assembly step is valid only for
P01 plug.
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
6 FO2-4 R01, R03 & R13 Receptacles with Wire Set
Assembly steps
Components list :
A – Connector Body
B – Insulator
C – Terminus
D – Support Washer
E – Crimp Sleeve
F – Shrink Tube
G – O-ring
H – Wire Set Body
I – Wire Set Nut
J – Connector Panel
Seal
K – Connector Nut
Note : the pictures shown in this section represent a R03 receptacle.
The following assembly steps are valid for R01 & R13 receptacles as well.
Picture
Process
Tools
Slide over the cable :
- the Wire Set Nut “I”
- the Wire Set Body “H”
- The O-ring “G”
- the Shrink Tube “F”
- the Crimp Sleeve “E”
Strip the cable to the dimensions
as given on the picture.
Ruler, aramid shears,
jacket stripper,
and strip tool
Terminus assembly : See section 7
Uniformly distribute the cable
strength members around the
back of the Terminus “B”.
Slide the Crimp Sleeve “E” over
the cable strength members until
the end of the crimp sleeve
bottoms against the Terminus
“B”.
Find tools drawing in
appendixes.
A B C D E F H I G J K
Assembly instructions Rev6.0
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Picture
Process
Tools
Slide the Shrink Tube “F” over the
Crimping Sleeve ”E” and heat it.
Heat gun
Shrink tube operating
temperature Range : 55°C to 110°C.
Polishing: See section 8
Insert all the termini “C” into the
insulator “B”.
When you insert the terminus
”C”, be careful to turn it during
the insertion to not “bend” the
contact O-ring.
Pin Layout front view.
Place the Support Washer “D”
around the termini ”C”.
Push the contact bloc (termini
“C” + insulator “B”) with the
Support Washer”.
Insert the Wire Set Body “H” into
the Connector Body “A”.
Receptacle
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Picture
Process
Tools
Screw the Wire Set Nut “I” on the
Connector Body “A”.
Recommended torque : 5.0 Nm
Torque wrench
[5Nm] Size 13
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
7 Terminus assembly
Assembly steps
Components list :
A – Housing O-Ring
B – Termini Housing
C – Ferrule O-Ring
D – Ferrule
E – Spring
F – Termini Closure
Picture
Process
Tools
Slide over the cable :
- the Termini Closure “F”
- the Spring “E”
Prepare the cable according to stripping dimension from the relevant section.
Insert epoxy into the Ferrule “D”
until a little drop appears at the
ferrule end.
Carefully insert the fiber into the
back of the Ferrule “D and make
sure the buffer slides inside the
ferrule the buffer bottoms on the
ceramic.
Extended Working Life,
2-Part Epoxy, 2.5 Gram
Packet
Frs : FIBER OPTIC
CENTER
Ref : ET383ND-2.5G
Remove any excess epoxy from
the assembly
Cure the epoxy
120 +10/- 20[°C]
during 20min.
Cleave fiber
Scribe Tool
A
B C D
E
F
Assembly instructions Rev6.0
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Position the Ferrule O-ring “C” on
the Ferrule “D” as shown on the
top left picture.
Slide the Spring “E” and Termini
Closure “F” at the back of the
Ferrule “D” and assemble them
into the Termini Housing “B”.
Position the Housing O-ring “A”
on the Termini Housing “B” as
shown on the left picture.
Assembly instructions Rev6.0
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8 Polishing
It is recommended polishing the fiber using a polishing machine.
Polish the fiber according to the machine manufacturer’s instructions.
Picture
Process
Tools
PC termini
Step1 : Air polish
Holding the polishing bushing and
terminus, place the polishing
bushing on the film.
Using light pressure on the
ferrule, polish the endface of the
ferrule in a small circular motion.
Polishing film:
9µm Silicon
carbide
Polishing Pad :
N/A
Lubricant: N/A
Tool: FO-10090
Clean the polishing pad with
demineralized water and lint-free
cloth, from the center outwards.
Spray some demineralized water
on the polishing pad and place
the polishing film, starting at
edges of the polishing pad.
Spray abundantly demineralized
water on the polishing film.
Après
cleave
Air
Polish
Après
Air
Polish
Assembly instructions Rev6.0
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Step 2 :
Polish the termini with 5µm
Silicon carbide polishing film,
until no peripheral chips are
visible.
Do not remove more than 100
µm.
Polishing film:
5µm Silicon
carbide
Polishing Pad : 90
duro black
Lubricant: DI-water
Fixture tool: FO-
10019
Wipe abundantly the polishing
tool holding the termini with
demineralized water and clean it
carefully with a lint-free cloth.
Use an airpressure gun to remove
residual water.
Clean the polishing pad with
demineralized water and lint-free
cloth, from the center outwards.
Spray some demineralized water
on the polishing pad and place
the polishing film, starting at
edges of the polishing pad.
Spray abundantly demineralized
water on the polishing film.
Step 3 :
Polish the termini with 1µm
Diamond polishing film in an 8
pattern motion (or pattern of the
polishing machine).
Polishing film:
1µm Diamond
Polishing Pad: 80
duro green
Lubricant: DI-water
Fixture tool: FO10019
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Wipe abundantly the polishing
tool holding the termini with
demineralized water and clean it
carefully with a lint-free cloth.
Use an airpressure gun to remove
residual water.
Clean the polishing pad with
demineralized water and lint-free
cloth, from the center outwards.
Spray some demineralized water
on the polishing pad and place
the polishing film, starting at
edges of the polishing pad.
Spray abundantly demineralized
water on the polishing film.
Step 4 :
Polish the termini with
AngstromLap Final Polish SiO2 in
an 8 pattern motion.
Do not clean the polishing tool
after this step, to avoid creating
scratches on the polished
ferrule.
Polishing film:
AngstromLap Final
Polish SiO2
Polishing Pad: 80
duro green
Lubricant: DI-water
Fixture tool: FO-
10019
Geometrical control :
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Ferrule Radius[mm]:
Min 5 - Max 12
Apex Offset[um]:
Min 0.0 – Max 50.0
If fail, repeat from step 3.
Fiber core inspection :
Examine the endface of the
ferrule for scratches according to
left pictures.
If fail, repeat from step 4.
If not installing the connector
immediately, install a protective
cover onto terminus to prevent
contamination to the endface of
the ferrule.
8° APC termini
Step1 : Air polish
Holding the polishing bushing and
terminus, place the polishing
bushing on the film.
Using light pressure on the
ferrule, polish the endface of the
ferrule in a small circular motion.
Polishing film:
9µm Silicon carbide
Polishing Pad :
N/A
Lubricant: N/A
Tool: FO-10090
NOK
OK
Après
cleave
Air
Polish
Après
Air
Polish
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Clean the polishing pad with
demineralized water and lint-free
cloth, from the center outwards.
Spray some demineralized water
on the polishing pad and place
the polishing film, starting at
edges of the polishing pad.
Spray abundantly demineralized
water on the polishing film.
Step 2 :
Polish the termini with 8° angle
using the fixture tool.
Make sure the endface of the
ferrule is fully polished, as shown
on the left pictures.
If not, repeat from step 2.
Polishing film:
5µm Diamond
Polishing Pad:
Glass
Lubricant: DI-water
Fixture tool:
TX00.285
Wipe abundantly the polishing
tool holding the termini with
demineralized water and clean it
carefully with a lint-free cloth.
Use an airpressure gun to remove
residual water.
NOK
OK
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Clean the polishing pad with
demineralized water and lint-free
cloth, from the center outwards.
Spray some demineralized water
on the polishing pad and place
the polishing film, starting at
edges of the polishing pad.
Spray abundantly demineralized
water on the polishing film.
Step 3 :
Polish the termini with 1µm
Diamond polishing film in an 8
pattern motion (or pattern of the
polishing machine).
Polishing film:
1µm Diamond
Polishing Pad: 80
duro green
Lubricant: DI-water
Fixture tool:
TX00.285
Wipe abundantly the polishing
tool holding the termini with
demineralized water and clean it
carefully with a lint-free cloth.
Use an airpressure gun to remove
residual water.
Assembly instructions Rev6.0
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This document must not be reproduced or distributed, in whole or in part, without prior written permission of Fischer Connectors.
Clean the polishing pad with
demineralized water and lint-free
cloth, from the center outwards.
Spray some demineralized water
on the polishing pad and place
the polishing film, starting at
edges of the polishing pad.
Spray abundantly demineralized
water on the polishing film.
Step 4 :
Polish the termini with
AngstromLap Final Polish SiO2 in
an 8 pattern motion.
Do not clean the polishing tool
after this step, to avoid creating
scratches on the polished
ferrule.
Polishing film:
AngstromLap Final
Polish
Polishing Pad:80
duro green
Lubricant: DI-water
Fixture tool:
TX00.285
Geometrical control :
Ferrule Radius[mm]:
Min 5 - Max 12
Apex Offset[um]:
Min 0.0 – Max 50.0
If fail, repeat from step 3.
Fiber core inspection :
Examine the endface of the
ferrule for scratches according to
Assembly instructions Rev6.0
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left pictures.
If fail, repeat from step 4.
If not installing the connector
immediately, install a protective
cover onto terminus to prevent
contamination to the endface of
the ferrule.
NO
Assembly instructions Rev6.0
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9 Appendix
Tool drawing for crimping the sleeve to the contact
Tool drawing for crimping the ground contact to the rear body (FOH)
Assembly instructions Rev6.0
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