Panduit FJJGM2.0C, FJEPGM5C, FJEPGM2.0C, FJJGM5C, FJJGS9CBUY Installation Instructions Manual

MINI-COM OPTI-JACK FJ Fiber Optic Connectors

Field Polish Termination - Singlemode and Multimode

Part Numbers: FJJGM5C, FJJGM2.0C, FJEPGM5C, FJEPGM2.0C, FJJGS9CBUY,

FJJGS2.0CBUY, FJEPGS9CBUY, FJEPGS2.0CBUY

© Panduit Corp. 2007

INSTALLATION INSTRUCTIONS PN256D

READ ALL INSTRUCTIONS COMPLETELY BEFORE PROCEEDING

REFER TO WEB SITE BELOW FOR MOST CURRENT INSTRUCTIONS

1. COMPONENT IDENTIFICATION

JACK

1.1 JACK ASSEMBLY

Jack Cap

3.0mm Crimp

Sleeves

2.0mm/1.6mm
Crimp Sleeves

Jacketed
Boot

FJJGS9C and FJJGM5C includes 3.0mm crimp sleeves
FJJGS2.0C and FJJGM2.0C includes 2.0mm/1.6mm crimp sleeves

Dust Cover

Jack Housing

Ferrule
Assemblies

900µm Buffered Boot

PLUG

PLUG ASSEMBLY

1.4

2.0mm/1.6mm
Crimp Sleeves

Jacketed
Boot

FJEPGS9C and FJEPGM5C includes 3.0mm crimp sleeves
FJEPGS2.0C and FJEPGM2.0C includes 2.0mm/1.6mm crimp sleeves

Ferrule
Assemblies

Plug Insert

Dust Caps

Plug Housing

3.0 mm Crimp
Sleeves

1.2 JACKETED STRIPPING DIMENSIONS

IMPORTANT! Due to printing variations, use a rigid
scale for both jack and plug stripping dimensions,
or the appropriate PANDUIT laminated template.

1.3 900µm BUFFERED STRIPPING DIMENSIONS

IMPORTANT! Due to printing variations, use a rigid
scale for both jack and plug stripping dimensions,
or the appropriate PANDUIT laminated template.

1.5 JACKETED STRIPPING DIMENSIONS

IMPORTANT! Due to printing variations, use a rigid
scale for both jack and plug stripping dimensions,
or the appropriate PANDUIT laminated template.

The plug side is not intended to be terminated using
900µm buffered fiber.

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Page 1 of 8

INSTALLATION INSTRUCTIONS PN256D

1.6 ITEMS REQUIRED FOR TERMINATION

ITEM

1 CST-115 Fiber Cable Jacket Stripper
2 FALC Alcohol Bottle (empty)
3 FBFSP Fiber Buffer Stripper

4 FCRP5

5 FCVR Fiber Cleaver
6 FGLS Safety Glasses
7 FJPKGU Universal Polishing Puck
8 FJPMR Primer

9 FJPXY Anaerobic Adhesive
10 FKS Strength Member (Aramid Fiber) Cutters
11 FPAD Polishing Pad
12 FPP5-L 5µm Polishing Film (Aluminum Oxide)
13 FSCDVR Screwdriver
14 FSTY Safety Stickers for fiber scraps
15 FSWB-C Cleaning Swabs
16 FSYR-X Syringes with needle tips
17 FTWZR Tweezers
18 FWP-C Cloth Wipes
19 PFX-0 Indelible Ink Marking Pen
20 FLOUPEX10 Eye Loupe 10X Power
21
22
23 FHSCT 110VAC/60Hz Heat Shrink Curing Tool (For 2.0mm/1.6mm terminations only)
24 -- Isopropyl Alcohol (Reagent Grade, 90% minimum concentration; not available from PANDUIT)
25 FLCFPLF-X .05µm Lapping Film (For singlemode terminations only)
26 FWBTL Distilled Water Bottle (empty)
27 -- Distilled Water (not available from PANDUIT)

OPTIONAL FHSCT-W 230VAC/50Hz Heat Shrink Curing Tool (For 2.0mm/1.6mm terminations only)
OPTIONAL FJJ9FRL-X Replacement ferrule and crimp sleeve for OPTI-JACK singlemode jack (10)
OPTIONAL FJEP9FRL-XY Replacement ferrule and crimp sleeve for OPTI-JACK singlemode plug (10)
OPTIONAL PN257 Stripping Template

PART

NUMBER

Universal Crimp Tool (hex sizes: .048, .100, .128, .151, .190) Hex sizes needed for M
.128 and .151

FPF1-V 1µm Diamond Polishing Film
FLPT Crimp Tool (For 2.0mm/1.6mm terminations only)

DESCRIPTION

INI-COM OPTI-JACK termination:

2. PRECAUTIONS

2.1 SAFETY GLASSES

WARNING: Safety glasses have to be worn when handling the adhesive or primer used with the connector or when han-

dling bare optical fiber. The bare fiber is very sharp and can easily damage the eye.

2.2 ISOPROPYL ALCOHOL

WARNING: Isopropyl alcohol is flammable. Contact with the alcohol can cause irritation to the eyes. In case of contact

with the eyes, flush with water for at least 15 minutes. Always use isopropyl alcohol with proper levels of ventilation. In

case of ingestion, consult a physician immediately.

2.3 RECOMMENDED ADHESIVE AND PRIMER

WARNING: The recommended adhesive (PANDUIT Part #FJPXY) may contain maleic acid and methacrylic ester. In

case of eye contact, flush with water for 15 minutes and get medical attention. Wash after skin contact. Request M.S.D.S.

for further safeguards. Check “Used By” date on bottle to ensure best performance.

WARNING: The recommended primer (PANDUIT Part #FJPMR) may contain acetone. The primer is harmful if inhaled

or swallowed. In case of contact with eyes or skin, flush with water. Get medical attention in case of ingestion or contact

with eyes. Do not induce vomiting. Check “Used By” date on bottle to ensure best performance.

2.4 DISPOSAL OF BARE FIBERS

WARNING: Pick up and discard all pieces of bare fiber with sticky tabs. Do not let cut pieces of fiber stick to clothing or

drop in the work area where they are hard to see and can cause injury.

2.5 LASER LIGHT PROTECTION

WARNING: Laser light is invisible. The invisible light is powerful enough to damage your eyes. Serious damage to the

retina of the eye is possible. Never look into the end of a fiber which may have a laser coupled into it. Should accidental

eye exposure to laser light be suspected, arrange for an eye examination immediately.

2.6 CABLE HANDLING

WAR NI N G: Fiber optic cable can be damaged by excessive pulling, twisting, crushing or bend-

ing stresses. Consult the appropriate specification sheets as provided by your cable vendor.

Any damage may result in decreased optical performance.

For Technical Support: www.panduit.com/resources/install_maintain.asp

Page 2 of 8

INSTALLATION INSTRUCTIONS PN256D

3. FERRULE TERMINATION

PLUG

ADHESIVE

3.1.1

3.2.1

3.1 TERMINATION PREPARATION

3.1.1 Remove the plunger from a syringe. Squeeze about 0.5 ml
of FJPXY Anaerobic Adhesive into the back of the syringe
barrel. Insert the plunger. Point opening upward, and
squeeze any air out of the barrel. Attach needle to syringe.
Adhesive that is stored in a syringe may start to harden
within 24 hours.

3.1.2 Partially fill a second syringe with about 0.5ml of FJPMR
Primer. Do this by drawing primer up into the syringe barrel
rather than pouring it in through the back.

3.2 3.0mm/2.0mm/1.6mm JACKET / 900µm BUFFER

STRIPPING

3.2.1 For jacketed duplex cable: Split the two cables

3.2.2 Insert the fiber end through the small end of the appropriate

Refer to Page 1 or appropriate PANDUIT laminated tem-

for stripping dimensions.

plate

approximately 6" (152mm) or as needed depending on
desired jacket stripping length.

boot for your specific fiber type. Slide the boot back out of
the way.

Note: For plug termination only, maintain proper
orientation of the fibers by using the ‘A’ and ‘B’ marks
on the plug insert and boot to your specific wiring
convention.

3.0mm Crimp
Sleeve

2.0mm/1.6mm
Crimp Sleeve

JACK

3.2.2

3.2.3

3.0mm Crimp Sleeve

2.0mm/1.6mm Crimp Sleeve

3.2.4

3.2.3 For jacketed cable only: To reduce wear on the jacket
stripper blades, do not slide the blades along the aramid
yarn. Instead, use the tool to cut through the jacket, then
pull off the jacket by hand. For 3.0mm jacketed fiber, use
the third hole (marked “1.3MM” or #16AWG) from the tip of
the jacket stripper. For 2.0mm/1.6mm jacketed fiber, use
the first hole (marked “.80MM” or #20AWG) from the tip of
the jacket stripper. Using the cable jacket stripper, strip the
required length of the jacket off of each fiber according to
the stripping dimensions.

3.2.4 For jacketed cable only: Insert each fiber through the
smaller end of the crimp sleeve. Use the crimp sleeve to
fold the aramid yarn back over the jacket, holding it out of
the way.

3.2.5 For jacketed cable only: Use the marking pen and
stripping dimensions provided to mark each buffer from the
end of the jacket.

3.2.6 For 900µm buffered fiber only: Using the marking pen,
place a mark 1" (25mm) from the end of the buffer.

3.2.7 With the buffer stripper provided, strip the buffer.

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Page 3 of 8

1/4" (6.4mm) MAX

Adhesive Bead

Drop of Primer

INSTALLATION INSTRUCTIONS PN256D

3.2.8 Repeat for the second fiber.

BUFFER STRIPPER GUIDELINES:

• PANDUIT recommends that you remove no more than 1/4"
(6.4mm) of buffer at a time to avoid breaking the fiber. Refer to
cable manufacturer’s buffer stripping guidelines for specific
recommendations.

• Hold the buffer stripper such that the arrow on the tool points in
the direction of buffer removal.

• Noting the location of the tool’s blades, position the fiber in the
tool’s V-notches. Squeeze the handles firmly and pull tool in the

3.2.8

direction of the arrow on the tool.

• Clean the buffer stripper blades after each strip by holding the
handles open, pulling the casings back away from the blades,
and letting them snap back against the blades.

3.3 FERRULE ATTACHMENT

Instructions intended for anaerobic adhesive only.

3.3.1 Clean bare fiber using an alcohol (90% minimum
concentration) soaked lint-free wipe. The fibers should be
free of all coating and residue after cleaning. Insert fiber

3.3.1

3.3.4

3.3.5

3.3.6

3.3.2 Apply primer onto the bare fiber with the brush from the

3.3.3 Insert the needle of the adhesive filled syringe into the

3.3.4 While pressing the needle firmly against the rear of the

3.3.5 Carefully but quickly insert the bare fiber through the

3.3.6 To speed hardening of the adhesive, apply a small drop of

3.3.7 Repeat for the second fiber.

3.3.8 Allow one minute for the adhesive to harden before

without adhesive or primer into ferrule assembly to ensure
a proper fit and to remove any debris which may be
blocking the ferrule hole. Remove fiber, clean fiber again,
and proceed to the next step.

primer bottle, and onto the first 1/8" (3.2 mm) of the buffer
next to the exposed fiber. Set fiber aside such that it will
not collect debris while completing the next three steps.

ferrule assembly until the needle bottoms against the rear
of the ferrule.

ferrule, gently squeeze the syringe plunger until you see a
small bead of adhesive form on the front tip of the ferrule.
Pull syringe out of the ferrule assembly.

Note: If a heat cured epoxy is used rather than the
anaerobic adhesive, do not expose the connector to
temperatures in excess of 75°C (167°F).

ferrule in a smooth forward motion. The fiber is fully
inserted when the buffer bottoms against the rear of the
ferrule. The adhesive will begin to set within seconds.

Note: If adhesive oozes out the back of the assembly,
you have injected too much. It is critical to the
function of the connector that you wipe away all
excess adhesive.

primer to the adhesive bead on the ferrule tip using the
primer filled syringe. Do not allow the primer to come in
contact with the plastic housing of the ferrule assembly.
Absorb any primer and unhardened adhesive from the
ferrule tip by gently dabbing it with the corner of a lint-free
wipe. Be careful not to break the fiber.

cleaving.

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Page 4 of 8

INSTALLATION INSTRUCTIONS PN256D

JACK

PLUG

JACK

PLUG

JACK

PLUG

FIRST
CRIMP

.151" HEX
DIE

FLANGE

FLANGE

FLARE ARAMID

YARN EVENLY

3.4.5

SECOND
CRIMP

.128" HEX

DIE

GAP

3.4.1

3.4.2

3.4.3

3.4.5

3.4 CRIMPING
For jacketed cable only.

Note: Be careful not to break the bare fibers

protruding from the ferrules during this step.

3.4.1 Slide the crimp sleeve back, freeing the aramid
yarn. The cable jacket should nearly touch the rear
of the backbone of the ferrule assembly.

Note: Do not press the cable jacket forward to
touch the rear of the backbone. There should be
a gap between the jacket and backbone.

3.4.2 With the appropriate strength member (aramid
yarn) cutters, cut the aramid yarn even with the
flange.

3.4.3 Flare the aramid yarn evenly around the perimeter
of the grooved area of the backbone of the ferrule
assembly. For 2.0mm/1.6mm jacketed cable, use
tweezers for best results.

3.4.4 Slide the crimp sleeve over the backbone, trapping
the aramid yarn between the crimp sleeve and the
grooved area of the backbone.

3.4.5 For 3.0mm jacketed cable: Make sure the crimp
sleeve is seated against the flange of the backbone,
crimp the large end of the crimp sleeve using a
.151" hex of the FCRP5 Universal Crimp Tool.
Using the .128" hex of the crimp tool, crimp the
small end of the crimp sleeve over the cable jacket.

3.4.6 For 2.0mm/1.6mm jacketed cable: Align the front
edge of the crimp sleeve with the front recessed
edge of the die pocket of the FLPT crimp tool.
Note: The front recessed edge of the crimp die
pocket is the side with the ribs.

Make sure the crimp sleeve is seated against the
backbone and crimp the crimp sleeve.

3.4.7 Repeat for the second ferrule assembly.

Recessed

Edge

Crimp die

pocket

2. PULL
FIBER

1. SCORE

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3.4.6

3.5 CLEAVING

3.5.1 Using a cleave tool, gently make one small score
mark across the bare fiber just above the endface of
the ferrule. Pull the fiber away from the ferrule and
discard it on one of the sticky tabs provided. A
short stub of fiber protruding from the tip of the
ferrule should be visible when viewed through the
FLOUPEX10 Eye Loupe.

3.5.2 Repeat for the second ferrule assembly.

3.5.1

Page 5 of 8

INSTALLATION INSTRUCTIONS PN256D

5µm

4.1

UNIVERSAL POLISHING PUCK

4.2

DRY

5µm

4.3

WET

1µm Diamond

4.5

Ferrule Tip After 1µm Diamond Polish

A B C D

A= Ideal. No blemishes on core or cladding.

B= Good. Cladding is chipped, but core is

not.

C= Poor. Scratch across core. Try

repolishing or else reterminate.

D= Unacceptable. Fiber has shattered.

Reterminate.

4.6

4. POLISHING

Carefully read this entire section before proceeding.

POLISHING GUIDELINES

• Keep the puck flat against the polishing film.

• Figure eights should be about 3" tall and 1.5" wide.

• Always polish on a clean area of the 5µm (micron) polishing film, with
figure eights traversing the film as shown in Figure 4.3.

• One sheet of 5µm (micron) polishing film will polish 2-4 ferrules.

• One sheet of 1µm diamond polishing film will polish 100 ferrules.

• One sheet of .05µm lapping film will polish approx. 18-20 ferrules.

• Clean the polishing puck and pad with a clean wipe after each step.

• DO NOT OVERPOLISH.

Repeat each step for each ferrule assembly.

4.1 Hold a piece of the 5µm (micron) polishing film in the air and
gently rub the fiber stub against it in a circular motion until the
height of the fiber stub is equal to or slightly less than its diameter.
This is indicated when the white trace on the film is no longer
obvious. Make sure fingers are at the edge of the film, not directly
behind fiber.

Note: Do not use the same 5µm (micron) film used in this
step for any of the following polishing steps.

4.2 Thoroughly clean polishing puck, puck hole, and pad with alcohol
and cleaning swab. Place a separate sheet of 5µm (micron)
polishing film on the soft side of the polishing pad. Set the
polishing puck on the polishing film.

4.3 Carefully insert the ferrule assembly into the puck hole until the
ferrule/fiber contacts the polishing film. While keeping the puck
flat against the film, apply very light pressure on the ferrule
assembly making figure eight motions with the puck. Gradually
increase pressure until the fiber stub no longer leaves a white
trace on the film (about 10 figure eights). At this point, the
adhesive will be gone.

4.4 Remove 5µm polishing film from polishing pad. Clean the ferrule
tip, pad, and bottom of the puck with an alcohol soaked wipe.

4.5 Place a sheet of 1µm diamond polishing film onto the polishing
pad. Place several drops of distilled water on the diamond film.
Polish the fiber endface with the puck using medium pressure for
approximately 10 figure eights.

4.6 Clean the ferrule tip and puck with an alcohol soaked lint-free
wipe. Clean the 1µm diamond film using an alcohol soaked wipe
after every 5 connectors.

4.7 Inspect the fiber endface using a microscope. If scratches remain,
repeat steps 4.5 and 4.6.

WARNING: NEVER LOOK INTO THE END OF A FIBER WHICH
MAY HAVE A LASER COUPLED INTO IT.

Note: Each time a mating takes place, clean the ferrule
endface thoroughly with an alcohol soaked lint-free wipe.

4.8 For singlemode only: Place a sheet of the .05µm lapping film on
the pad. Apply several drops of distilled water onto the center of
the film.

4.9 For singlemode only: Place the puck in the center of the distilled
water on the film and pad. Keeping the puck flat against the film
and pad, apply even pressure for 4 figure eights.

4.10 For singlemode only: Wipe the ferrule, pad, and puck with a dry
wipe.

4.11 For singlemode only: Clean the ferrule with a distilled water
soaked wipe. Do not use alcohol to clean after using the

.05µm lapping film.

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Page 6 of 8

INSTALLATION INSTRUCTIONS PN256D

5. CURING HEAT SHRINK TUBING

For 2.0mm/1.6mm jacketed cable only.

5.1 Turn the heat adjustment knob of the heat shrink curing
tool so the white line is centered in the notch.

5.2 Turn heat shrink curing tool “on”. (The temperature of the
hot air stream at the nozzle should be 220°F - 240°F)

5.4

5.5

5.3 Hold onto the connector and support the cable.

5.4 Bring the heat shrink tubing into the hot air stream. Hold
the heat shrink tubing about 1/2" away from the nozzle.
Rotate the connector for 20-30 seconds so that the heat
shrink tubing is completely cured onto the jacket.

5.5 Remove the connector from the hot air stream.

5.6 Turn heat shrink curing tool “off”.

Jack Cover

YES

Jacketed Cable

SLIDE
FORWARD

NO

Ferrules are located

too far forward

6. JACK ASSEMBLY

6.1 Turn the snap-on jack cover over in your hand so that the ‘A’
and ‘B’ marks inside the cover are facing you and are
upright. Then, place each ferrule assembly in the jack
cover. Maintain proper orientation of the fiber runs by using
the ‘A’ and ‘B’ marks to your specific wiring convention.

6.2 Slide the boot up to the cover until the holes of the boot lock

6.1

6.3

6.3 Next, position snap-on jack cover behind the jack housing.

on to the tabs of the cover.

The ferrules should start to enter the split sleeves which are
held within the jack housing. Slide cover forward, aligning
the rails in the cover and jack housing.

Note: If you are using O
verify that plug mates with intended jack.

NO

Ferrules are located

too far backward

FJJGM5CWBL
FJJGM5CXRD
FJJGM5CYOR
FJJGM5CZYL

YES

Buffered Cable

6.1

PTI-JACK Keyed connectors,

FJEPGM5CWBL
FJEPGM5CXRD
FJEPGM5CYOR
FJEPGM5CZYL

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Page 7 of 8

INSTALLATION INSTRUCTIONS PN256D

With screwdriver,
push each side of
snap-on cover UP
and BACK
simultaneously

Lift UP & Slide
BACK

For Duplex Cable, one of
these two fibers will be
lettered.

A

B

Insert

Screwdriver

B

A

A RUNS TO B
B RUNS TO A

6.5

7.1

6.4 Finally, push the snap-on cover forward until it clicks
into place.

6.5 Should it be necessary to remove the ferrules, the
snap-on cover can be removed by simultaneously lifting
and sliding with a small screwdriver.

6.6 To clean the jack ferrules once they are enclosed in the
jack housing, use the lint-free swabs. Gently insert a
swab through the split sleeve to wipe the jack ferrule
endface. Swabs can be moistened with alcohol.

6.7 The jack dust cover should be inserted to keep the jack
housing clean when the jack is not in use.

7. PLUG ASSEMBLY

7.1 Place the insert onto the cables between the boot and
terminated ferrule assemblies by sliding the cables into
the slots on the side of the insert. Be careful not to
pinch the cable. The “A” and “B” on the insert should
line up with the “A” and “B” on the boot.

7.2 Slide the insert inside the boot until the tabs on the
insert lock into the holes on the boot.

7.3 Push the ferrule assemblies into the housing. Make
sure the cables are not crossed inside the assembly.
The latch on the housing should be on the same side as
the hood on the boot.

Note: If you are using O
verify that plug mates with intended jack.

PTI-JACK Keyed connectors,

Boot

Boot Hood

For Instructions in Local Languages

and Technical Support:

www.panduit.com/resources/install_maintain.asp

Ferrule

Housing

7.2

7.3

Housing
Latch

7.4

FJJGM5CWBL
FJJGM5CXRD
FJJGM5CYOR
FJJGM5CZYL

FJEPGM5CWBL
FJEPGM5CXRD
FJEPGM5CYOR
FJEPGM5CZYL

7.4 With the ferrule assemblies inside the housing, push
the boot/insert assembly into the housing until it snaps
in place.

7.5 Immediately after assembly, place the black dust caps
over the ferrule ends.

Dust Caps

7.5

E-mail:

[e-mail]

Fax:

www.panduit.com

Page 8 of 8

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