By Ben Hamlich, Director of Technical and Product Innovation, trueCABLE RCDD, FOI
In the heart of any strong Fiber optics Networking involves a very important process: preparing a fiber optic cable for termination of a connector or splice. Two types of splices are used in fiber optic cables, one is mechanical and the other is fusion. Whether you are installing a new network, expanding an existing network, or performing maintenance, the ability to properly prepare, splice, or splicing fiber optic cables is an essential skill for any fiber optic technician or network engineer.
Fiber optic splicing is the art and science of joining separate optical fibers to create a continuous optical path. This process requires precision, patience, and a deep understanding of the delicate nature of optical fibers. Before any splicing process, whether mechanical or fusion splicing, can be made, the fiber optic cable must be carefully prepared.
The preparation process is not just about removing the protective coating layers, it involves a series of carefully executed steps, each of which is critical to ensuring high-quality conductivity with minimal loss. From removing the outer jacket to cleaning the bare fibers and achieving perfect bonding, each stage requires attention to detail and the use of specialized tools.
In this guide, we’ll walk you through the complete process of preparing a fiber optic cable for splicing and termination with fiber connectors. We’ll explore the tools needed, safety precautions, and step-by-step procedures for cable connectors, mechanical splice methods, and integration. Whether you’re a seasoned professional looking to hone your skills or a newcomer to the field seeking to understand the basics, this guide will provide you with the knowledge and insights you need to master these critical steps in fiber optic installation.
In this article we will discuss the general preparation steps and tools required for both techniques. These steps will ensure that your fiber optic cable is ready for mechanical splicing or fusion splicing.
It is important to make sure you have the right tools when it comes to preparation. Fiber optic cable Whether for connectors, mechanical joints or fusion joints. There are a variety of tools available and some are better than others. When searching, stick to well-known brands in the fiber industry or look for tools that have received good reviews and feedback from actual users of those tools.
Fiber Optic Stripping Tool Strong Member Cutters (Kevlar Cutters) Lint-Free Wipes Fiber Optic Cleaning Solution Fiber Optic Cleaver Safety Glasses Work Mat Fiber Shard Container
Always handle fiber optic strands with care. Fiber safety Not only is this important, it can be hazardous to health if ingested or gets on the skin when working with fiber cable. Dispose of fiber scraps immediately in designated disposal units to prevent physical injury. Due to the thin strands of glass or plastic that make up these cables, breakage can result in small, almost invisible fragments. It is vital that technicians and workers wear protective gloves when working directly with optical fibers to prevent these fragments from embedding in the skin. Furthermore, it is always advisable to work in well-lit areas to easily identify and manage any broken fibers, ensuring that no fragments are left behind after operations.
When it comes to disposing of fiber optic cable fragments, they cannot be treated as ordinary waste. Because they can cause harm, these fragments should be collected using tape or specialized waste containers designed for fiber optic debris. Once collected, they should be disposed of in clearly marked containers or bags marked “Fiber Optical Waste” to alert others to the potential hazard. Regularly inspecting the work area and ensuring that all fiber optic cable debris is contained and safely disposed of can prevent accidental exposure and injury while ensuring an environmentally responsible disposal process.
Always wear safety glasses to protect your eyes from fiber fragments. Dispose of fiber debris properly in a fiber fragment container. Work in a clean, well-lit area to avoid contamination.
Fiber optic cable preparation steps
In this example, we will show how to prepare a 2mm or 3mm indoor fiber optic cable. However, depending on the type of cable, this can vary whether it is armored or outer, loose tube or tight insulation. This example covers many of the basic steps for indoor tight insulation cable types.
In these examples, we will demonstrate how to remove the aramid fiber sheath from the Kevlar, insulation, and acrylic coating using the three-hole wire stripper tool shown below. The first three steps will use this tool. There are many tools when it comes to stripping fiber optic wire and the methods for doing so. This is just one example.
Step 1: Remove the outer casing.
Use the fiber optic stripper to remove the outer protective layer. Carefully scratch the jacket without damaging the inner insulation layer. Remove the jacket at the scratch point in the jacket to expose the aramid threads and fiber strands. (Note that this may look different on the inside depending on the type of fiber cable used.) Next, cut off the aramid (Kevlar) strength element.
The tool shown below is used to remove the aramid force element. The reason for using a different tool is that the tool requires a very sharp pair of cutters designed to remove this type of force element. After all, this is Kevlar, the same material used in bulletproof vests. It is extremely strong and is designed to protect the cable from damage or breakage. For this reason, a specialized type of cutter has been designed and is required for this step.
Image provided by Amazon.com
Step 2: Remove the insulating layer.
Use the 900 µm stripper tool, which is the second slot on the 3-slot stripper tool. To remove the insulation mechanically, place the fiber in the appropriate sized groove of the stripper tool. Gently pull the tool along the stripper tool to remove the insulation layer. It is best to do this in ¼” increments so as not to break the fiber cable. To remove the insulation chemically, follow the manufacturer’s instructions for the specific product.
Step 3: Remove the acrylic coating.
Use the last slot of the 3-slot fiber stripper. Slowly move the tool across the 250 µm fiber. The acrylic coating will begin to peel off the fiber holder. If necessary, make one or more passes to remove the acrylic coating.
Now that the sheath, 900 µm buffer and acrylic coating have been removed from the bare fiber, the bare fiber is now exposed and ready for the next step in the process.
Step 4: Clean bare fibers.
This step of cleaning the bare fibers is very important to ensure that the fibers are clean and free of dust or lint, before cutting them.
It is important to clean the fibers before slitting, but not after slitting. There is nothing cleaner than the finished surface of freshly slitting fibers.
The fiber should never be cleaned after splicing. If you do, the end face of the fiber will be contaminated. This will increase the work on the fusion connector in the pre-burning stage, shorten the life of the module electrodes, deteriorate the mechanical strength of the connector in the form of non-linear connections with bubbles, and cause excessive signal losses.
If you are splicing, it is very important to clean the fibers before splicing. A common misconception is that you only need to worry about cleaning at the end of the connector assembly process. This is not true. Pre-cleaning the fibers removes any debris left over from the stripping process as well as any other contaminants that may be on the fibers. Once the coating has been stripped from the fibers, they should be cleaned with a damp, lint-free wipe. The liquid used to moisten the lint-free wipe should dry quickly to prevent any liquid from remaining on the fibers. Below you can find the process to ensure you clean the fibers properly.
Use a lint-free cloth dampened with fiber cleaner. Gently clean the exposed fibers to remove any debris or residue. Be careful not to touch the cleaned portion of the fiber. As you clean the fibers, you will hear a soft squeaking sound. This is a good indication that the fibers are clean and that any dirt or debris has been removed.
Image provided by fastlaser.co
Step 5: Slit the fibers.
Fiber optic splicers are precision tools used to create a clean vertical cut at the end of a fiber. This is critical for both mechanical splicing and fusion splicing. Types of splicers include:
Hand Knives Table Knives Precision Angle Knives
Always work in a clean environment to avoid contamination. Practice proper fiber handling techniques to prevent damage. Regularly maintain and inspect any tools you use to ensure they are ready for use and will not cause problems when performing fiber optic work. Below you can find the process to ensure fiber optics are cut correctly
Place the stripped and cleaned fiber into the fiber optic cutter. Make sure to position the fiber correctly according to the cutter instructions. Activate the cutter to create a precise cut perpendicular to the end of the fiber. Select the appropriate groove size for the fiber. Place the fiber into the groove and close the tool. Gently pull the tool along the fiber to remove the insulation layer.
Fiber optic connection
Generally speaking, there are two ways to connect fiber optic cable: (1) Mechanical connection; (2) Fusion connectionThe choice of connection method may depend on the optical fiber performance required for any particular installation. See Fiber Optic Connection: A Study of Factors Affecting Connection Performance
mechanical connection
If you want to make a mechanical connection, you need to place the quick connect fiber optic connectors in a straight line to the fiber. Hold the ends of the fibers in a precisely aligned position that allows light to pass from one fiber to the other. (Typical loss: 0.3 dB)
Fusion connection
In the fusion splicing process, a fusion splicer is used to precisely align the two ends of the fiber. You must move the fusion splicer guard to the fiber, and place the spliced fiber inside the fusion splicer. The two ends of the fiber are then “fused” or “welded” together using some type of thermal or electrical arc. This creates a continuous connection between the fibers, allowing light to be transmitted with very low loss. (Typical loss: 0.1 dB)
conclusion
In conclusion, careful preparation of fiber optic cables is a critical process that supports the success of both mechanical and fusion splicing operations. Each step, from careful stripping of the protective layers to precise slitting of the fibers, requires a deep understanding of the tools and techniques used. Proper handling and cleaning are also essential to ensure low-loss connections and long-term reliability of the fiber network. By adhering to the procedures outlined and maintaining a clean and well-organized workspace, technicians can achieve optimal performance, resulting in robust and efficient fiber optic networks.
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