Fiber Fusion Splicing

Ver. E 100607

Prepared & Presented By:FiberNext, LLC

3 Robinson Rd., Suite A3, Bow, NH 03304Ph: 603-226-2400 - www.fibernext.com

“Fiber Optics 301”A training guide for installing

fiber optic cabling systems in accordance withANSI/EIA/TIA & IEEE standards

Fiber Cleaving

Fiber Splicing: CleavingBefore a technician can make a quality fiber optic join with either

mechanical fittings or fusion systems, the fiber must be cleaved tovery tight tolerances. Cleaving is always the first (and most

important) step toward successful splicing.

InnoVF-77

Fusion Splicing: Cleave ToolsThe purpose of fiber cleaving is to cut the glass strand with a

“close to perfect” 90 degree cut for specific processes. Cleaverselection begins with basic, hand held tools that offer cleavequality within 2 to 7 degrees. These are low cost hand toolsdesigned for general purpose cleaving. The can be used for

mechanical splicing and pre-polished connectors.

AFLCT02

FitelS310

T&B92208

Fusion Splicing: Cleave ToolsCleaver selection continues with precision “bench-top” tools that offer

cleave quality of 0.0 to 1.0 degrees. These are more expensive toolsdesigned for critical quality fiber cleaving. Can be used for mechanical

splicing, pre-polished connectors and fusion splicing.

FitelS323

SumitomoFC6SC

AFLCT30

Fusion Splicing: Cleaving Process

Precision cleavers utilize a highquality carbide wheel that is calibratedto engage the fiber by less than 1-2 um

Retention Pads1

Retention Pads2

This process creates a “score” line thatwill be opened to create a quality cleave.



Retention Pads

Anvil

At this point the user depresses an anvil that “activates”the score point and opens the cleave face. Pressure is

controlled by the retention pads to help keep theshear line of the cleave as close to 90 as possible.


As the anvil is depressed, the scored point in the fiberopens under the pressure and moves upward toward the

anvil. During this process, on certain models, the retentionpads release as a final step (after the cleave is complete).

Retention Pads

Anvil

Fusion Splicing: Cleaving Inspection

Examples of Shattered Fibers

Examples of Poorly Cleaved Fibers

Examples of Properly Cleaved Fibers

MechanicalSplicing

Mechanical Splicing

A mechanical splice is a semi-permanent connection between twofibers made with an alignment device and index matching fluid or

adhesive. Back reflection and loss can vary dramatically therefore, it’smost common use is for restoration of multi-mode fiber.

Mechanical Splicing: Splice Process

Utilizing a hand held cleaver, the fiber must be cleaved to length asdetermined by the type of splice being used. Note the graduated

scale. In the example shown, the “hammer” will be depressed ontothe fiber to create a score on the glass.


Gently bend the tongue of the cleaver to open the cleave face.Do not clean the bare fiber after completing this step due to possible

contamination.


Pictured in this example is the typical packaging of a mechanicalsplice. This product is hermetically sealed to eliminate the possibility

of contamination to the index matching gel.


Utilizing the 3M brand “Fiberlok”splice tool, simply insert the spliceinto the holder. Insert cleaned and cleaved fibers into each end of the

splice cavity as illustrated. Be sure that the cleave length isappropriate for the mechanical splice being used.


Once the fiber ends have been fully seated into the splice, lower theactivation head and fully depress the splice mechanism.


Shown here is a close up a fully depressed andactivated mechanical splice.

Section 4:Fusion Splicing

Fusion Splicing: Splice Process

Fusion splicing optical fibers creates an extremely low loss connection,with little to no back reflection. Essentially, this equipment “welds”

optical fiber strands together utilizing an electrical arc current. Thereare a variety of devices available including V-groove machines with SM

losses averaging .05dB and Core-Align machines with SM lossesaveraging .02dB.

Fusion Splicing: V-GrooveEntry level fusion splicing equipment is in a category called V-

groove technology. These machines can produce splice losses thatare typically .05dB for singlemode and .02 (or less) for multimode.

Price range is between $7K and $10K.

AFLFSM17S

CorningX75

DiamondZeus

Fusion Splicing: Portable FTTXThese highly portable machines, designed for the FTTX market, come in

both V-Groove and Core Align models and can produce splice losses thatare typically between .05dB for singlemode and .02dB (or less) for

multimode. Price range is between $9K and $12K.

FitelS177A

AFLFSM11S

SumitomoTomcat

Fusion Splicing: Modern Core AlignToday’s modern splicing equipment is capable of splicing fibers inunder 9 seconds, including cleave estimate, alignment, splice, loss

evaluation and proof test. These splicers are capable of .01dBsinglemode splices in each arc. Prices range from $19K to $24K.

Data is downloadable to a PC for archiving.

FitelS176 AFL

FSM50S

SumitomoType 39

Single FiberSplicing

Fusion Splicing: Device Generalities

Splice Bed Cover /Wind Protector

Fiber View Screen

Battery Pack or ACCharger Module

Fusion Splicing: Device Generalities

Protection Sleeve Heater

Device Controls forPerforming the FusionProcess and Setting UpMenu Operations

X/Y Axis Views /Fiber Profile

Fusion Splicing: Mechanics of a Splicer

Fiber Alignment Guides

Fiber Illumination LED

Motor operated sleds


Magnetic Latches

Primary Fiber Retention Cleat

Retention Pad

Secondary Cleat /Alignment Guide


CCD Cameras for fiber viewing


Electrodes


Fiber is manually inserted into the “splice bed” area. This area is locatedbetween the center (apex) of the electrodes and the outside edge of the

V-groove. Use caution not to contact the endface of the fiber to the V-grooveThen, flip down the retention cleats. Be sure to install heat shrink first!

A B


A B

Flip down the primary retention cleat firstThen, flip down the alignment guide


A B

Then, flip down the environmental coverand initiate a splice.

Fusion SplicingTechnology

Fusion Splicing: V-groove Fundamentals

CCDLens

Example of PAS Alignment

LED (a)

LED(b)

CCD (a)

CCD(b)

The index of refraction mismatchbetween the cladding and the

core material causes a profile orshadow of the core diameter tobe cast against a CCD camera.

Fusion Splicing: Core-align Fundamentals

CCDLens

Fusion Splicing: Core-align Fundamentals

Fusion Splicing: Splice Quality

Bubbled Splice, Endface Debris

Lossy Splice (Shaded), Incorrect ARC Power

Core Mismatch, Poor Alignment

Fusion Splicing: Splice Quality

Normal Splices, Correct ARC Power

After splicing is complete, remove the spliced fibers fromThe splice bed

And guide the splice protection sleeve up to the splice point.

Cure the heat shrink tube in the oven for the proper time.Notice adhesive sealing the fusion tube.


Efficient fiber splicing is a direct byproduct of proper area setupwhich includes sufficient space, lighting, and well planned fiber

management practices.

Splicing Process Summary

Splicing Process Examples

UniprisePanel


PLP StainlessEnclosure


Corning Butt StyleEnclosure


Century Fiber OpticsFTS350 S/TM Panels


Raychem Butt StyleEnclosure

Fiber Fusion Splicing

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