Connectorisation

Cable Jointing -
Importance
 To make a continuous links for long distance networks

 Cable can not be made as per network length

 Cable length standardisation (2 to 6 Km)

 For Branching and Looping of cable
 For Network Transfer (one carrier to another)
 For Signal Splitting and Multiplexing in Optical Networking
 For Routing and distribution of cables
 For Signal launch, detect and regeneration

Cable Jointing and Termination forms the

backbone of Networking without which network
is not possible
Cable Jointing - Problems

Every joint in the network induce signal loss which limit

signal transmission distance.

Network reliability more dependent on joints rather then

cable and transmission equipment.

Additional cost for jointing components - Planning, purchase,

storage, installation and maintenance (including spares and
tools).

Training and skilled manpower maintenance.

Cable (Fiber) Jointing - Methods
 Splicing - Mechanical Splice & Fusion splice
 Splicing is used to connect two fibers in a permanent joint.

 Both capable of splice losses in the range of 0.15 to 0.1 dB .

 It is most preferred way in making a cable to cable link in trunk

routes and cable termination to a exchange boxes.

Connector Termination
 Used to connect two fibers in a temporary flexible joint which
can be jumped /interchanged with other cables in the network

 Capable of insertion losses in the range of 0.5 to 0.1 dB.

 It is most preferred way in Distribution and networking of cables

in exchanges and user side
Mechanical
Splicing
 Ends of two fibers are stripped, cleaned, carefully butted
together and aligned using a mechanical assembly having
precision V groove.

 Gel is used at the point of contact to reduce light reflection and

keep the splice loss at a minimum.

 Ends of the fiber are held together by friction or compression

 Splice assembly features a locking mechanism so that the

fibers remained aligned.

 Fiber can be removed anytime and same mechanical splice can

be used again for same or other fiber jointing.

 Similar concept is used for loss / continuity testing of fiber by

OTDR / Power meter where number of fibers needs splicing.
 Fusion
Splicing
 Ends of two fibers are stripped, cleaned, carefully brought
together and fused together after melting using an electric arc.

 Gel is not required at the point of contact as arc produces

continuous fiber without a break

 Require special expensive splicing equipment but can be

performed very quickly, so cost becomes reasonable for quantity.

 Fusion splices being fragile, a heat shrink sleeve with metal

rod is placed over it to protect them.

 This is the method by which smaller lengths (2 – 6 Km) of cable

are joined together to make long route varying from few to
hundreds of Km.

 Fiber can’t be removed without cutting and same splice sleeve

can not be used again for fiber jointing.
How is Splicing
done??
Connectorisati
on
➘ Optical connectors are the means by which fiber optic cable is
usually connected to peripheral equipment and to other fibers.

➘ Similar to their electrical counterparts in function and outward

appearance but are actually high precision devices.

➘ Connectors are used to couple two optical fibers (cables)

together or to connect fibers to transmitters or receivers.
Connectors are designed to be de-mountable.

➘ FO connector centers the small fiber so that its light gathering

core lies directly over and in line with the light source (or other
fiber) to tolerances of microns.

➘ FO cables are connectorised at both the ends with various

types of FO connectors. These cable assemblies are called patch
cords. If they are cut in two pieces, they become pigtails (with
only one connector end).
Cable Constructions
o Mainly less costly indoor cables are used, which does not
have high strength requirement.

o Basic 250µ fiber will be tight buffered to 900 or 600µ with

Nylon/ PVC and then sheathed with PVC/ LSOH. Aramid Yarns
are put in between them to provide tensile strength.

o Based on fiber count, three variations are popular

oSimplex – Single Fiber cord.

oDuplex – Two fiber cord. Three variations are used.

o(1) Flat – Thin oval outer jacket over two parallel simplex
cords.
o(2) Zip – Outer sheath of two simplex cords joined by a thin
web (or zip) during production. Most popular construction in
duplex.
o(3) Round –Two tight buffered fibers are placed along side
and sheathed with Aramid yarn around them.

o Multi-fiber Cord Cable –

oTwo or more Simplex cord are stranded over CSM or around
 Cable
Constructions
Cable Constructions

Types of Fibers–
SM (9/125/250micron) – Standard
MM (50/125micron) – Standard
MM (62.5/125 micron) – Standard
MM (100/140 micron) – Standard but not used much

Diameter of Cords
Simplex cord can have different diameters.
900µ (0.9mm) Tight buffered fiber –
1.6mm - Buffer diameter will be 600 micron
1.8mm - Buffer diameter will be 600 micron.
2mm -
2.5mm -
3.0mm – Most popular size.

Duplex cord can also have different diameters as above.

 Types of FO Connectors -
Standard
(1) FC (Ferrule Convex) -
•Keyed ferrule with a screw-on threaded barrel fastening system.
•All metal connector gives durable, reliable & low loss
connection.
•Industry standard particularly in SM telecom applications.

(2) SC (Subscriber Connector) -

•Latched type connection makes it impossible for the connector
to pull out without releasing the latch by pressing.
•Popular both for SM and MM fibers.
•Body is generally made of plastic.

(3) ST (Straight Tip) -

•Developed by AT&T, now mostly used in MM applications.
•Twist lock bayonet coupling mechanism ensures quick, highly
repeatable, low loss over all connection
•Anti-rotation tab makes the fiber to always return to the same
rotational position assuring constant, uniform performance.
Types of FO Connectors -
Standard
 Types of FO Connectors - SFF
(1) LC -
•RJ45 style housing allows easy disengagement in dense spaces.
•All plastic connector designed and patented by Lucent.
•Ferrule size, half of standard make double fiber density in shelves.
•Popular both for SM and MM fibers.

(2) MT-RJ -
•RJ45 style housing allows easy disengagement in dense spaces
•Designed and patented by AMP and used mostly for MM fibers.
•Very small duplex connector where body & ferrule both made of
plastic and one ferrule accommodate two fibers (MT style ferrule).
•Thermoset and thermoplastic options in ferrule

(3) MU -
•Designed and patented by NTT, Japan, it really is a shrunken SC.
•Popular both for SM and MM fibers.
•Plastic Body with Latched type connection like SC Connectors.
•Very popular for high density, low profile interconnect applications
and backpanel connector applications.
Types of FO Connectors - Others

SIMPLEX DUPLEX
(1) SMA (1) FDDI

(2) E-2000 (2) ESCON

(3) D4 (3) VOLITON

(4) BICONIC (4) OPTI-JACK

(5) SC-DC
(5) DIN 47256 (LSA)
FO Connectors - SFF v/s Standard

SC-DC, LC, MT-RJ, Current Duplex SC, Volition, and Opti-Jack.

 Connector
Ferrule
♦ Ferrule is the heart of the connector.

♦ It is basically a hollow rod with a through hole of around

125micron diameter at the center for inserting the fiber.

♦ Metal, glass, plastic and ceramic ferrules have been used, but
ceramics seems to be the best choice currently.

♦ Ceramic is the most environmentally stable material, closely

matching the expansion coefficient of glass fibers. It is easy to
bond to fiber with epoxy glues, and its hardness is perfect for a
quick polish of the fiber.

♦ New type of plastic, Liquid Crystal Polymer (LCP), offers

promise for molded ferrules at lower costs. Performance and
durability yet to be proven.
 Adapters &
Sleeves
Adaptors are used to connect two or more cable assemblies to
each other through connector mating.

Mostly made of plastic or metal. Outer shapes vary and could

be rectangular, circular, square or any other flanged type.

Adaptors use one split sleeve per connection for aligning the
ferrules of the two connectors together. Split sleeves have been
made from metal, plastic and ceramic also. Ceramic sleeves gives
less insertion loss as compared to others. For SM applications,
Ceramic sleeves are preferred.

Based on the connectors to be mated on both side adaptors can

be of different types like FC-FC, SC-SC, ST-ST, FC-SC, SC-ST.

Generally simplex or duplex type adapters are used for simplex

and duplex cable assembly respectively, but sometimes adaptor
with more than two ports like Quadruple, 8 port are also used.
Connector Termination
Process
(1) Cutting Cable -
Longer length cable is unwinded from reel, checked physically and cut
into smaller length depending upon the requirement.

(2) Stripping the Cable -

Outer jacket of cable is removed at a specified length using hand-tool.

(3) Cutting Aramid Yarn -

Aramid yarn strength member are cut at specified length by scissors.

(4) Buffer Stripping –

Tight Buffered fiber is fed into the automatic stripping machine, set to
strip specified length. Machine strips off the buffer to leave bare fiber.

(5) Fiber Termination -

Epoxy glue is first prepared by mixing with hardener and then feed into
the ferrule hole by syringes and needles. Then fiber is feed into the
connector ferrule by hand till some bare fiber protrudes out of ferrule.
Connector Termination Process
Connector Termination
Process
(6) Crimping -
Crimping of the Kevlar around the fiber is done to provide retention
strength to the connector.

(7) Curing -
Connector having fiber is put into heat curing oven for a specified time to
cure the epoxy and make it fix the fiber inside the connector.

(8) Cleaving -
Protruded fiber above ferrule is cut by special diamond cutting tool.

(9) Polishing-
Most critical step and done in 3-4 steps. A batch of terminated
connectors are placed in the polishing machine. Machine carries out
polishing of ferrule end face in 3-4 steps by changing the polishing
papers and rubber pads in between the process.

(10) Visual Inspection and Re-polish -

Surface of the ferrule end face is checked through a microscope for
smoothness. If not smooth then, polishing process is performed again.
 Connector
Termination Process
Insertion Loss
 Insertion Loss (IL) denotes the amount of optical power lost at
the interface of two connectors.

 It is a function of the polishing equipment & the technique

used for the polishing. A machine that produces poor end-face
geometry will almost always generate unacceptable levels of loss.

 Current industry standard and TEC specifications for SM is ≤

0.3dB, but commonly expected level is ≤0.2dB. Current industry
standard for MM is ≤0.5dB,

 Poor insertion loss readings are generally a result of fiber

misalignment, separation between connections and/or the
quality of the finish on the end of the connector.

 It is the most important parameter for determining the

performance of the connector and cable assembly.
Back Reflection / Return
Loss
 Back Reflection (BR) is light reflected back through the fiber
toward the source. Light reflection occurs at the contact point of
two connectors when they are mated.
 Quality of the polish on the connector end-face determines if it
will pass/fail the Back Reflection test.
 Return loss (RL) has the same meaning but in opposite
context. Return loss should be high for better performance. BR is
specified such as ≤ -55dB whereas RL is specified such as ≥55dB.
 A high level of Back Reflection will cause transmission
problems for systems that depend on the speed and clarity of a
fiber system, since the desired high data rates can encounter bit
errors if the signal is distorted. A distorted signal will transmit a
poor image or sound.To minimize interference low levels of Back
Reflection must me maintained.
 TEC Specifications for RL is ≥ 45dB (or BR ≤ -45dB). Current
industry standard is -55dB for normal PC polishing.
Factors Affecting IL &
BR
 PC, SPC, UPC / MPC and
APC
These are terms that describe connector end-faces and also relate
to the Back Reflection designation:

PC -
Physical Contact, a description of the contacting spherical end-
face. It generally means a Back Reflection value of -35db.

SPC -
Super PC, designates a PC connector with a BR value of -45db.

UPC -
Ultra PC (also called MPC means Maximum PC), designates a PC
connector with a BR value of -55db.

APC -
Angled PC, indicating the application of an angle (usually 8°)
which deflects Back Reflection to <-65db.
What is Angled
PC??
Geometrical
Parameters
Apex Offset
Apex defines the highest point on the spherical surface at the
end-face of the polished connector. Apex Offset is the distance
between the center of the fiber and this actual high point.

Although Apex Offset describes a physical condition of the

polished fiber, rather than a performance parameter, it is
considered an acceptance criterion in itself.

Excessive Apex Offset leads to a high IL and high BR.

TEC specification is 50mm maximum.

Geometrical
Parameters
Radius of Curvature
•It is the radius generated on a connector’s end face. It is the
measurement of a connector's end-face spherical condition.

•It must be such that when mated with another connector most of
the compression that occurs is applied to the material that
surrounds the fiber (also referred to as ferrule absorption).

•A proper radius, in conjunction with fiber under-cut allows for

correct fiber-to-connector compression.

•TEC specification for radius of curvature is 10-25mm.

 Geometrical
Parameters
Fiber Undercut/Protrusion
 When fiber is recessed inside ferrule, it is known as Undercut.
When it protrudes above the ferrule it is called Protrusion.

 Undercut affects both BR & IL. When connectors are mated,

ferrule material surrounding the fiber compresses, which allows
fibers with an acceptable undercut to make contact. Fibers that do
not make intimate contact have air gap which increases BR & IL .

 Limited fiber undercut is preferred to fiber protrusion. Generally,

undercut is much more common than protrusion as a result of the
polishing process. If excessive protrusion is present, fiber chipping
and/or cracking may take place during the connector mating.

TEC specifications is ±100nm.

 Current standard is ± 50nm.

Factors Affecting Connector
Performance
 Connector Selection

 Cable/Fiber Selection

 Epoxy type

 Fiber Stripping & Cleaving

 Polishing Process
Polisher and the polishing technique used are the most
important factors. Machine needs to attack the connector evenly
from all sides to assure proper end-face geometry. Polishing
technique used will contribute to the finished result and will
control the clarity of the polish and control Fiber Undercut.

 Cleanliness

 Reference cables / Adapters

Cable Assemblies -
SC to SC
Cable Assemblies -
LC to LC
Cable Assemblies - Various
Types