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Contents 1 X75 Fusion Splicer, Overview 2 Preparatiss 3 Parameters and Programs 4 Splicing 5 Ending of Operation 6 Troubleshooting and Maintenance 7 Supplements / Changes / Notices Index Appendix A: Accessories...
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All obligations on the part of Corning arise exclusively from the relevant sales contract which also contains the only valid and comprehensive warranty conditions. The...
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D-81359 Munich, Germany Tel. +49-89-72222068 Fax +49-89-72248324 If you have technical questions or questions regarding our training program, please con- tact: Corning Cable Systems GmbH & Co. KG Abteilung PLM TS Profilstraße 4 D-58093 Hagen, Germany Tel. +49-2331-3571145, 3571146, 3571155 or 3571402...
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Definitions for Terminology used in Warnings The following definitions apply to the terminology used in the warnings: Danger In these operating instructions, as well as in warnings on the products themselves, this term means that death, serious injury or substantial property damage will result if the rele- vant precautions are not observed.
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DANGER When electrical equipment is operated, certain parts of such equipment are bound to reach hazardous voltage levels. If the appropriate warnings are not observed, serious injury or property damage may occur. Only suitably qualified personnel should work on this equipment or in its vicinity.
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Password Request Activating the The fusion splicer must be opened in order to activate or deactivate the password request. Password Request DANGER The fusion splicer or electrically operated accessories may only be opened by suitably qualified personnel. Switch the fusion splicer off and disconnect it from the power supply (power supply plug and 12V battery supply)! Two phillips head screws are located on the left of the housing and two on the right.
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password is known. To redefine the password, select the parameter “Password” and pro- ceed according to the following flow chart. Only if password already exists Enter password? Change password? Enter new password Confirm password Password wrong Operator menu X75 Fusion Splicer Operating Instructions Password Request revision: 06/01...
General The X75 Fusion Splicer is suitable for producing reliable, low-loss splices of optical fibers. It can be used for all common single-mode and multimode fibers with a cladding diameter of 125 µ m and coating diameters of 250 to 900 µ m. Due to its L-PAS (Lens-Profile Alignment System) video image evaluation with two CCD cameras and an optic system, the X75 Fusion Splicer enables the fiber alignment, end face quality inspection, fiber offset detection, contamination detection and splice loss esti-...
Splicing Unit 1 Electrode Flap 2 Electrodes 3 Fiber guides (silicon v-grooves) 4 Holder flaps 5 Clamping flaps L-PAS Video The X75 Fusion Splicer is equipped with the L-PAS Video Image Evaluation System. Image Evalua- The position and quality of the fiber ends are evaluated by a video image evaluation sys- tion System tem which uses two cameras and a magnifying optic.
Monitor The LCD monitor shows the fibers from two different perspectives (along the X and Y axes). Keyboard The keyboard consists of 6 keys with the following functions: Enter key: The displayed operation is performed or the previously entered value is acknowledged.
Terminals for Additional 1 RS 232c Serial Interface Functions 2 Video Output Serial Interface Splicing parameters or the contents of the splice data memory can be read out to a printer or a computer via the RS 232c serial interface. The serial interface at the fusion splicer is configured for use with the XON/OFF protocol.
Technical Data cladding diameter: 125 µ m Fiber Requirements: coating diameters: 250 to 900 µ m Fiber Display: 140 mm (5.5“) LCD monitor Magnification: approximately 100 times Fiber Alignment: fully automatic, automatic and manual (Z axis) Typical splice loss for identical stand- <...
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2 Preparatiss Contents Page Putting the Fusion Splicer into Operation ...................... 2-2 Supply Power ............................2-2 Switching the Fusion Splicer On ......................2-2 Preparing the Fiber Ends ..........................2-4 Stripping the Coating..........................2-4 Cleaning the Fiber ..........................2-5 Cleaving the Fiber ..........................2-5 Inserting the Fiber ............................
Putting the Fusion Splicer into Operation DANGER In order to assure safe operation, the fusion splicer must be placed into operation and properly operated by qualified personnel under consideration of the warnings included in these operating instructions. Non-observance may lead to death, severe bodily injury or substantial property damage.
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The positioning slides are then automatically advanced to the insertion position. In battery mode, the charge level of the battery is displayed. If the charge level is too low to operate the unit, the “battery discharged” message appears at the monitor and the unit is switched off automatically.
Preparing the Fiber Ends NOTE Minimum splice loss can only be achieved if the fiber ends are prepared with great care. Preparation of the fiber ends includes the following steps: • Stripping the coating • Cleaning the fibers • Cleaving the fibers with a suitable cleaver •...
Cleaning the Clean the fiber ends over a length of approx. 100 mm (coating and uncoated fiber) with a Fiber lint-free paper towel dampened with alcohol. DANGER Risk of fire exists if solvents are spilled. Cleaving the Use a suitable cleaver, e.g. cleaver S46999-M9-A8, to cleave the fiber. Select the correct fiber guides for the cleaver (Fiber Optic Cleaver A8: Universal fiber guide for 250 to 900 µm Fiber coating diameter).
Close the flap (4) at the cleaver and press it down slowly and carefully. Open the flap before removing the cleaved fiber in order to avoid damaging the fiber end face. NOTE If you press the flap down too quickly, you will obtain a poor quality fiber end face and the diamond blade may be damaged.
1 Electrode Flap 2 Holder Flap 3 Clamping Flaps 4 Fiber 250 µ m Coating Other Coating Please note that the coating diameter must be adapted in the parameter menu, see Diameters »Significance of the Parameters« on page 3-13. Adjusting Monitor Brightness NOTE Monitor brightness can be only changed in the main menu.
Checking the Fiber End Faces NOTE Good splicing results can only be obtained with good end face quality. After inserting the fiber in the fusion splicer and before ignition of the arc, the fiber ends can be observed on the monitor. If more time is needed select the menu item “Search fibers?”...
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3 Parameters and Programs Contents Page ““Parameter Menu“............................3-3 General..............................3-3 Open / Exit.............................. 3-4 “Options / Language“ Menu ........................... 3-5 Common Parameters ..........................3-5 Language ............................... 3-7 Heat-shrink Oven ........................... 3-8 Service Data............................3-9 Configuration ............................3-10 “Program Selection“ Menu ........................... 3-11 Program Descriptions...........................
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Cleaving Quality ........................... 3-17 Optimizing Parameters for Single-mode Fibers ................... 3-18 Required Accessories........................... 3-18 General Rules............................3-19 Fusion Current and Fusion Time ......................3-19 Ambient Temperature........................... 3-19 Procedure ............................. 3-19 Optimizing Parameters for Multimode Fibers....................3-21 X75 Fusion Splicer Operating Instructions Parameters and Programs revision: 06/01...
“Parameter Menu“ General Parameters can be matched to ambient conditions and to different types of fiber in the parameter menu. The parameters menu is subdivided into “Options / Languages”, “Pro- gram selection” and “Data output”. Operating Instructions X75 Fusion Splicer revision: 06/01 Parameters and Programs...
Open / Exit The “parameter menu“ is opened by pressing the key with closed electrode flap. The display returns to the main menu when the key is activated from within the parameter menu (see diagram). X75 Fusion Splicer Operating Instructions Parameters and Programs revision: 06/01...
“Options / Language“ Menu Parameters selected in the “Options / Language“ menu effect all programs. NOTE Parameters in the “Options / Language“ menu can only be changed or reset if password query has been deactivated, or if the correct password is entered. Common Open menu: –›...
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Parameter Significance Values (default) off/autom . /manual/ Splice Memory Stores up to 250 splice loss values. Stored values can be displayed at the monitor (see delete »Displaying the Splice Memory at the Moni- tor« on page 4-9) or printed via the serial interface (see »Data Output Menu«...
Parameter Significance Values (default) Altitude above In order to assure uniform, high-quality 0 to 4000 m, 550 m Sea Level splices, the selected altitude must roughly correspond to actual altitude. Alarm Limit As soon as the estimated loss value is OFF / 0.05 to 0.2 dB equal to or exceeds the selected alarm limit, a brief warning signal sounds.
Heat-shrink Open menu: –› parameter menu –› options / languages –› heat-shrink oven. Oven Parameter Significance Values (default) Heat-shrink If you intend to control the heat-shrink oven internal / external Parameters from the fusion splicer, select “internal”. If “external” is selected, heat-shrinking is con- trolled by the parameters selected at the heat-shrink oven.
Service Data Open menu: –› parameter menu –› options / languages –› service data. Parameter Significance Values (default) Operating Hours Total number of operating hours Splices Total number of splices Cleaning Cycle Number of splices performed before opera- 50 to 700 in steps of 10, tor is reminded to clean the electrodes Reset Counter: Reset “Cleaning cycle”...
Configuration Open menu: –› parameters menu –› options / languages –› device configuration Parameter Significance Values (default) Electrode Automatic electrode cleaning with closed on / off Cleaning electrode flap after the splicer has been switched on. Status Report Current settings are displayed after the on / off splicer is switched on.
“Program Selection“ Menu Program Descriptions Program Applications Fixed Programs Standard Single- 1 For all standard, single-mode fibers (matched cladding or mode (SM) depressed cladding). 2 For gradient index fibers with a core diameter of 50 µ m. Position- Multimode 50 µ m (MM50) ing and loss estimation are performed by video image evaluation.
Program Applications User Programs 1…10 All available programs, i.e. preset programs, special programs and already existing user programs, can be used as the basis for the creation of a new user program. The parameters from the selected program are copied into the new user program.
The user program has now been created, and is identical to the program which was copied. The parameters are now displayed and can be changed as desired. NOTE At first, use the preset parameters for fusion current and fusion time (for pre-fusion and fusion) from the copied preset or the special program.
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Parameter Significance Values Pre-fusion Temperature of the arc during pre-fusion 10.0 to 20.0 mA Current Pre-fusion Time Time between ignition of arc and start of 0.0 to 10.0 s feeding operation Fusion Current Temperature of the arc during primary 10.0 to 20.0 mA fusion Fusion Time Ignition time during primary fusion...
Editing and Open the parameter menu with the key. Renaming User Select the user program to be edited (see »Creating User Programs« on page 3-12) Programs and acknowledge. Parameters can now be changed: : change the value of the displayed parameter. : acknowledge and save the changed value.
Data Output Menu Open menu –› parameters menu –› data output NOTE Parameters in the data output menu can only be changed or reset if password query has been deactivated, or if the correct password is entered. Parameter / Significance Setting Range Function Baud Rate...
Special Program for TrueWave Fiber Cleaving Quality TrueWave fiber reacts with great sensitivity to worn or damaged cleavers. If the cleaver is not in flawless condition, splintering occurs in the coating. As a rule, this damage is not allways visible at the display and is thus not recognized by the splicer.
Optimizing Parameters for Single-mode Fibers The pre-selected parameters for the preset and special programs are suitable for all com- mon fiber types. Nevertheless, an optimization of the parameters mays become neces- sary, for example: • If special fiber types are used which demonstrate unusual characteristics or excessive core eccentricity.
General Rules The following rules apply to practically all single-mode fibers. Deviations from these rules are only necessary for a few special fibers, for example if bubbles are formed. • The standard parameters are always used for Z gap, auto-feed and pre-fusion time. •...
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Press key and initiate with “Refusion“. Measure the loss again. The parameters are set correctly when the loss worsens slightly relative to the first meas- urement ( by 0.01 to 0.03 dB ). If the loss remains unchanged, the fusion current or the time selected was too low.
Optimizing Parameters for Multimode Fibers NOTE The parameters can only be optimized if the electrodes are in flawless condition. In the case of multimode fibers, the optimization of parameters with respect to attenuation is largely non-critical. As opposed to single-mode fibers, it can be assumed that splice attenuation is always good, if the splice demonstrates good visual characteristics.
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Symptom Possible Cause Remedy Constriction In the center of the monitor the Reduce pre-fusion current in steps of fiber appears thinner than at 0.5 mA. the edges. X75 Fusion Splicer 3-22 Operating Instructions Parameters and Programs revision: 06/01...
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4 Splicing Contents Page General ................................4-3 Selecting the Splicing Program........................4-3 The Splicing Sequence ..........................4-4 Cleaning ..............................4-5 Alignment ............................... 4-5 Fusion..............................4-6 Visual Inspection ............................ 4-6 Automatic Splice Loss Estimation ......................4-6 Re-Fusing............................... 4-7 Tensile Test............................4-7 Removing the Splice ..........................
General NOTE Make sure that all required splicing preparations have been performed correctly and com- pletely. If not, perform the necessary preparations to the splicer and the fiber (see chapters 2 and 3). Each splicing operation includes: • Arc cleaning of fiber ends. •...
The Splicing Sequence After the fibers have been prepared and inserted (see chapter 2 “Preparations”), the dis- play at your monitor will be similar to the diagram below. Press the key in order to start the splicing sequence. The entire splicing sequence is menu-driven.
Manual fiber For special purposes you can position the optical fibers manually using keys positioning Cleaning The fiber ends are cleaned with an electric arc. Alignment After cleaning an evaluation of fiber endface quality and fiber offset is carried out during alignment.
Fusion Pre-fusion and fusion of the fibers is performed after alignment. Visual The fiber cladding has a smooth surface if the splice is good. The cores, however, are not Inspection visible at the monitor. The bright line in the middle of the fiber is a result of the lens effect of the fiber itself.
• The fusion parameters have been set correctly. • Core eccentricity relative to the outside contour must be minimal. Chapter 6 provides examples of poor splices, possible causes and appropriate remedies. Re-Fusing Re-fusing can be used to optimize parameters and to enhance splicing results, if the selected fusion time was too short, or if fusion current was too low.
Removing the For removing the spliced fibers all flaps must be opened. The completed splice should be Splice removed immediately because 5 sec after the elctrode flap has been opened the slides advance to the insertion position. After the message “fully automatic?” has appeared, the fusion splicer is once again ready for operation.
Splice Memory Activating the The splice memory can be activated in the parameters menu, see »Configuration« on Splice Memory page 3-10. Up to 250 values can be stored and transmitted via the RS 232c serial inter- face. Displaying the If you scroll through the entire splicing sequence by repeatedly pressing the key, the Splice Memory contents of the splice memory are displayed at the monitor.
5 Ending of Operation Contents Page Switching the Fusion Splicer Off ........................5-2 Stowing Accessories............................5-2 Operating Instructions X75 Fusion Splicer revision: 06/01 Ending of Operation...
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Switching the Fusion Splicer Off Simultaneously press the keys. The slides are automatically advanced to the transport position, after which the fusion splicer switches off. WARNING Always switch the fusion splicer off at the control panel. If you simply remove the power supply plug, the slides are not advanced to the transport position.
6 Troubleshooting and Maintenance Contents Page Basic Procedures............................6-2 List of Error Messages ........................... 6-3 Error Messages during Start-Up......................6-3 General Error Messages during Operation .................... 6-4 Error Messages during Fiber Alignment....................6-5 Error Messages during Splice Loss Estimation..................6-8 Splice Memory Error Messages ......................
Basic Procedures Proceed as following if malfunctions occur or if error messages are displayed at the fusion splicer: • If an error message occurs only once, repeat the questionable operation step. For example, if the “bad endfaces” message appears, prepare the fibers again. •...
List of Error Messages The following pages contain explanations of the error messages displayed at the monitor, together with notes concerning remedies. The error messages are arranged in the order of the operations during which they might occur. Please note that several of the error messages may have various causes and symptoms, and may therefore be listed more than once on the following pages.
Error Message Possible Cause Remedy battery discharged! The power supply is not con- Make sure the power supply, The fusion splicer will nected to the battery and AC battery and fusion splicer are be switched of f . power operation is not possi- connected properly.
Error Message Possible Cause Remedy Z-gap too large or fibers Error Messages Fibers inserted incorrectly or Insert the fibers correctly, see during Fiber not detected wrong cleave length. »Inserting the Fiber« on page Alignment 2-6. The fibers must be centered between the electrodes when the holder flaps are closed.
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Error Message Possible Cause Remedy Fiber not detected Contaminated optical Remove contamination and system. coating residue from the pro- tection glass at the optical sys- tem, see »Cleaning and Replacing the Protection Glass« on page 6-15. Condensation at optical sys- Prevent condensation by plac- tem.
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Error Message Possible Cause Remedy Fiber offset too large Fiber contaminated or inserted Check whether the fiber is Offset.. µm incorrectly. clean and correctly inserted in the v-groove. The fiber offset is clearly If necessary, prepare the fiber visible prior to align- again and insert correctly.
Error Message Possible Cause Remedy Video digitizer error Video system electronics not Switch off the fusion splicer functioning. and switch it back on again. If the error occurs again, the fusion splicer must be repaired at the service center. You can continue working with manual fiber alignment.
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Error Message Possible Cause Remedy Bad splice - fuse again? Pre-fusion parameter values to Reduce pre-fusion current or high. pre-fusion time. Time may not The actual splice loss be set too low. may still be OK under certain circumstances. Contaminated optical system. Check the image at the moni- tor for visible signs of contami- nation with no fibers inserted.
Other Errors The following table describes remedys for errors which are not displayed at the monitor. Symptom Possible Cause Remedy Battery mode not possi- The battery is missing or is not Check that the battery has ble, AC supply mode connected, or the battery fuse been correctly installed and is faulty.
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Symptom Possible Cause Remedy Fibers burn away. Pre-fusion current or pre- Set the parameters (see chap- fusion time too high. ter 3). Try using the fixed pro- gram for the appropriate fiber Auto-feed too small. type. Fusion current considerably too high. Charging indicator lamp No AC power.
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Symptom Possible Cause Remedy Constriction Contaminated electrodes. Clean electrodes. The arc burns irregularly. Fusion current too high. Reduce in steps of 0.2 to 0.3 mA. Increase in steps of 1 µm. Autofeed too small. Pre-fusion time too long. Change only under extraordi- nary circumstances.
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Symptom Possible Cause Remedy Not fused through Fusion current too low. Increase in steps of 0.2 to 0.3 mA. Pre-fusion time too short. Change only under extraordi- nary circumstances. Increase in steps of 0.05 s. Bubble or inclusion Contaminated end faces prior Clean end faces before fusion! to splicing.
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Symptom Possible Cause Remedy Matchheads Electrodes contaminated, arc Clean electrodes. burns irregularly. Fusion current is far too high. Reduce in steps of 0.5 to 1.0 mA. Pre-fusion time is far too long. Set pre-fusion parameters to default values from preset pro- gram.
Maintenance and Care The fusion splicer must be cleaned regularly and kept clean at all times. Clean the following components at the end of each working day or more often if required: • V-grooves • Electrodes • Cleaver WARNING Do not clean the fusion splicer with chemical solvents except alcohol. Cleaning and The protection glass for the optic system is located beneath the fiber guide.
Clean the protection glass (4) with a leather wipe. If the protection glass is excessively contaminated, clean with alcohol or replace. Replace the protection glass with the tweezers. NOTE Be certain to insert the protection glass into the recess provided for this purpose. No contamination may be present beneath the protection glass (on the achromatic lens)! Insert the fiber guide with the tweezers making certain that no contamination is present, and that the guide is properly aligned (the two markings (3) must be adjacent...
Cleaning and The fusion process causes the electrodes to become contaminated. If they become exces- Replacing the sively contaminated, they can no longer function properly. The electrodes function prop- Electrodes erly: • when the arc burns regularly, and • when no hissing sounds are audible during the fusion process. NOTE The electrode tips may not be bent or broken.
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Open the electrode flap. Loosen the bolt about on half turn with the 2.5 mm, special Allen wrench. Pull the electrode out. Push the new electrode into the holder up to the stud. Clamp the electrode with the Allen screw while pushing the electrode against the stud. CAUTION Only use the special wrench included with the tool kit.
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Mechanical If the electrodes still do not function properly after they have been burned clean, clean Cleaning them mechanically. Use only the electrode cleaning tool and the emery cloth included with the tool kit for mechanical cleaning. yy yy íí íí...
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Index CCIR ..............1-6 AC Power Connection ........2-2 Checking the Fiber End Faces ......2-8 Activating the Splice Memory ......4-9 Cleaning ............4-5 Adjusting Monitor Brightness ......2-7 Cleaning the Fiber Guides ......6-17 Alarm Limit ............3-7 Cleaving the Fiber ..........
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Mounting Block ..........A-2 Program Selection ........... 3-11 Mounting Bracket ..........A-3 Protecting the Splice ......... 4-8 Multimode, 50 µm ........... 3-11 Protection Glass ........6-15, A-3 Multimode, 62.5 µm ........3-11 Replacement Interval ........3-9 Number of Splices ..........3-9 Replacing the Battery Fuse ......
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Switching the Splicer Off ........5-2 Switching the Splicer On ........2-2 Z-gap ............... 3-13 Technical Data ..........1-7 Temperature ............ 3-19 Tensile Test ............1-7 Terminals for Additional Functions ....1-6 Titanium-Coated Single-mode Fiber ....3-11 Transport Case ..........A-3 TrueWave Fiber ........
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Appendix A: Accessories In order to assure that documentation for subsequently purchased accessories for your X75 Fusion Splicer is always readily available, we recommend that you attach such documentation at the end of this chapter. Contents Page Order Numbers .............................A-2 Accessories ............................A-2 Spare Parts ............................A-3 Consumables / Splice Organization .......................A-4...
Order Numbers Accessories Designation Order Number Description Attachment Power Supply S46999-M7-S630 For 90 to 260 V AC, for mounting onto the bottom of the fusion splicer, battery 2.3 Ah can be slid Battery 2.3 Ah S46999-M7-S601 To be slid into attachment power supply, can be changed without tools.
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Accessories Designation Order Number Description Fusion Splicer Case 2 S46999-M7-V13 For adaption of fusion splicer especially when powered by attachment power supply and vari- ous accessories, without work platform. Fusion Splicer Case 5 S46999-M7-S875 Incl.100 VA power supply in the workstation you can integrated the fusion spicer and optional accessories.
Zero Modem Cable The zero modem cable is required in order to print out splice data or splicing parameters from the X75 Fusion Splicer (see »Data Output Menu« of page 3-16). Cable Wiring If the original Z modem cable is not used, the cable must be wired as shown below: Splicer Printer or Splicer...
Splice Tray Holder Fix the splice tray holder (pos. 1) with both screws (pos. 3) to mounting bracket (pos. 2). These set fixing with both screws (pos. 4) on the backside from the splicer. X75 Fusion Splicer Operating Instructions Accessories revision: 06/01...
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