THORLABS Vytran LFS4100 User manual

LFS4100
Fiber Splicer
User Guide

LFS4100
Table of Contents
Chapter 1 Warning Symbol Definitions .......................................................................................... 1
Chapter 2 Safety ................................................................................................................................ 2
Chapter 3 Description ....................................................................................................................... 3
3.1.Introduction .....................................................................................................................3
3.2.Filament Fusion Splicing................................................................................................3
3.3.Features ...........................................................................................................................3
3.4.LFS4100 System and Accessories ................................................................................4
3.5.System Overview............................................................................................................. 4
3.5.1.External Workstation Connections ........................................................................................ 5
3.5.2.Fiber Holding Blocks ............................................................................................................. 6
3.5.3.Fiber Holding Block Inserts ................................................................................................... 6
3.5.4.Fiber Holder Transfer Inserts (Bottom Inserts for Fibers ≤Ø1047 µm) ................................. 6
3.5.5.Splice Head ........................................................................................................................... 7
3.5.6.Filament Assembly ................................................................................................................ 7
3.5.7.Filaments ............................................................................................................................... 8
3.5.8.Mirror Tower .......................................................................................................................... 9
3.5.9.Imaging System .................................................................................................................... 9
Chapter 4 Set-Up ............................................................................................................................. 10
Chapter 5 Software Interface ......................................................................................................... 12
5.1.Menu Bar ........................................................................................................................12
5.1.1.File ....................................................................................................................................... 12
5.1.2.View ..................................................................................................................................... 13
5.1.3.Configuration ....................................................................................................................... 13
5.1.4.Splice ................................................................................................................................... 18
5.1.5.Reset ................................................................................................................................... 18
5.1.6.Execute ............................................................................................................................... 18
5.1.7.Help ..................................................................................................................................... 18
5.2.Command Bar................................................................................................................19
5.3.Camera Bar ....................................................................................................................19
5.4.Processes Bar ...............................................................................................................19
5.5.Macro Bar.......................................................................................................................19
5.6.Quick-Open File Bar......................................................................................................20
5.7.Main Toolbar ..................................................................................................................20
5.8.Camera Image................................................................................................................21
5.9.Movement Control Bar..................................................................................................22
5.10.Status Bar ......................................................................................................................23
Chapter 6 Fusion Splicing .............................................................................................................. 24
6.1.Filament Fusion.............................................................................................................24
6.2.Multiple-Stage and Multiple File Splicing....................................................................26
6.3.Fiber Alignment .............................................................................................................27

LFS4100
6.3.1.Edge Alignment ................................................................................................................... 27
6.3.2.Core Alignment ................................................................................................................... 27
6.3.3.End-View Alignment (PM Alignment) .................................................................................. 27
6.3.4.Active XY Alignment ............................................................................................................ 28
6.4.Loss Estimation.............................................................................................................28
6.5.Filament Normalization.................................................................................................28
6.6.System Malfunction ......................................................................................................29
6.7.Initialization and Shutdown..........................................................................................29
6.8.Storage and Transportation .........................................................................................29
Chapter 7 Maintenance ................................................................................................................... 30
7.1.Fiber Holding Block Maintenance................................................................................30
7.1.1.Changing the Fiber Holding Block Inserts ........................................................................... 30
7.1.2.Cleaning the Fiber Holding Block Inserts ............................................................................ 30
7.1.3.Adjusting the Transfer Insert Clamp ................................................................................... 30
7.2.Filament Replacement Procedure ...............................................................................31
7.3.Cleaning the Mirror .......................................................................................................33
7.4.Measuring and Setting the Argon Flow Rates............................................................34
7.5.RMA Process .................................................................................................................34
Chapter 8 Fiber Holder Insert Selection Guide ............................................................................ 35
Chapter 9 Specifications ................................................................................................................ 38
9.1.Electrical Power.............................................................................................................38
9.2.Gas Supply.....................................................................................................................38
Chapter 10 Regulatory ...................................................................................................................... 39
Chapter 11 Thorlabs Worldwide Contacts ...................................................................................... 40

LFS4100 Chapter 1: Warning Symbol Definitions
Rev B, July 24, 2018 Page 1
Chapter 1 Warning Symbol Definitions
Below is a list of warning symbols you may encounter in this manual or on your device.
Symbol Description
Direct Current
Alternating Current
Both Direct and Alternating Current
Earth Ground Terminal
Protective Conductor Terminal
Frame or Chassis Terminal
Equipotentiality
On (Supply)
Off (Supply)
In Position of a Bi-Stable Push Control
Out Position of a Bi-Stable Push Control
Caution: Risk of Electric Shock
Caution: Hot Surface
Caution: Risk of Danger
Warning: Laser Radiation
Caution: Spinning Blades May Cause Harm

LFS4100 Chapter 2: Safety
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Chapter 2 Safety
WARNING
The filament in the LFS4100 furnace generates intense light when it is in operation. It is strongly
advised that the user NOT look directly at it during splicing or tapering operations.
CAUTION: HOT SURFACE
The furnace gets extremely hot when the filament turns on. Touching the furnace immediately after
the filament has been on for a few seconds, such as after a splicing or tapering operation, is
STRONGLY ADVISED AGAINST.
WARNING
The fiber handlers and the splice head can exert a fair amount of force as they move from side to
side. It is strongly advised that users NOT put their fingers between them, or between the fiber
handlers and the slot end walls, while the machine is in operation.
WARNING
Similarly, the camera tower can generate a fair amount of force as it moves forward and back, and
up and down. It is strongly advised that users NOT put their fingers between it and the furnace or
mirror tower while the machine is in operation.
CAUTION
Be sure your electrical power and gas supplies meet the criteria detailed in Chapter 9.

LFS4100 Chapter 3: Description
Rev B, July 24, 2018 Page 3
Chapter 3 Description
3.1. Introduction
Thorlabs' Vytran® LFS4100 is a dedicated process tool for splicing standard, large-diameter, and specialty fibers.
Designed for volume production of fiber assemblies, it is intended for manufacturers that want the splicing
performance of Vytran’s proven filament fusion, multi-function splicing, and glass processing products from a
stand-alone, easy-to-use tool.
The LFS4100 is designed to perform high-quality fusion splicing of fibers with claddings from Ø125 um to Ø1.25
mm. The system consists of a filament-based heater, precision stages with multi-axis control, a microscopic high-
resolution CCD imaging system, and a desktop computer. The filament heater has a wide temperature tuning
range that extends up to 3000 °C, which makes it possible to fuse and process various fiber types and sizes. The
multi-axis stages precisely control and align the fibers for high quality splicing. The imaging system displays a
magnified fiber image with sub-micron resolution; the camera can display views of both the fiber sides and fiber
ends. Using these images, the XY and rotation stages automatically manipulate the fibers to achieve optimum
positioning and ensure high-quality, low-loss splicing. The LFS4100 also has the ability to rotate fibers, making it
possible to align PM fibers, eccentric-core fibers, and non-circular fibers.
3.2. Filament Fusion Splicing
Thorlabs’ unique filament fusion technology provides a consistent, reliable method of making high-strength, low-
loss splices. Precision control of the fusion process is achieved by purging the splice region with an inert gas and
using a resistive graphite or iridium filament to supply the thermal input necessary for fiber fusion. Because the
fusion heat source is isolated for the environment, filament fusion splicing is not dependent upon ambient
conditions. The controlled conditions inside the system in combination with constant power control ensure
repeatable performance splice after splice.
3.3. Features
 Automated splice head
 XY alignment blocks with rotary capability
 Camera tower with ring illuminator.

LFS4100 Chapter 3: Description
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3.4. LFS4100 System and Accessories
1. LFS4100: Splicing system
2. Desktop Computer: Dell
3. External Power Supply: Dual voltage power supply and cable
4. Vacuum Pump: Vacuum pump LV-125A for vacuum V-groove (alternative model
supplied for 230V markets.)
5. Gas Tank Regulator: Regulator for argon tank (Note: European DIN 477 Number 6 fittings are
supplied in European markets. An adapter may be required to allow
connection of the supplied CGA-580 output port to the gas tank fittings in
other areas or countries).
6. 1/8” PTFE Gas Line: Gas line for gas tank regulator
7. RS-232 Comm. Cable: 9-pin D-sub cable for RS-232 communication
8. Camera Cable: 6-pin IEEE-1394 firewire cable
9. Tool kit: Allen wrenches for filament and V-groove replacement
10. FHB inserts: Top and bottom inserts for fiber holding blocks (Sold Separately)
11. Filament Assemblies: Filament heating elements and protective shrouds (Sold Separately)
Figure 1 LFS4100 System and Components
3.5. System Overview
The LFS4100 splicing system has three basic components: a splicing
workstation, a desktop computer, and a gas supply. The splicer workstation
is illustrated in Figure 2:
Figure 2 LFS4100 Splicing Workstation

LFS4100 Chapter 3: Description
Rev B, July 24, 2018 Page 5
3.5.1. External Workstation Connections
The splicer workstation is the main component of the LFS4100 system. The PC and gas supply, as well as
peripheral components such as an optical power meter, are connected to its back panel as illustrated below.
Figure 3 Splicing Workstation Connections
Power:
The LFS4100 workstation is powered from an external dual-voltage supply. Connection is made via a 5-pin round
connector.
Communication:
PC – LFS4100 Control communication: RS-232 9-way D-Sub connector, Connect to Com 1 on the PC
Camera - PC: IEEE-1394 6-pole connection, Connect to IEEE1394 4 pole on
PC
Note: The computer and the LFS4100 have to be powered off before connecting and disconnecting the camera
firewire cable between the LFS4100 and the computer.
Analog Outputs: 2 BNC connectors - Analog 1 and Analog 2
Gas:
Argon: 1/8” push-fit connector
Vacuum: 5/32” push-fit connector

LFS4100 Chapter 3: Description
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3.5.2. Fiber Holding Blocks
The fiber holding blocks are used for holding, positioning, and moving the fibers during the splice process
implemented on the LFS4100. Fiber alignment can be performed using either the edges of the fibers or their
cores. Standard fibers require only an XY alignment, while specialty fibers may require both XY alignment and
rotational alignment. The rotation function permits each fiber to be rotated by up to 200 degrees. This is used to
align the stress members of PM fiber, the cores of eccentric-core fiber, and the surface features of non-circular
fiber.
Figure 4 Fiber Holding Blocks
3.5.3. Fiber Holding Block Inserts
The LFS4100 fusion splicer requires fiber holder inserts to be placed in the fiber holding blocks in order to clamp
the fibers during the splicing process. A top and bottom insert (sold separately) is required for each of the two
fiber holding blocks. A variety of fiber holder inserts are available for different fiber diameters. To see the available
fiber holder inserts, see the selection chart in Chapter 8. In addition to the standard sizes, custom inserts may be
specially designed for various applications. Contact Thorlabs for more information.
Figure 5 Fiber Holder Inserts
3.5.4. Fiber Holder Transfer Inserts (Bottom Inserts for Fibers ≤Ø1047 µm)
There are two types of bottom inserts that are compatible with the LFS4100 fusion splicer. The bottom inserts for
fibers with cladding or buffer diameters up to 1.047 mm (indicated with Item #'s starting with VHF) are transfer

LFS4100 Chapter 3: Description
Rev B, July 24, 2018 Page 7
inserts; they allow for a single fiber to be transferred between the Vytran FPS300 Fiber Preparation Station,
LDC400 Series of Fiber Cleavers, and LFS4100 Splicer without loss of positional reference. For example, a fiber
can be placed in a transfer insert and cleaved using the LDC400 cleaver. Then, the entire transfer insert can be
placed in the LFS4100, and it will already be roughly aligned for splicing. This process works because the transfer
inserts are precisely located within each Vytran system and the VHT1 magnetic lid on the transfer inserts
prevents axial movement of the fiber during transport. These transfer inserts include vacuum holes that provide a
small suction force to hold the fiber in place.
Figure 6 Fiber Holder Transfer Bottom Insert
3.5.5. Splice Head
The splice head employs a filament assembly that can be changed if a different filament size is desired. This
assembly is held down by two filament clamps. In addition to holding down the filament assembly, the filament
clamps also serve to limit the influx of room air into the splicing area, as they have protrusions that cover most of
the filament cavity.
Figure 7 Splice Head with Filament Assembly
3.5.6. Filament Assembly
Thorlabs supplies filaments as part of a filament assembly, as shown in the Figure 8. These assemblies contain a
graphite or iridium filament within a protective shroud. One filament assembly (sold separately) is required to
operate the LFS4100 fusion splicer.

LFS4100 Chapter 3: Description
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Figure 8 Filament Assembly
3.5.7. Filaments
The filaments are omega-shaped resistive heaters. Proper filament selection
and splice parameters are essential for optimum splice performance. Graphite
filaments are capable of achieving the high temperatures necessary for
splicing large-diameter fibers, making them ideal for most applications. Iridium
filaments operate at slightly lower temperatures than graphite filaments,
making these ideal for working with softer glass fibers. The filaments have an
approximate operation lifetime of 40 minutes, which depends on a number of
factors such as argon quality, splice duration, and fiber glass quality.
Table 1: Filament Assembly Specifications
Filament Item # Filament Material Fiber Cladding Diameter (Min / Max)
FTAV2
Graphite
80 µm / 250 µm
FTAV4 125 µm / 600 µm
FTAV5 250 µm / 1000 µm
FTAV6 400 µm / 1300 µm
FRAV1
Iridium
≤200 µm
FRAV3 ≤400 µm
FRAV5 250 µm / 1050 µm

LFS4100 Chapter 3: Description
Rev B, July 24, 2018 Page 9
3.5.8. Mirror Tower
The mirror tower holds two sets of mirrors and an LED. The first set of mirrors makes it possible to view the sides
of the fibers. They provide the front view and back view, respectively. The second set of mirrors makes it possible
to view the ends of the fibers. The LED provides backlighting for viewing the ends of the fibers.
Figure 9 Mirror Tower
3.5.9. Imaging System
The LFS4100 splicing station comes with an automated camera assembly for imaging the fibers. This tower can
be moved forwards and backwards as well as up and down. It is equipped with a ring illuminator that provides
backlighting for the front and back views of the fiber. The camera objective may be replaced if a larger field of
view is desired.
Figure 10 Imaging System

LFS4100 Chapter 4: Set-Up
Page 10 TTN047498-D01
Chapter 4 Set-Up
1. Unpack the desktop computer and set it up using the included instructions from the computer
manufacturer. If the operator is right handed, the computer should be set up to the right of the operator. If
the operator is left handed, the computer should be set up to the left of the operator.
2. Unpack the LFS4100 and place it on a workbench. Make sure not to damage any components of the
LFS4100 during handling of the workstation. Lift by the built-in handles on the side of the system.
Remove the labeled transport block from the base of the camera tower.
3. Connect the external vacuum pump:
a. Connect the muffler to the top connector of the vacuum pump
b. Using the included tube, connect the bottom connector on the vacuum pump, labeled "VAC," to the
connection labeled "VACUUM" on the back of the LFS4100.
Figure 11 External Vacuum Pump for Bottom Fiber Holder Inserts
4. Use the included IEEE-1394 firewire cable to connect the camera to the port on the LFS4100 labeled
"CAMERA" (6-pin side) and to the firewire port on the computer (4-pin side).
Note: The computer and the LFS4100 have to be powered off before connecting and disconnecting the
camera firewire cable.
5. Use the RS-232 serial communication cable to connect the port labeled "SERIAL COMMS" on the back of
the LFS4100 to the computer’s serial communication connector (see instructions from computer
manufacturer). Tighten the screws on both sides of the cable.
6. Install the supplied CGA-580 gas regulator to the gas tank as shown below, using the manufacturer-
supplied operating and safety instructions. (NOTE: a European DIN 477 Number 6 fitting is supplied as
required in European markets. An adaptor may be required to allow connection of the supplied CGA-580
output port to the gas tank fittings in other areas or countries).
Figure 12 Gas Tank Regulator and Gas Line

LFS4100 Chapter 4: Set-Up
Rev B, July 24, 2018 Page 11
7. Connect the gas line to the back of the LFS4100. Make sure to push the gas line all the way into the
fitting. To check if the line is connected properly, pull lightly on it to make sure it is held by the fitting.
8. Connect the ferrite end of the DC-power cable to the port on the back of the LFS4100 labeled "POWER".
Plug the other end of the cable into the DC power supply. Be sure to align the red dot on the plug with the
red dot on the receptacle.
Figure 13 DC Power Cable Connections
9. Connect the AC power cord to the DC power supply and a power source of 110/230 VAC, 47-63 Hz.
10. If a cooling jacket is to be fitted to the splice head (optional), follow the set-up instructions provided with
the cooling system.
Figure 14 Splice Head Cooling System Connected to LFS4100 (optional)

LFS4100 Chapter 5: Software Interface
Page 12 TTN047498-D01
Chapter 5 Software Interface
The software interface involves a graphical user interface, or GUI, and an SQL database. The GUI is the main
window when working on the LFS4100. It has different menus and toolbars that are explained in this chapter. The
buttons are described from top to bottom. The graphical user interface is illustrated below.
Figure 15 LFS4100 Graphical User Interface
The following sections describe each component of the GUI in detail.
5.1. Menu Bar
5.1.1. File
The File menu is structured as shown to the left.
Open: Open a new splice data file.
Open Recent: Show recently opened files.
Save: Save current splice parameters to the current splice data file.
Save As: Save current splice parameters to a new splice data file.

LFS4100 Chapter 5: Software Interface
Rev B, July 24, 2018 Page 13
Database Options: Enables or disables the database and resets
the database. The database has preconfigured settings that should not
be altered.
Engineer Mode: Not yet activated.
Engineer Password: Not yet activated.
Exit: Close the GUI.
5.1.2. View
The view menu allows the user to hide or display the various toolbars,
data windows, and guides (such as crosshair and alignment guides)
associated with the GUI. The Processes Toolbar, Macro Toolbar, and
Quick-Open File Toolbar can only be activated if functions are
assigned to them. You can assign functions to these toolbars using
the Configuration menu.
5.1.3. Configuration
The Configuration menu allows the user to
edit the properties of the user interface and
set the required parameters for the LFS4100
workstation.

LFS4100 Chapter 5: Software Interface
Page 14 TTN047498-D01
Toolbars: The Process
Toolbar, Macro Toolbar,
Quick-Open File Toolbar,
and Camera Toolbar can
be modified through the
Toolbars menu.
Edit Processes Bar: Allows the
user to define which process will be
shown on the Processes Toolbar for
quick usage. The Selected
Processes window includes all the
processes which will be shown on
the screen.
Edit Macro Bar: Allows the user to
define which macro or commands will be
shown on the Macro Toolbar.

LFS4100 Chapter 5: Software Interface
Rev B, July 24, 2018 Page 15
Edit Quick-Open File Bar: Allows
the user to choose which files appear on
the Quick-Open File Toolbar. Users can
add or remove files from this window.
Camera Bar Properties: Allows the
user to edit the properties of each fiber view
provided by the camera. Each tab of the
View Properties window includes the
settings for a different fiber view.
Image: The properties of the
CCD imaging system can be
modified within the Image menu.

LFS4100 Chapter 5: Software Interface
Page 16 TTN047498-D01
CCD Camera: The view
settings within this window
allow the user to turn on
and off all the cursors on
the screen. Options on the
Camera Settings tab are
pre-set; the user should not
change them.
Mechanical: The
Mechanical menu includes
options for the fiber holding
blocks.
Home to View Distance: This option sets the distance between the splice home and the actual viewing
position of the splice head.
Time Delays: Set by the manufacturer.
Fiber Load Positions: This window sets the position of
the fiber holding blocks when they are ready for fiber loading.

LFS4100 Chapter 5: Software Interface
Rev B, July 24, 2018 Page 17
Argon Flow Rates: Three argon flow rate
options can be set using this window. The
Purge and Background settings are controlled
in this window, while the argon flow rate for the
splice is set in the Splice Properties window.
Cleave Angle Limits: The system can
measure the cleave angle of the fibers before
splicing them together. The user can set the
cleave angle limits to reject poorly cleaved
fibers.
Filament Normalization: The values in
this window are set by the manufacturer. The
process will be explained in Chapter 6.