THORLABS Vytran FFS2000 Series User manual

FFS2000 Series
Fiber Splicer
User Guide

FFS2000 Series
Table of Contents
Chapter 1Warning Symbol Definitions..............................................................................................1
Chapter 2Safety....................................................................................................................................2
Chapter 3Description...........................................................................................................................4
3.1.Introduction .....................................................................................................................4
3.2.System Overview............................................................................................................. 4
3.2.1.Gas Supply............................................................................................................................4
3.2.2.Computer...............................................................................................................................5 
3.3.Standard Features...........................................................................................................5
3.4.Standard Accessories.....................................................................................................5
3.5.System Overview............................................................................................................. 6
3.5.1.Fiber Holding Block and Transfer Jig....................................................................................6
3.5.2.Standard Fiber Holding Block (Item #s FFS2000 and FFS2000PT).....................................7
3.5.3.Rotary Fiber Holding Block for PM Alignment (Item #s FFS2000PM and FFS2000WS) .....8
3.5.4.Soak Station..........................................................................................................................8
3.5.5.Strip and Cleave Station .......................................................................................................9
3.5.6.Clean Station.......................................................................................................................11
3.5.7.Splice Station ......................................................................................................................12
3.5.8.Recoat Station.....................................................................................................................13
3.5.9.Proof Test Station (Item #s FFS2000PT and FFS2000WS)...............................................14
Chapter 4Setup....................................................................................................................................16
4.1.Initialize ..........................................................................................................................16
Chapter 5Software...............................................................................................................................17
5.1.Software Interface .........................................................................................................17
5.2.Menu bar ........................................................................................................................17
5.2.1.File.......................................................................................................................................18
5.2.2.View.....................................................................................................................................18
5.2.3.Configuration.......................................................................................................................18
5.2.4.Fiber Preparation ................................................................................................................19
5.2.5.Splice...................................................................................................................................19
5.2.6.Proof Test............................................................................................................................20
5.2.7.Recoat .................................................................................................................................20
5.2.8.Reset ...................................................................................................................................20
5.2.9.Execute ...............................................................................................................................20
5.2.10.Help .....................................................................................................................................20
5.3.TxRx Command Toolbar...............................................................................................20
5.4.Camera Toolbar ............................................................................................................. 21
5.5.Processes Toolbar ........................................................................................................21
5.6.Macro Toolbar................................................................................................................21
5.7.Quick Open File Toolbar...............................................................................................21
5.8.Main Toolbar ..................................................................................................................21
5.9.Camera Image................................................................................................................23

FFS2000 Series
5.10.Movement Control Bar..................................................................................................23
5.11.Status Bar ......................................................................................................................25
5.12.Initialization and Shutdown..........................................................................................25
5.13.Failure.............................................................................................................................25
5.14.Splice Properties ........................................................................................................... 26
5.14.1.Multi Stage Splice Properties ..............................................................................................27
Chapter 6Fiber Preparation................................................................................................................32
6.1.Loading the Fiber ..........................................................................................................32
6.2.Coating Removal ........................................................................................................... 33
6.2.1.Setting Up............................................................................................................................33
6.2.2.Soaking Procedure (Chemo-Mechanical Only)...................................................................34
6.2.3.Stripping Procedure ............................................................................................................35
6.2.4.Diagnostics..........................................................................................................................37
6.3.Cleaning the Fiber .........................................................................................................39
6.3.1.Setting Up............................................................................................................................39
6.3.2.Cleaning Procedure ............................................................................................................39
6.3.3.Diagnostics..........................................................................................................................40
6.4.Cleaving the Fiber .........................................................................................................40
6.4.1.Setting up ............................................................................................................................40
6.4.2.Cleaving Procedure.............................................................................................................40
6.4.3.Diagnostics..........................................................................................................................41
Chapter 7Splicing the Fiber...............................................................................................................43
7.1.Introduction ...................................................................................................................43
7.1.1.Filament Fusion...................................................................................................................43
7.1.2.Fire Polish ...........................................................................................................................43
7.2.Setting Up ......................................................................................................................43
7.2.1.Splice Settings ....................................................................................................................44
7.3.Splicing and Fire Polishing Procedure .......................................................................44
7.3.1.Preparing the Splice Station................................................................................................44
7.3.2.Loading the Fibers ..............................................................................................................45
7.4.Splice Routine ...............................................................................................................47
7.4.1.Fiber Alignment Methods ....................................................................................................47
7.4.2.Splice Method .....................................................................................................................47
7.5.Guidelines for Achieving a High Strength Splice....................................................... 48
7.6.Diagnostics ....................................................................................................................49
Chapter 8Recoat..................................................................................................................................51
8.1.Manual Injection System ..............................................................................................51
8.2.Setting Up ......................................................................................................................51
8.3.Priming the Remote Manual Injection System ...........................................................52
8.4.Fiber Recoating Procedures ........................................................................................53
8.4.1.Positioning the Fiber ...........................................................................................................53
8.4.2.Injecting the Acrylate...........................................................................................................53
8.4.3.Curing the Coating ..............................................................................................................53

FFS2000 Series
8.5.Diagnostics ....................................................................................................................54
Chapter 9Proof Test (Item #s FFS2000PT and FFS2000WS)........................................................56
9.1.Setting Up ......................................................................................................................56
9.2.Proof Testing .................................................................................................................56
9.2.1.Loading the Fiber ................................................................................................................56
9.2.2.Adjusting the Proof Test Cycle............................................................................................57
9.2.3.Proof Testing.......................................................................................................................58
9.3.Diagnostics ....................................................................................................................59
Chapter 10Shutting Down and Storage..............................................................................................60
10.1.Shutting Down ...............................................................................................................60
10.2.Storage and Transportation .........................................................................................60
Chapter 11Maintenance........................................................................................................................61
11.1.Planned Maintenance....................................................................................................61
11.2.Fiber Holding Block ...................................................................................................... 61
11.2.1.Inspect/Clean FHB Vacuum V-Grooves .............................................................................61
11.2.2.Change / Remove FHB Inserts ...........................................................................................62
11.2.3.Adjust Cleave Tension ........................................................................................................63
11.3.Strip/Cleave Station ......................................................................................................64
11.3.1.Inspect/Clean Cleave Inserts ..............................................................................................64
11.3.2.Change/Remove Cleave Inserts .........................................................................................64
11.3.3.Inspect/Clean TMS Inserts..................................................................................................64
11.3.4.Change/Align TMS Inserts ..................................................................................................65
11.3.5.Inspect/Clean Cleave Blade................................................................................................67
11.3.6.Reposition the Cleave Blade...............................................................................................67
11.3.7.Check/Adjust Cleave Blade Forward Move ........................................................................68
11.3.8.Rotate/Replace the Cleave Blade.......................................................................................69
11.3.9.Replace Ionize Unit .............................................................................................................70
11.4.Splice Station.................................................................................................................71
11.4.1.Clean Mirror.........................................................................................................................71
11.4.2.Check/Clean Graphite V-Grooves ......................................................................................72
11.4.3.Replace Filament ................................................................................................................72
11.4.4.Filament Calibration ............................................................................................................74
11.5.Recoat Station ...............................................................................................................74
11.5.1.Check/Replace Recoat Bulb ...............................................................................................74
11.5.2.Remove/Align Recoat Assembly.........................................................................................75
11.5.3.Flush Recoat System ..........................................................................................................76
11.6.Soak / Clean Station......................................................................................................77
11.6.1.Replace Indicator Bulb ........................................................................................................77
11.6.2.Replace Solvents ................................................................................................................77
11.7.Proof Test Station ......................................................................................................... 79
11.7.1.Replace Proof Test Grip......................................................................................................79
Chapter 12Specifications.....................................................................................................................80
12.1.Common Specifications ...............................................................................................80
12.2.FFS2000 Specifications ................................................................................................81
12.3.FFS2000PT Specifications............................................................................................ 81

FFS2000 Series
12.4.FFS2000PM Specifications...........................................................................................81
12.5.FS2000WS Specifications............................................................................................. 82
Chapter 13Regulatory...........................................................................................................................83
Chapter 14Thorlabs Worldwide Contacts..........................................................................................86

FFS2000 Series Chapter 1: Warning Symbol Definitions
Rev B, July 21, 2017 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

FFS2000 Series Chapter 2: Safety
Page 2 TTN047338-D02
Chapter 2 Safety
All statements regarding safety of operation and technical data in this instruction manual will only apply when the
unit is operated correctly.
SHOCK WARNING
Unplug the power cord before servicing the unit. Do not operate the unit without all covers and items
properly installed.
CAUTION
Before connecting the AC power cord, make sure the source voltage is between 85 and 265 VAC, 47-
63 Hz. Input voltages outside these ranges may result in damage to the unit.
Ensure that the Personal Computer voltage switch is set appropriately for the local supply.
CAUTION
The colorless solution used to clean the fibers may either be acetone (> 99%) or isopropanol (>
99.5%). Both are volatile and flammable. Ensure that the work area is well ventilated to avoid
excessive inhalation of the solution being used. Do not ingest and avoid contact with the skin and
eyes. Prolonged skin contact may result in severe irritation.
CAUTION
The recoat material is a flammable, toxic, acrylate compound. Avoid contact with the skin and eyes.
WARNING
Argon is a chemically inert gas. It is colorless, odorless, tasteless, non-flammable, non-corrosive and
non-toxic. However, the work area should be well ventilated so as to ensure that the correct oxygen
level is maintained.
WARNING
Ensure that the operator is properly trained for the handling of compressed gases and regulators.
Small transparent fiber shards may be present in and around the work area, and as such, the
necessary measures should be taken to ensure the safety of the employee(s).
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FFS2000 Series Chapter 2: Safety
Rev B, July 21, 2017 Page 3
WARNING
This unit must not be operated in explosive environments. The equipment should be used in a
standard laboratory environment with temperature and humidity control.
WARNING
Acrylate can be wiped using Kimwipes and Acetone. All chemicals should be disposed of with
chemical waste.
Materials containing chemicals should be disposed of in chemical solid waste.
The fuse can be replaced by using a flat head screwdriver to turn the fuse housing and remove the housing/fuse
from the back of the unit. The fuse can be removed from the housing and replaced. Then the fuse housing can be
secured in place using the flat head screwdriver.
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FFS2000 Series Chapter 3: Description
Page 4 TTN047338-D02
Chapter 3 Description
3.1. Introduction
The Vytran®FFS2000 Series is a fusion splicing workstation designed to meet the demands of both volume
manufacturing and R&D splicing. All splicing processes - strip, cleave, clean, splice, recoat, and proof test - are
logically integrated into a single, automated system that produces consistent splices quickly and efficiently.
The FFS2000 Series offers convenient user control of all splicing parameters from the included Windows®7 PC
with GUI. Additionally, a fully automated 4-axis positioning system is available (Item #s FFS2000PM and
FFS2000WS) for precise rotary alignment of polarization-maintaining fibers. This complete and convenient
automation control, combined with the advantages of our Filament Fusion technology, makes the FFS2000 Series
ideal for high-strength, specialty fiber splicing, and manufacturing.
All of the FFS2000 Series components and procedures have been designed to yield consistent, reliable high-
strength, low-loss splices. These include:
Fiber holding blocks (FHBs, sold separately) and transfer jig minimize fiber handling by precisely
positioning the fiber for each process.
Soaking and stripping procedures safely remove the fiber’s acrylate coating while maintaining fiber
strength.
A built-in cleaver provides a low-end-angle cleave, important for achieving low-loss splices.
Ultrasonic cleaning prior to splicing removes any coating particles or residue left on the glass surface
which would otherwise reduce splice strength.
A Charge Coupled Device (CCD)-based imaging system used in conjunction with sub-micron-level
stepper-motor positioners automatically aligns the fibers prior to splicing.
An incorporated video imaging system displays the fibers alternately in two perpendicular axes.
Precise control of fusion temperature necessary for splicing is achieved by using an inert purging gas and
an electric filament.
A post-fusion fire polish process cleans any deposits or impurities on the regions adjacent to the splice
thereby enhancing splice strength.
The recoat process maintains splice strength by restoring a protective polymer coating over the fusion
splice.
The proof tester ensures that a splice meets a minimum strength requirement (Item #s FFS2000PT and
FFS2000WS)
In order to achieve optimum quality splices, it is important to read the instruction manual carefully and completely
before attempting to operate the machine. Additionally, the required maintenance and service work should be
performed on a regular basis to ensure that the splice quality is not compromised. This manual provides
instructions for performing such services. When in doubt, please contact tech support
([e-mail]) as they are best qualified for diagnosing problems. Improper and/or incomplete
maintenance may result in impairment of the operating characteristics of your splicer.
3.2. System Overview
3.2.1. Gas Supply
Use only zero- or research-grade argon gas supply. Any other gas may damage the unit. Zero-grade argon is
specified as 99.999% pure with O2< 0.5 ppm, H2O < 3.5 ppm, and THC (Total Hydrocarbons) < 3.5 ppm.
Research-grade argon is cleaner with specifications of 99.9995% purity with CO2< 0.5 ppm, H2O < 0.5 ppm, N2<
3.0 ppm, O2< 1.0 ppm, and THC < 0.5 ppm.
When using a large tank of gas, be sure the regulator is set to approximately 10 to 11 psi. Do not exceed 25 psi
under any circumstances. If no gas pressure is present at the input port the splice process will abort.

FFS2000 Series Chapter 3: Description
Rev B, July 21, 2017 Page 5
Use only a Thorlabs-supplied gas line to interconnect the regulator to the splicing system. If an extended length
gas line is required between regulator and splicer, please contact Thorlabs for purity requirements and line
specifications.
NOTE: Thorlabs does not supply the gas cylinder.
3.2.2. Computer
The Windows®7 PC, monitor, keyboard, and mouse are included. FFS3 software is preinstalled on the PC.
3.3. Standard Features
Fiber Coating Soaking Station
Thermal Coating Removal Station
Ultrasonic Fiber Cleaning Station
Fiber Cleaving Station
True Core Imaging™ for Automatic Fiber Alignment and Accurate Splice Loss Determination
Automatic 3-axis Fiber Positioning System (Item #s FFS2000 and FFS2000PT)
Automatic 4-axis positioning system for PM rotation (Item #s FFS2000PM and FFS2000WS)
Filament Fusion Splicing Station with Automatic Post-Fusion Fire Polishing for Strength Enhancement
Recoat Station for Acrylate Buffer Restoration
Built-in Proof Tester / Tension Tester (Item #s FFS2000PT and FFS2000WS)
Personal Computer with Windows GUI and Networkable Database
Analog BNC Inputs for Test and Measurement Equipment
3.4. Standard Accessories
When unpacking the FFS2000 Series splicing system for the first time, check to make sure that you have the
following accessories:
External Power Supply Unit
DC Power Supply Cord
AC Power Cord
Firewire Camera Cable
RS-232 Cable
PC, Monitor, Keyboard, Mouse, and Software
External Vacuum Pump
Clear Polycarbonate Tension Test Shield (Item #s FFS2000PT and FFS2000WS Only)
Recoat Mold Injector System
Color Coating Agent (Item #s FFS2000PM and FFS2000WS only)
Large Tank Regulator with Gas Line
Tool Kit Containing:
oLens Tissue
oFlat Head Screwdriver
oFilament Extraction Tool
oEye Dropper
oTwo (2) 3/32” Hex Keys
oTwo (2) 5/64” Hex Keys
o0.028" Hex Key
o0.035" Hex Key
o0.050" Hex Key
oSoft Cleaning “Toothbrush”
o0-300 Gram Tension Gauge

FFS2000 Series Chapter 3: Description
Page 6 TTN047338-D02
3.5. System Overview
The splicer workstation (splicer) is the main component of the FFS2000 Series splicing system. It performs all the
splicing process steps: soaking, stripping, cleaving, cleaning, splicing, recoating, and proof testing. The PC and
gas supply, as well as peripheral components such as an optical power meter, are connected to the splicer back
panel.
Figure 1 System Overview
The following subsections describe the components of the splicer workstation in the order of use during a splice
process.
3.5.1. Fiber Holding Block and Transfer Jig
Left- and right-hand fiber holding blocks (FHBs) are used to provide an efficient, convenient, step-by-step method
for preparing the fibers prior to splicing. The FHBs are also used in conjunction with a transfer jig to position the
fiber for splicing and to transfer the completed splice to the recoat station.
In addition to simplifying the handling of the fiber throughout the splicing process, the FHBs and transfer jig also
improve the consistency and strength of the splice by precisely positioning the fiber for each step. Fiber holding
blocks are sold separately from the FSX2000PM base unit, but are installed and factory-aligned with the purchase
of the system.

FFS2000 Series Chapter 3: Description
Rev B, July 21, 2017 Page 7
Figure 2 Transfer Jig with Fiber Holding Blocks
3.5.2. Standard Fiber Holding Block (Item #s FFS2000 and FFS2000PT)
The fiber holding block (Item # FHB1) consist of a U-shaped frame and a center, spring-loaded block that
contains a replaceable vacuum V-groove bottom insert as well as a top insert. A magnetic top is used to clamp
the fiber in the V-groove as the FHB is moved from station to station.
Figure 3 Standard Non-Rotating Fiber Holding Block
FHB Bottom V-Groove Insert and Top Insert: The V-groove insert captures the fiber securely and
allows the fiber to be transported within the fiber holding block between the stations. The bottom V-
Groove inserts and top inserts are purchased separately; if purchased with an FFS2000PM base unit they
will have been installed and factory aligned. Various sizes are available to support a range of coating
diameters; for details please see Chapter 12. Replacements can be purchased from www.thorlabs.com
and can be installed by the end user.

FFS2000 Series Chapter 3: Description
Page 8 TTN047338-D02
Fiber Cleave Lever: The lever is used at the cleave station on the FPC200 Preparation Station (sold
separately) to apply tension to the fiber.
Alignment Pins: The alignment pins position the fiber holding block during the fiber handling at each
station.
Z-Axis Drive: The Z-axis drive positions the fiber in axial direction.
3.5.3. Rotary Fiber Holding Block for PM Alignment (Item #s FFS2000PM and FFS2000WS)
The fiber holding block (Item # FHBR1) consist of a U-shaped frame and a center, spring-loaded block that
contains a replaceable vacuum V-groove insert within a rotary mechanism. A magnetic top is used to clamp the
fiber in the V-groove as the FHB is moved from station to station.
Figure 4 Rotary Fiber Holding Block
FHB V-Groove Insert: The V-Groove Insert captures the fiber securely and allows the fiber to be
transported within the fiber holding block between the stations. The bottom V-Groove inserts are
purchased separately; if purchased with an FFS2000PM base unit they will have been installed and
factory aligned. Various sizes are available to support a range of coating diameters; for details please see
Chapter 12 Specifications. Replacements can be purchased from www.thorlabs.com and can be
installed by the end user.
Fiber Cleave Lever: The lever is used at the FPC200 Fiber Preparation Station (Sold Separately) to
apply tension to the fiber.
Alignment Pins: The alignment pins position the fiber holding block during the fiber handling at each
station.
Z-Axis Drive: The Z-axis drive positions the fiber in axial direction.
Rotary Mechanism: The rotary mechanism is used to rotationally align the fiber with a resolution of
0.01°.
3.5.4. Soak Station
The soaking station is used to soften the acrylate polymer coating on the fiber so that it can be stripped off without
scratching or abrading the underlying glass surface. The coating is softened by immersing the fiber in a solvent
appropriate for the stripping method used. Presoaking will not be necessary for most fibers stripped using the
thermo mechanical method. The soaking station consists of left- and right-hand dunking jigs, solvent container,
and indicator lamps.

FFS2000 Series Chapter 3: Description
Rev B, July 21, 2017 Page 9
Figure 5 Soak Station
Dunking Jig: The dunking jig is used to mount the fiber holding blocks at the soaking station. Vacuum is
turned on when a FHB is inserted into the dunking jig in horizontal position. Vacuum turns off when
dunking jig is raised to immerse the fiber in the solvent (max. 90°).
Solvent Container: The solvent container holds the solvent which softens the acrylate coating on the
fiber. Solvent should be filled up to 1/8” of the top of the can.
WARNING
Read the MSDS Sheet for any chemical used in the soak station.
Solvent Shield: The solvent shield reduces splashing of the solvent during ultrasonic operation.
Indicator Lamp: The indicator lamps light up when the soaking time expires and stay lit until the dunking
jig is lowered.
Flange Clamp: The flange clamps hold the solvent container in place. Unscrew 1/2 turn to release the
container.
3.5.5. Strip and Cleave Station
This station serves the dual functions of stripping and cleaving. Two positions are provided for the FHBs: a slot
allowing it to slide during the stripping procedure and precision aligned bushings to hold it securely for the
cleaving procedure.
Strip Station
With the FHB in the stripping position, the acrylate fiber coating is captured by a matched set of stripper blades
and can be removed with a light sliding force.
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!

FFS2000 Series Chapter 3: Description
Page 10 TTN047338-D02
Figure 6 Strip Station
Stripping Slot: The stripping slot is used to position the FHB at the stripping station. Positioning a FHB in
the slot automatically activates the internal vacuum, pulling the fiber into the FHB and TMS V-groove.
Simultaneously the TMS blades warm up to their preset stripping temperature. When stripping, the FHB is
slid away from the stripping station assembly using a smooth, steady motion.
Stripping Stop: The strip length of the fiber can be adjusted by changing the position of the stripping
stop. This can be accomplished by loosening the stripping stop and manually adjusting it.
Stripper Inserts: The top and bottom inserts contain a matched set of stripping blades at each end,
which capture and remove the acrylate coating. In the thermo mechanical stripping set, the bottom insert
also contains a heating element, used to soften the acrylate coating.
Strip Indicator: The strip indicator displays the status of the thermo mechanical stripping station, as
follows:
oFlashing: TMS blades are heating up
oLit: TMS blades reached preset stripping temperature
oOff: TMS blades not in use
Cleave Station
When the FHB is located in the cleaving position, a tension-and-scribe method of cleaving provides low-end-
angle fiber end faces.

FFS2000 Series Chapter 3: Description
Rev B, July 21, 2017 Page 11
Figure 7 Cleave Station
Cleave Bushing: The cleave bushings are used to position the FHB at the cleaving station.
Cleave Blade: The polycrystalline diamond cleave blade is used to score the fiber during the tension-
and-scribe cleaving process.
Cleave Button: The cleave button is used to initiate the cleaving process.
Cleave Insert: The cleave insert is used to hold the fiber in place at the cleaving station until the lid is
closed.
3.5.6. Clean Station
The cleaning station is used to remove any coating particles or residue left on the glass surface which may
reduce splice strength. The prepared fiber is immersed in the cleaning solution by raising the dunking jig, which
automatically activates the ultrasonic cleaner to run for a chosen period. The cleaning station consists of left- and
right-hand dunking jigs and an ultrasonic cleaning solution container.
Figure 8 Clean Station

FFS2000 Series Chapter 3: Description
Page 12 TTN047338-D02
Dunking Jigs: The dunking jig are used to mount the fiber holding blocks at the cleaning station. Vacuum
is turned on when a FHB is inserted into the dunking jig in horizontal position. Vacuum turns off when
dunking jig is raised to immerse the fiber in the solvent (max. 90°). Raising the dunking jig activates the
ultrasonic cleaning mechanism.
Solvent Container: The solvent container holds the cleaning solvent which removes fiber coating
residue. Solvent should be filled up to 1/8” of the top of the can.
WARNING
Read the MSDS Sheet for any chemical used in the ultrasonic cleaner.
Solvent Shield: The solvent shield reduces splashing of the solvent during ultrasonic operation.
Indicator Lamps: The indicator lamps light up when the cleaning time expires and stay lit until the
dunking jig is lowered.
Flange Clamps: The flange clamps hold the solvent container in place. Unscrew 1/2 turn to release the
container.
3.5.7. Splice Station
The splicing station is used to precisely position and fuse the fiber ends together. A tungsten or iridium filament
(sold separately) provides the heat necessary for the fiber fusion.
Standard Splice Station (Item #s FFS2000 and FFS2000PT)
Figure 9 Standard Splice Station
Splice Head: The splice head contains the tungsten or iridium filament, viewing optics, and XY
illuminators. It moves axially during the high-strength fire polishing process.
Filament Port: The filament port allows argon to escape during the splice process.
Fiber Positioner: The stepper-motor pivot positioner is used for aligning fibers in the XY-direction with a
resolution of 0.01 μm.
Vacuum V-Groove Fiber Holders: The vacuum v-grooves are used to position the stripped fiber. The
non-abrasive material maintains the fiber strength.
Side Illuminators: The side illuminators are used to illuminate the cladding structure for end view during
rotary alignment.
Fiber Holding Block Drive Shaft: The drive shafts position the fiber holding blocks in Z-direction and
rotate the fiber for PM alignment.
Transfer Jig Bushings: The bushings are used to position transfer jig at the splice station.
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Splice Station with PM Alignment (Item #s FFS2000PM and FFS200WS)
Figure 10 Rotary Splice Station
Splice Head: The splice head contains the tungsten or iridium filament, viewing optics, and XY
illuminators. It moves axially during the high-strength fire polishing process.
Filament Port: The filament port allows argon to escape during the splice process.
Mirror Toggle: The mirror toggle is used to switch between the side view (for XY alignment) and the end
view (for PM alignment).
Fiber Positioner: The stepper-motor pivot positioner is used for aligning fibers in the XY-direction with a
resolution of 0.01 μm.
Vacuum V-Groove Fiber Holders: The vacuum v-grooves are used to position the stripped fiber. The
non-abrasive material maintains the fiber strength.
Side Illuminators: The side illuminators are used to illuminate the cladding structure for end view during
rotary alignment.
Fiber Holding Block Drive Shaft: The drive shafts position the fiber holding blocks in Z-direction and
rotate the fiber for PM alignment.
Transfer Jig Bushings: The bushings are used to position transfer jig at the splice station.
3.5.8. Recoat Station
The recoat station is used to reinstate the polymer coating on the fiber, maintaining its strength and flexibility by
protecting the glass surface from damage. Liquid UV acrylate material is injected into the recoat cavity and cured
around the fiber using tungsten-halogen lamps to provide the necessary UV radiation.

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Figure 11 Recoat Station
Injection Port: The injection port is used to inject the UV acrylate into the mold cavity.
Viewport: The viewport allows the user to watch the UV acrylate as it flows into the mold cavity.
Fused Quartz Mold Plates: The mold plates form a mold cavity for the UV acrylate material.
Flange Screws: Flange screws are used to secure the position of the recoat station assembly.
Transfer Jig Bushings: The bushings are used to position the transfer jig at the splice station.
3.5.9. Proof Test Station (Item #s FFS2000PT and FFS2000WS)
The proof tester can be used either to determine the breaking strength of a fiber or to ensure that a fiber or fusion
splice meets a minimum strength requirement. Fiber is tested by placing it between the two mandrels. The ends
of the fiber are wrapped once around each mandrel and held in place by an integral clamping mechanism. A load
is automatically applied to the fiber by the rotation of one of the mandrels. The proof test or breaking load level is
measured via a load cell and is recorded by the software interface.
Figure 12 Proof Test Station

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Rev B, July 21, 2017 Page 15
Mandrel: During the proof test, the fiber is wrapped around the mandrels. The right mandrel will rotate,
applying tension to the fiber.
Clamp: The clamps hold the fiber taut between the mandrels and keep it from slipping during the proof
test.
Release Button: The buttons are used to release the tension on the clamps, allowing the fiber to be
inserted or removed from the mandrel.
Ramp Screw: The screw is used to adjust the ramp rate (the rate at which fiber tension increases during
the proof test). To decrease the ramp rate turn clockwise; to increase the ramp rate turn
counterclockwise.