Tyco Electronics LightCrimp Plus ST User manual

Instruction Sheet
LightCrimp Plus* ST 408--10272
LOC B
1of 8
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
31 AUG 09 Rev CFiber Optic Connector Kit 2064757- 1
Figure 1
Connector
Assembly
Plunger
Dust CapG
Strain
Relief
Crimp
Eyelet
Small White
Tubing
Black
Tubing
GConnector kit is shipped with these installed onto connector
assembly. Keep them in place until ready for assembly.
Ferrule
Dust CapG
1. INTRODUCTION
LightCrimp Plus ST Fiber Optic Connector Kit
2064757--1 is designed for use with 125--mm
multimode glass fiber optic cable. This kit can be
used with any of the following media (paragraph of
assembly procedure is indicated next to media).
5.1. 2.0- mm Tight Jacketed Cable
5.2. 2.0- to 2.4- mm Loose Jacketed Cable
With 250- mm or 500- mm Blown Optical Fiber (BOF)
Read these instructions thoroughly before assembling
the connector kit.
All numerical values in this instruction sheet are
in metric units. Dimensions are in millimeters
[and inches]. Figures are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
The connector kit consists of a connector assembly,
crimp eyelet, small white tubing, black tubing, and
strain relief. Also included, assembled onto the
connector, are dust caps for the ferrule (front of
connector) and plunger (rear of connector). See
Figure 1.
3. SAFETY PRECAUTIONS
Be very careful to dispose of fiber ends properly.
The fibers create slivers that can easily puncture
the skin and cause irritation.
NEVER look into the end of terminated or
unterminated fibers. Laser radiation is invisible
but can damage eye tissue. NEVER eat, drink, or
smoke when working with fibers. This could lead
to ingestion of glass particles.
DO NOT use defective or damaged components.
Replace them with new components.
4. REQUIRED TOOLS AND MATERIALS
— Cable Holder Assembly 492703--1
— Fiber Optic Strip Tool 2064765--1
— Scissors 501014--1
— Alcohol Fiber Wipe Packet 501857--2
NOTE
i
DANGER
DANGER
CAUTION
!

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LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
Rev C2 of 8 Tyco Electronics Corporation
— isopropyl alcohol
— Fiber Optic Cleaver 1871696--3
— LightCrimp Plus ST Die Set with Crimping Tool
492623--1 (consists of Die Set 492622--1 and
PRO--CRIMPER* III Hand Tool 1976850--2)
— Cable Clamp 1278625--1 (for loose jacketed
cable with 250--mmor500--mmBOF)
LightCrimp Plus ST Tool Kit 2064764--1 contains
preparation tools required to apply this connector.
5. PREPARING THE CABLE
5.1. 2.0- mm Tight Jacketed Cable
Kit Components Required
Connector
Assembly
Plunger
Dust CapG
Strain
Relief
Crimp
Eyelet
GConnector kit is shipped with these installed onto connector
assembly. Keep them in place until ready for assembly.
Black
Tubing
Ferrule
Dust CapG
1. Slide the strain relief (small diameter end first)
over the cable. Slide the black tubing over the
cable. See Figure 2 A, Detail A.
2. Remove both dust caps from the connector
assembly. Keep the ferrule dust cap; discard the
plunger dust cap.
3. Push the connector into the holder of the cable
holder with the ferrule facing outward. See Figure
2 A, Detail B. Make sure that the connector butts
against the lip of the arm of the cable holder. Slide
the cable into the channel marked “CABLE” on the
cable holder. Make sure that the tip of the jacket
butts against the end of the channel.
4. Mark the cable at each cross--slot of the
channel. See Figure 2 A, Detail B. Remove the
cable from the cable holder.
5. Using the outer notch of strip tool, cut through
the jacket at each mark. See Figure 3, Detail A.
6. Remove the first jacket segment, and flare the
strength members away from the buffer. Using the
scissors, cut the strength members even with the
jacket. Then, remove the remaining jacket
segment. See Figure 3, Detail B.
7. Slide the crimp eyelet onto the buffer and, using
the crimp eyelet, fold the strength members back
over the jacket. Continue sliding the crimp eyelet
over the jacket until the strength members appear
at the front of the crimp eyelet. See Figure 3,
Detail C.
8. Slide the buffer into the channel marked
“BUFFER” on the cable holder. Make sure that the
tip of the buffer butts against the end of the
channel. See Figure 4, Detail A.
9. Mark the buffer at each cross--slot of the
channel. See Figure 4, Detail A. Remove the buffer
from the cable holder.
10. Using the inner notch of the strip tool, strip the
fiber to the first mark. It is recommended holding
the tool at an angle and stripping the fiber in small
sections (approximately 6 mm [.25 in.] long) at a
time. See Figure 4, Detail B.
Before using the strip tool, make sure that the “V”
opening is clean; otherwise the fiber could break.
Only use isopropyl alcohol on the tool.
Typically, the buffer and coating are tightly
adhered to one another and will strip from the
fiber at the same time.
11. Using an alcohol fiber wipe, remove fiber
coating residue by wiping from the end of the
buffer toward the end of the fiber.
Wipe the buffer only once; repeatedly wiping a
bare fiber will weaken the fiber.
Cable preparation for 2.0--mm tight jacketed cable is
now complete. Proceed to Section 6, ASSEMBLY.
NOTE
i
CAUTION
!
NOTE
i
CAUTION
!

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LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
3of 8Rev CTyco Electronics Corporation
5.2. 2.0- to 2.4- mm Loose Jacketed Cable with
250- mm or 500- mm Blown Optical Fiber (BOF)
Kit Components Required
Connector
Assembly
Ferrule
Dust CapG
Plunger
Dust CapG
Strain
Relief
Crimp
Eyelet
GConnectors are shipped with dust caps installed onto
connector. Keep dust caps in place until ready for assembly.
Black
Tubing
Small White
Tubing
1. Slide the cable into the cable clamp, then
position the cable clamp approximately 23 cm
[9 in.] away from the end of the cable. Tighten the
thumb wheel to hold the cable in place. See Figure
2 B, Detail A.
2. Slide the strain relief (small diameter end first)
over the cable. Slide the black tubing over the
cable. See Figure 2 B, Detail B.
3. Remove both dust caps from the connector
assembly. Keep the ferrule dust cap; discard the
plunger dust cap.
4. For this step, either: insert the small white
tubing into the plunger of the connector assembly
until the tubing bottoms as shown in Figure 2 B,
Detail C, or skip this step and slide the small white
tubing over the fiber after the fiber has been
cleaved as instructed in Paragraph 6.1.
5. Push the connector into the holder of the cable
holder with the ferrule facing outward. See Figure
2 B, Detail D. Make sure that the connector butts
against the lip of the holder. Slide the cable into the
channel marked “CABLE” on the cable holder.
Make sure that the tip of the jacket butts against
the end of the channel.
6. Mark the cable at each cross--slot of the
channel. See Figure 2 B, Detail D. Remove the
cable from the cable holder.
7. Using the outer notch of the strip tool, cut
through the jacket at each mark. See Figure 3,
Detail A.
8. Remove the first jacket segment, and flare the
strength members away from the buffer. Using the
scissors, cut the strength members even with the
jacket. Then, remove the remaining jacket
segment. See Figure 3, Detail B.
9. Slide the crimp eyelet onto the buffer and, using
the crimp eyelet, fold the strength members back
over the jacket. Continue sliding the crimp eyelet
over the jacket until the strength members appear
at the front of the crimp eyelet. See Figure 3,
Detail C.
10. Using the center notch of the strip tool, cut the
buffer tube flush with the end of the cable jacket.
Remove the cut piece of tubing. See Figure 3,
Detail D.
11. For cable with 500--mmBOF, using the center
notch of the strip tool, remove the buffer coating
from the exposed fiber, leaving the 250--mm coated
fiber. It might be necessary to use the strip tool
several times to remove all of the buffer coating.
See Figure 3, Detail D.
12. Slide the fiber into the channel marked
“BUFFER” on the cable holder. Make sure that the
tip of the fiber butts against the end of the channel.
See Figure 4, Detail A.
13. Mark the fiber at each cross--slot of the
channel. See Figure 4, Detail A. Remove the fiber
from the cable holder.
14. Using the inner notch of strip tool, strip the
fiber to the first mark. It is recommended holding
the tool at an angle and stripping the fiber in three
sections. See Figure 4, Detail B.
Before using the strip tool, make sure that the “V”
opening is clean; otherwise the fiber could break.
Only use alcohol on the tool.
15. Using an alcohol fiber wipe, remove fiber
coating residue by wiping from the end of the
buffer toward the end of the fiber.
Wipe the buffer only once; repeatedly wiping a
bare fiber will weaken the fiber.
Cable preparation for 2.0-- to 2.4--mm loose jacketed
cable with 250--mmor500--mm BOF is now complete.
Proceed to Section 6, ASSEMBLY.
CAUTION
!
CAUTION
!

408- 10272
LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
Rev C4 of 8 Tyco Electronics Corporation
Detail A
Figure 2 A: Preparing the Cable
Tip of Jacket Against
End of Channel
Mark Cable at
Cross--Slots
Detail B
Connector in Holder
with Ferrule Facing
Outward
Cable Holder
Assembly
Small Diameter End
of Strain Relief
Cable
Black
Tubing
2.0-mm Tight Jacketed Cable
Detail A
Detail B
Figure 2 B: Preparing the Cable
Tip of Jacket Against
End of Channel
Mark Cable at
Cross--Slots
Detail D
Connector in Holder
with Ferrule Facing
Outward
Cable Holder
Assembly
Small Diameter End
of Strain Relief
Cable
Black
Tubing
Small White
Tubing
Plunger of Connector
Assembly
2.0- to 2.4-mm Loose Jacketed Cable
23 cm [9 in.]
Tighten Thumbwheel
End of Cable
EndofCableClamp
Detail C Note: An alternate step may be used,
refer to Step 4 of Paragraph 5.2.

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LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
5of 8Rev CTyco Electronics Corporation
Figure 3: Preparing the Cable
Detail B First Jacket
Segment Removed
Cut Strength Members
Even with Jacket
Remaining
Jacket Segment
Removed
Strength Members
Folded Over Jacket
Small Diameter End
of Crimp Eyelet
For 2.0-- to 2.4--mm Loose Jacketed Cable with 500--mmBOF
Cut Buffer Tube Flush
withEndofCableJacket
Remove Buffer Coating
from Fiber
Detail C
Detail A
Cut Through Jacket
Center Notch
of Strip Tool
Outer Notch
of Strip Tool
Detail D
Figure 4: Preparing the Cable
Strip Fiber in
Sections to
First Mark
Direction
of Strip
Hold Strip Tool
at Angle
Inner Notch
of Strip Tool
Detail A
Tip of Buffer Against
End of Channel
Mark Buffer at
Cross--Slots
Connector in Holder
with Ferrule Facing
Outward
Detail B
6. ASSEMBLY
6.1. Cleaving (Figure 5)
1. Open the fiber clamp of the fiber optic cleaver.
Press the button, and slide the carriage back
(toward the fiber clamp). Then move the fiber slide
back until it stops.
2. Place the stripped fiber into the slot so that the
end of the 900--mm buffer (for tight jacketed cable)
or the end of the 250--mm fiber (for loose jacketed
cable) is at the 8--mm marking. See Figure 5,
Detail A.
3. While applying pressure on the buffer, carefully
slide the fiber slide forward (toward the carriage)
until it stops. See Figure 5, Detail B.

408- 10272
LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
Rev C6 of 8 Tyco Electronics Corporation
4. Gently close the fiber clamp, and slide the
carriage forward. DO NOT touch the button while
sliding the carriage. See Figure 5, Detail C.
5. Open the fiber clamp, and remove the cleaved
fiber, and properly dispose of the scrap fiber.
DO NOT attempt to clean the fiber after it has
been cleaved.
6. For loose jacketed cable, if the small white
tubing was not inserted into the plunger of the
connector assembly (in Step 4 of Paragraph 5.2),
slide the small white tubing over the fiber as shown
in Figure 5, Detail D.
6.2. Crimping (Figures 6, 7, and 8)
1. Open the cable clamp of the cable holder, and
hold the buffer (with the cleaved end of the fiber
facing the connector) inside the clamp. Pull the end
of the fiber even with the front of the arm of the
cable holder, and holding the buffer in place, close
the clamp. See Figure 6, Detail A.
2. Carefully insert the fiber into the plunger of the
connector assembly until the the fiber bottoms
against the internal fiber. Make sure that the
remaining mark on the buffer enters the plunger.
The resultant bend in the buffer should hold the
fiber against the internal fiber. See Figure 6,
Detail B.
It is important that the fiber bottoms against, and
remains against, the internal fiber. If the mark
does not enter the plunger or if the fiber does not
seem to bottom against the internal fiber, the
fiber may be caught on internal guides. Rotating
the connector and backing the fiber out a small
amount and re--entering may help. However, if
the mark will not enter the plunger, the fiber must
be re--stripped.
Make sure that the fiber does not pull rearward
from the contact (with the internal fiber) during
the crimping operation.
3. Squeeze the handles of the hand tool until the
ratchet releases. Allow the handles to open fully.
Gently close the handles until you hear three clicks
from the ratchet.
4. With the connector assembly in the cable
holder, position the ferrule in the upper cavity of the
front die and the plunger in the upper cavity of the
rear die. It is important to make sure that the tip of
the plunger sits in the channel of the rear die with
the protruding disk of the plunger flat against the
wall of the cavity. If the plunger is not positioned
correctly, it will be crushed when the tool is
actuated. See Figure 6, Detail C.
The arrows marked on the front die indicate the
direction that the ferrule must be pointing when
the connector is positioned in that cavity.
For proper placement, and to avoid damage to
the fiber, the direction of the arrows must be
observed. Refer to Figure 6, Detail C and
Figure 7, Detail A.
5. Gently push the buffer toward the connector to
make sure that the fiber is still bottomed, then
slowly squeeze the tool handles together (using
both hands) until the ratchet releases. Allow the
handles to open fully, and remove the connector
assembly from the dies.
6. Position the plunger of the connector assembly
in the first (smallest) cavity of the front die with the
shoulder of the plunger against the edge of the
groove in the die and the ferrule pointing in the
direction of the arrow. See Figure 7, Detail A.
7. Slowly squeeze the tool handles together until
the ratchet releases. Allow the handles to open
fully, and remove the connector assembly from the
die.
8. Slide the crimp eyelet away from the connector
until the strength members are free, then slide the
crimp eyelet toward the connector until the strength
members and crimp eyelet butt against the
connector. See Figure 7, Detail B.
9. Slide the black tubing forward into the small
diameter end of the crimp eyelet until it butts
against the rear of the connector. See Figure 7,
Detail B.
10. Position the large diameter end of the crimp
eyelet in the last (largest) cavity of the front die
with the ferrule pointing in the direction of the
arrow. See Figure 7, Detail C. Slowly squeeze the
tool handles together until the ratchet releases.
Allow the handles to open fully.
11. Position the small diameter end of the crimp
eyelet in the middle cavity of the front die with the
ferrule pointing in the direction of the arrow. See
Figure 7, Detail D.
12. Slowly squeeze the tool handles together until
the ratchet releases. Allow the handles to open
fully, and remove the connector assembly from the
die.
13. Install the ferrule dust cap onto the ferrule.
Open the cable clamp of the cable holder, and
remove the cable from the clamp. Slide the strain
relief over the crimp eyelet until the strain relief
butts against the connector. See Figure 8.
14. Remove the connector assembly from the
cable holder. If not connecting connectors, keep
the ferrule dust cap on the ferrule.
CAUTION
!
NOTE
i
CAUTION
!

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LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
7of 8Rev CTyco Electronics Corporation
Figure 5: Cleaving
Detail A
Detail B
Detail C
Stripped Fiber in Slot
End of 900--mm Buffer (Tight Jacketed Cable) or End of
250--mm Fiber (Loose Jacketed Cable) at 8--mm Marking
Slide Fiber Slide Forward
Slide Carriage Forward
Fiber Clamp Closed
Detail D
For Loose Jacketed Cable
Small White
Tubing
Cleaved Fiber
Tip in Channel
Disk Flat Against
Wall of Cavity
Ferrule in Upper Cavity of
Front Die and Pointing in
Direction of Arrow
Detail C
Figure 6: Crimping
Plunger in Upper
Cavity of Rear Die
Detail A
Detail B
Fiber Bottomed in Plunger
of Connector Assembly
Bend Formed to
Hold End of Fiber
in Place
Ferrule Facing
Outward
Buffer Held in
Cable Clamp Cleaved End of Fiber
Even with Front of
Arm of Cable Holder
Small White Tubing
If Alternate Step (6 of
Paragraph 6.1) was Used

408- 10272
LightCrimp Plus ST Fiber Optic Connector Kit 2064757- 1
Rev C8 of 8 Tyco Electronics Corporation
Figure 7: Crimping
Detail A Plunger in First Cavity of
FrontDiewithFerrule
Pointed in Direction of Arrow
Detail B
Shoulder of Plunger
Against Edge of
GrooveinDie
Black
Tubing
Detail C
Large Diameter End
of Crimp Eyelet in
Last Cavity of
FrontDiewithFerrule
PointedinDirection
of Arrow
Small Diameter End
of Crimp Eyelet in
Middle Cavity of
Front Die with
Ferrule Pointed in
Direction of Arrow
Detail D
Figure 8: Crimping
Ferrule Dust Cap
Over Ferrule
Strain Relief Over Crimp Eyelet
and Against Connector
DANGER: Never View Active Fiber Signals
7. REVISION SUMMARY
Revisions to this instruction sheet include:
SModified Step 4 of Paragraph 5.2
SAdded Step 6 to Paragraph 6.1
SAdded Detail D to Figure 5 and modified
Detail A of Figure 6