Vytran PTR-200-XLR User manual

PTR
PTRPTR
PTR-
--
-200
200200
200-
--
-XLR
XLRXLR
XLR
Operator’s Manual
Version 3.0
United States:
1400 Campus Drive West •Morganville, NJ 07751
[phone] •[phone] •Fax [phone]
England:
8, Kew Court •Pynes Hill Office Campus •Exeter, EX2 5AZ
[phone] •Fax [phone]
Web: http://www.vytran.com
This manual is currently being
reviewed. An updated version
in Thorlabs’ template will be
available in the coming weeks.
Please refer to the website for
the most up-to-date specifications.

PTR-200-XLR Operator’s Manual Version 3.0. Printed in the United States.
The contents of this manual are the property of Vytran LLC and are copyrighted. Under the copyright
laws, the documentation may not be copied, photocopied, reproduced, translated, or reduced to any
electronic medium or machine-readable form, in whole or part, without the prior written consent of Vytran
LLC.
Copyright 2005 Vytran LLC
1400 Campus Drive
Morganville, NJ 07751 USA
Phone: [phone]
[phone]
FAX: [phone]
http://www.vytran.com

Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 iii
Table of Contents
1 Introduction.............................................................................................................................................1
1.1 Parts Checklist ................................................................................................................................1
1.2 Setting UP the PTR-200-XLR..........................................................................................................2
2 Controlling the PTR-200.........................................................................................................................3
2.1 Unit Control Buttons........................................................................................................................3
2.2 Handset Controller ..........................................................................................................................4
2.2.1 Power Up .................................................................................................................................4
2.2.2 User Parameter Files...............................................................................................................4
2.2.3 Recoat Parameters..................................................................................................................5
2.2.4 Options Menu...........................................................................................................................6
3 Priming the PTR-200..............................................................................................................................7
3.1 Cleaning Recoat Mold.....................................................................................................................7
3.2 Priming the Injection System...........................................................................................................7
3.2.1 Manual Injection System..........................................................................................................8
3.2.2 Remote Manual Injection System ............................................................................................8
3.2.3 Automatic Injection System....................................................................................................10
4 Recoat Process....................................................................................................................................12
4.1 Loading the Fiber ..........................................................................................................................12
4.2 Recoating......................................................................................................................................13
4.2.1 Manual Injection System........................................................................................................13
4.2.2 Manual Remote Injection System ..........................................................................................14
4.2.3 Automatic Injection System....................................................................................................14
4.2.4 Curing the Coating.................................................................................................................15
4.3 Recoat Diagnostics .......................................................................................................................16
5 Maintenance.........................................................................................................................................17
5.1 Planned Maintenance....................................................................................................................17
5.2 Cleaning........................................................................................................................................17
5.2.1 Clean Mold.............................................................................................................................17
5.2.2 Check/Clean FHB Inserts ......................................................................................................18
5.3 Recoat System Maintenance ........................................................................................................18
5.3.1 Check Recoat Lamps.............................................................................................................18
5.3.2 Empty the Manual Injection System.......................................................................................18
5.3.3 Flush the Manual Remote Injection System ..........................................................................18
5.3.4 Purge the Automatic Injection System...................................................................................19
5.3.5 Flush Automatic Injection System..........................................................................................20
5.3.6 Replace Recoat Material........................................................................................................20
5.3.7 Replace and Align Mold Assembly.........................................................................................21
5.3.8 Replace Tungsten Halogen Lamps........................................................................................21
5.3.9 Replace Vacuum V-Groove Inserts .......................................................................................22
Appendix A: Material Data Safety Sheet......................................................................................................23

Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 iv
Table of Figures
Figure 1: System Components......................................................................................................................2
Figure 2: Controller Options...........................................................................................................................3
Figure 3: Unit Control Buttons .......................................................................................................................3
Figure 10: Handset Controller........................................................................................................................4
Figure 14: Loading the manual injection port.................................................................................................8
Figure 15: Remote Manual Injector ...............................................................................................................9
Figure 16: Recoat bottle access ..................................................................................................................10
Figure 17: Recoat material flow...................................................................................................................11
Figure 18: Recoat and Proof Test Components..........................................................................................12
Figure 19: Manual Recoat Injection.............................................................................................................13
Figure 20: Remote Manual Recoat Injection ...............................................................................................14
Figure 21: Automatic Recoat Injection.........................................................................................................15
Figure 22: Remote Injection System............................................................................................................19
Figure 23: Recoat System ...........................................................................................................................20
Figure 24: Remove Recoat Assembly.........................................................................................................21
Figure 25: Align Recoat Mold.......................................................................................................................21
Figure 26: Replace V-groove insert.............................................................................................................22

Introduction
Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 1
1 Introduction
The PTR-200-XLR is an extended length optical fiber recoater that restores a flexible protective polymer
coating to a stripped section of fiber. It is designed for fiber gratings and similar applications where longer
sections of bare (stripped) fiber need to be recoated.
Vacuum V-groove fiber holding blocks are used to position the fiber at the recoat station. A split quartz
recoat mold is manually closed around the fiber to form the mold cavity.
1.1 Parts Checklist
When unpacking the PTR-200 for the first time, check to make sure that you have the following:
•PTR-200-XLR Recoater
•12.5V Power Supply
•AC power cord
•DC power cable
•RS-232 communication cable
•Tool kit containing:
UV curable acrylate
5/64” Allen wrench
Cotton swabs
3/32” Allen wrench
Lens tissue
0.035” Allen wrench
Quartz mold cleaning brush
Two (2) replacement UV lamps
Injection syringes and caps (for units without automatic or manual injection)
XLR-200-CX Handset Controller
If you are missing any of the above or need replacements, please contact Vytran.

Introduction
Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 2
Figure 1: System Components
1.2 Setting UP the PTR-200-XLR
1. Connect the DC power cable from the “DC Out” connector on the power supply to the connector
labeled “POWER 12.5V” on the back of the PTR-200-XLR. Plug the power supply into an AC
source of 85-264 volts, 47-63 Hertz, using the power cord provided.
2. Make sure power to the XLR is turned off. Connect the cable of the Handset Controller (XLR-200-
CX) to the connector on the back of the XLR labeled “Display/Serial”.

Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 3
2 Controlling the PTR-200
The PTR-200-XLR can be operated using either the two (2) buttons on the unit, or via a display controller:
•A Handset Controller (XLR-200-Cx) can be used to control the PTR-200 or to reprogram process
parameters
Figure 2: Controller Options
2.1 Unit Control Buttons
The PTR-200-XLR has two Unit Control Buttons that enable the user to inject and cure recoat material.
The inject button is only enabled if an optional Automatic Injection System is purchased with the PTR-200-
XLR. All parameters are preset and cannot be changed without an optional controller in conjunction with
the Unit Control Buttons (see below for control options).
Figure 3: Unit Control Buttons
Inject Button:
Injects recoat material while button is depressed (for units with Automatic Injection
and Handset Controller.)
Cure Button: With recoat mold lid closed, it turns on the UV lamps for the preset cure time.
With Recoat lid open, it performs a bulb check (low intensity illumination of the
lamps to verify that all lamps are working correctly.

Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 4
2.2 Handset Controller
2.2.1 Power Up
With the Handset Controller connected to the XLR:
•Turn on the external power supply using the switch above the output cable.
•Turn on the XLR using the switch located at the back of the unit.
The system will go through an initialization process that will home and fill the internal recoat pump (if so
equipped). During initialization the serial number of the Handset Controller and version of code in the
Controller will be displayed. Once initialization is complete, the display will switch to the Main Menu
screen.
Figure 4: Handset Controller
2.2.2 User Parameter Files
The Handset Controller provides five user definable parameter files, designated as “File1” through “File 5.
To load a User file:
•At the Main Menu screen, press OPT button.
•Press ‘1’ to scroll through the list until Load Fiber File is displayed and press Select.
•Press ‘1’ to scroll through the list of User files until the desired file is displayed.
•Press select to load the displayed User file.
To save a User file:
•At the Main Menu screen, press OPT button.
•Press ‘1’ to scroll through the list until Save Fiber File is displayed and press Select.
•Press ‘1’ to scroll through the list of User files until the desired file to overwrite is displayed.
•Press select to Save the file to the displayed User file number.
The Handset Controller will always load the User file that is stored in the unit upon power up.

Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 5
2.2.3 Recoat Parameters
The Recoat parameters are accessible by pressing the “CFG” button on the handset. Press the “1” key to
scroll through the parameters. Press the “Select” key to choose the parameter to edit. Then press the
“CFG” key to save changes.
The recoat parameters are defined as follows:
Cure Time:
The amount of time in seconds(1~480) that the curing lamps are on.
Lamp1 Start % Sets the start time of the 2 outer lamps(Set from 0~100% of cure time).
Lamp2 Start %
Lamp3 Start %
Lamp4 Start %
Sets the start time of the 2 Middle Outer lamps(Set from 0~100% of cure time).
Sets the start time of the 2 Middle Inner lamps(Set from 0~100% of cure time).
Sets the start time of the 2 Inner lamps(Set from 0~100% of cure time).
Lamp1 Stop % Sets the stop time of the 2 outer lamps(Set from 0~100% of cure time).
Lamp2 Stop % Sets the stop time of the 2 Middle Outer lamps (Set from 0~100% of cure time).
Lamp3 Stop %
Lamp4 Stop %
Sets the stop time of the 2 Middle Inner lamps (Set from 0~100% of cure time).
Sets the stop time of the 2 Inner lamps (Set from 0~100% of cure time).
Cool Down Time Set from 1~300s. Used to keep the mold from overheating during cure times
longer than 2 minutes. For cure times between 2-4 minutes, the curing process
will be split into 2 equal cure cycles with a Cool Down Time pause in the middle.
Cure times between 4 and 8 minutes will be divided by 4. (For using Low Index
Recoat Material)
Inject Rate: The speed at which recoat material is injected into the mold in microliters per
second (µl/sec). The maximum inject rate is 1.8µl/sec.(Auto Inject systems
only)
Shrink Qty:
Amount of additional recoat material in µl(0.00~5.00) added during the curing
process and is intended to compensate for material shrinkage during cure.
Set to Zero to disable .(Auto Inject systems only)
Shrink Time: Length of the Cure time(listed as a percentage (1~100%)) that the Shrink Qty
will be injected. (Auto Inject systems only)
On non Auto-Inject systems, menu functions relating to the inject pump are not accessible. Any changes
made to the recoat parameters effect only the currently selected User file.
Because recoat material tends to shrink while it cures, the Shrink Qty amt can be set to help compensate
for this shrinkage and help to maintain a smooth surface with minimal imperfections. The table below will
give a safe starting point for some of our most common mold sizes. These are only rough estimates and
should be adjusted until your desired results are achieved.
Shrink Qty amount settings
MOLD SIZE 280µm 430µm 600µm 900µm
SHRINK
AMOUNT
.09µl .25 µl .72 µl 1.44 µl

Vytran LLC: PTR-200-XLR Operator’s Manual Version 3.0 6
2.2.4 Options Menu
The Options Menu provides individual process commands for set-up and service of the MRC. The Options
Menu is accessible by pressing the “OPT” button on the handset. Press the “1” key to scroll through the
Menu. Press the “Select” key to choose the command to execute. A description of all applicable
commands available in the Options Menu is given below.
Lamp Test: Run basic lamp test by flashing the lamps(outer to inner) to
confirm functionality.
Mould Check: Run lamps at low intensity to aid mold alignment. The lamps will
illuminate for up to 30 seconds, or until the ESC button is pressed
on the handset regardless of whether the mold is open or closed.
CAUTION – Appropriate eye protection should always be used when staring at a mold to
prevent unwanted exposure to UV light, especially when the mould lid is open.
Purge Inject Pump: Runs the inject pump purge process as might be required when the
system has been in storage or bubbles have entered the system
following a reservoir bottle replacement. The default number of
purge cycles is 5, with each cycle taking approximately 7 minutes.
During the process, a count is displayed on the handset of the
number of remaining purge cycles. (Auto Inject only)
Inject to Mould: Inject a configurable recoat quantity into the mold. The material is
injected at the configured inject rate and the macro will run
regardless of whether the mould is open or closed. At the end of
the inject process, the handset will display the level of recoat
material left in the syringe. (Auto Inject only)
Load Fiber File: Load one of the 5 saved sets of parameters
Save Fiber File: Save the current set of parameters to another memory ‘slot’