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”.

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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.

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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.

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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

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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’

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3 Priming the PTR-200
The recommended recoat material for use in the XLR is ANGSTRÖMBOND
®
950-200, which is
manufactured by Fiber Optic Center™, Inc. This is a UV curable multifunctional acrylate coating that has
been optimized for recoating applications. Do not attempt to use alternate recoat materials without first
consulting Vytran on compatibility with the XLR.
Note: UV Curable recoat materials do have a limited shelf life of approximately 18 months from date of
manufacture. Using material that has passed its expiration date may cause both pump performance and
recoat quality issues.
WARNING
UV curable acrylate recoat materials can be hazardous to your health if not handled properly. Read the
Material Safety Data Sheet provided in: 5.3.9Appendix A: Material Data Safety Sheet, and make sure to
follow all precautionary guideline when working with this material.
3.1 Cleaning Recoat Mold
The recoat mold assembly contains two very flat quartz plates, each with a semi-circular channel running
longitudinally down the center of their mating surfaces. One plate is mounted in the hinged top which,
when closed, forms a circular mold cavity with the bottom plate. In order for the top and bottom plates to
mate flush together, they must be cleaned of all dirt and/or coating particles.
The quartz mold plates can be cleaned with a cotton swab wetted with acetone or isopropyl alcohol.
Acetone cleans more thoroughly than alcohol and will also soften and lift away any cured recoat material.
Do not use excessive scrubbing or scraping action to clean the mold plates. Typically a single wipe from
left to right across both top and bottom mold plate is sufficient to clean the plates.
If the recoat mold does have an accumulation of cured recoat material stuck to the plates, allow the
cleaning solution (preferably acetone) time (60-90 seconds) to soften and lift any cured material. The soft
Vytran “toothbrush” provided can be used occasionally to clean the mold channels of any cured coating
particles.
Note: The top surface of the bottom mold plate has an optical coating that blocks UV light. Great care
must be taken not to scratch or abrade this coating. Do not rub any hard objects across the surface of
the plates as this could scratch the optical coating or chip the edges of the mold channel and
degrade the quality of the recoat.
3.2 Priming the Injection System
The PTR-200-XLR can be configured with one of three recoat injection systems:
•Manual Injector
•Remote Manual Injector
•Automatic Injector
For priming the injection system go to the appropriate chapter below.
WARNING
UV curable acrylate recoat materials can be hazardous to your health if not handled properly. Read the
Material Safety Data Sheet provided in: 5.3.9Appendix A: Material Data Safety Sheet, and make sure to
follow all precautionary guideline when working with this material.

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3.2.1 Manual Injection System
The top quartz plate contains an injection port, which must be filled with UV acrylate material prior to
placing the fiber in the recoat mold. The injection port can be filled by using a syringe (supplied) to
dispense the UV material. Care must be taken to prevent the formation of bubbles in the UV material
when loading both the syringe and the injection port.
To load the injection port, use the following procedures (see Figure 5):
1. Fill the syringe by inserting the tip into the bottle of UV material. Make sure that the tip is
immersed in the material and slowly draw out the plunger.
2. If an air bubble gets trapped within the syringe, turn the syringe upside down for several minutes
to allow the bubble to rise to the tip. Gently push in on the plunger to force out the air bubble.
3. Remove the threaded plunger form the injection port.
4. Slowly dispense material from the syringe into the injection port. Make sure not to trap or inject air
bubbles in the port. A good procedure is to dispense a small drop of recoat material at the tip of
the syringe and then touch the drop to the inside back surface of the injection port. Give the
material time to flow down into the inject port – repeating with additional drops until material
almost reaches the top. Some room should be left at the top in order to insert the o-ring plunger.
If too much material is dispensed into the port such that it protrudes above the top, insert a small
scrap piece of fiber into the port to remove some material.
5. Raise the recoat top slightly and press the o-ring of the injection plunger into the port.
6. Rotate the plunger clockwise until the threads just catch.
7. Raise the recoat top and wipe away any excess UV material that may have injected out through
the top. Once the recoat port has been filled, it should contain enough UV material for several
recoats.
8. Clean the mold plates of all excess recoat material.
Figure 5: Loading the manual injection port
3.2.2 Remote Manual Injection System
The PTR-200-XLR is available with an optional remote manual recoat injector that can be fitted to the right
side of the unit. This option provides a method of manually dispensing recoat material directly from the
recoat bottle into the injection port. This system consists of a syringe with a knurled dispensing screw,
which is fitted to a distribution valve with a two-position selection lever. The lever can be positioned
downward (toward the recoat bottle) to draw up material from the recoat bottle, or horizontally (toward the
syringe) to inject material into the mold. The knurled syringe screw is unscrewed (turned counter-
clockwise) to fill the syringe, and screwed in (turned clockwise) to inject material. The selection lever must
always be in the correct position for the desired operation (see table below).
OPERATION
LEVER POSITION
TURN SYRINGE SCREW
Fill syringe with recoat material Down (toward recoat bottle) Counter-clockwise
(unscrew)
Inject recoat material into mold Horizontal (toward syringe) Clockwise (screw in)

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Figure 6: Remote Manual Injector
Prior to first use, the following steps must be followed to load the system with recoat material and purge all
air from lines.
WARNING
UV curable acrylate recoat materials can be hazardous to your health if not handled properly. Read the
Material Safety Data Sheet provided in: 5.3.9Appendix A: Material Data Safety Sheet, and make sure to
follow all precautionary guideline when working with this material.
1. Make sure to have lens tissue and cleaning solution (acetone or alcohol) available prior to
proceeding.
2. Raise the recoater top.
3. Position the selection lever to the Inject position (lever horizontal) and screw in (turn clockwise)
the knurled syringe screw until a slight resistance is felt at the end of travel. Do not use excessive
force when turning in the screw once the end of travel is reached. The end of travel point is
reached when the leading edge of the syringe screw is approximately level with the step in the
syringe body.
4. Fit a recoat bottle with fresh recoat material to the system. The red inject tube should be long
enough to just reach the bottom of the recoat bottle. If using a short (30ml) recoat bottle the red
tube may need to be trimmed to length.
5. Turn the selection lever to the Fill position (lever down). Unscrew (turn counter-clockwise) the
knurled syringe screw to draw recoat material from the bottle into the syringe. Continue
unscrewing the syringe screw approximately ¾ inches or until it is felt to spin freely. Do not pull on
the syringe screw once the end of travel is reached; this will pull the plunger out from the syringe
body.
6. Turn the selection lever to the Inject position (lever horizontal) and screw in (turn clockwise) the
syringe screw until the inject end of travel point is reached.
Note: If the syringe screw was fully unscrewed until it spun freely, a slight forward pressure may
initially be required to re-engage the threads.
7. Watch the injection port for signs of recoat material. Make sure to collect the recoat material as it
comes out of the mold injection port. Do not allow recoat material to run down the face of the
mold and under the mold plate.
8. The above steps of filling and injecting the syringe must be repeated several times to fully
displace air from the system. Recoat material should run freely from the mold without bubbles. If
bubbles are still present, run additional fill-inject sequences. It may help to turn the recoat plunger
back and forth several times during the inject sequence in order to remove air trapped at the
o-ring seal. It is also sometimes helpful to fill the syringe and then lift the left side of the unit such
as to angle the syringe approximately 45 degrees. Leave the unit angled in this position for
approximately 15 minutes. This will allow any air trapped in the syringe to rise up towards the
distribution valve such that it can then be injected out.
9. Once the system runs free of air bubbles, clean the mold plates of any excess recoat material.

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3.2.3 Automatic Injection System
The PTR-200-XLR is available with an optional automatic recoat injection pump fitted inside the unit. If
equipped with this option, the system must first be filled and purged with recoat material prior to operation.
Follow the below steps to initialize this system.
WARNING
Prior to handling the UV acrylate material, be sure to read the Material Safety Data Sheet provided in the
5.3.9Appendix A: Material Data Safety Sheet.
1. Remove the front panel by removing four (4) socket head cap screws. A 3/32 Allen wrench is
provided in the tool kit.
2. Unscrew the recoat reservoir (brown bottle) shown in Figure 7 and fill ¾ full with recoat material
(ANGSTRÖMBOND
®
950-200), being careful not to generate air bubbles.
3. Screw the reservoir bottle back into place and replace the front panel.
Figure 7: Recoat bottle access
4. Before turning on the XLR, connect the Handset Controller.
5. Switch the XLR on and wait for the system to initialize.
6. Execute 5 purge cycles, which will take approximately 30 minutes. Each purge cycle will draw
recoat material from the bottom of the bottle through the red fill tube and inject material back into
the top of the bottle through the green purge tube.
7. After completion of the pump purge cycle, the green inject tube that runs from the pump to the
inject port of the mold must also be purged. Raise the recoat mold top and make sure to have
cotton swabs and cleaning solution (alcohol or acetone) available prior to proceeding.

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Figure 8: Recoat material flow
8. Set the inject rate to 1.8µl/sec.
9. Inject 50µl of recoat material.
Note: Make sure to collect the recoat material as it comes out of the mold injection port. Do not
allow recoat material to run down the face of the mold and under the mold plate.
10. If the system was “dry” prior to proceeding, it will take 4 “inject 50” sequences to purge air
completely from the inject tube.
Note: The syringe in the recoat pump only holds 100µl. The pump will need to fill each time 100µl is
used.
11. Once the pump and the inject tube are purged, clean the mold plates of all excess recoat material.
12. Re-set the inject rate to the appropriate setting.

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4 Recoat Process
The purpose of the recoat is to maintain the strength and flexibility of the fiber or fusion splice by
protecting the glass surface from damage. It should be noted that recoating a splice does not make the
splice stronger.
To recoat fusion splice, the section of exposed fiber is placed in a quartz recoat mold assembly. External
holding fixtures secure the fiber, centering it within the recoat assembly. To allow for tolerance variations
from fiber manufacturers, the diameter of the recoat mold cavity is generally specified to be slightly larger
than the nominal outside coating diameter (e.g. 280 µm for a nominal 250 µm coating).
The recoat process maintains a near original fiber diameter and delivers a flexible fusion splice that can
be handled or tightly coiled as if no splice were present. The integral fiber holding fixtures ensure that the
fiber strength is not degraded by the recoat process.
Figure 9: Recoat and Proof Test Components
4.1 Loading the Fiber
A vacuum V-groove fiber holding block is mounted on each side of the recoat mold assembly to position
the fiber in the mold channel. Vacuum to the fiber holding blocks is automatically turned on when one of
the holding tops is raised.
To position a fiber for recoating, use the following procedures:
1. Raise the recoat top and both holding block tops.
2. Make sure both quartz plates are clean and that the injection port has enough UV material for the
recoat (Manual Injection System) or that the injection system is purged (Automatic Injection
System or Remote Manual Injector).
3. Hold the section of fiber to be recoated taut and lower it down over the fiber holding block such
that the exposed section (fusion splice) is centered in the recoat mold. The fiber will be drawn by
the vacuum into the V-grooves of the holding blocks.

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Note: Vacuum to the V-groove holding fixtures will automatically shut off if left on for more than 30
seconds. To restart the vacuum, close both holding fixture tops and then raise one of the tops. It
is good practice to keep both holding fixture tops closed when not in use.
4. Double check that the exposed section of fiber is centered in the mold. Lower one of the holding
block tops to clamp the fiber.
5. Make sure that the fiber is taut between the holding fixtures and lower the second holding top.
The fiber should be held in line with the recoat mold channel.
6. Lower the recoat top gently to capture the fiber within the mold cavity.
It is important to keep the fiber taut between the holding fixtures to prevent the fiber from bowing at the
recoat. It is also important to avoid touching the exposed glass surface as this could significantly lower
the strength of the fiber. Care should therefore be taken when positioning the fiber in the holding blocks to
avoid rubbing the exposed section of fiber against the mold assembly. If proper care is taken when
positioning the fiber, the recoat process will not degrade the strength of the fiber.
4.2 Recoating
Proceed to the appropriate section based on the type of injection system being used.
4.2.1 Manual Injection System
Once the fiber has been captured in the recoat mold assembly, the injection plunger should be turned
clockwise to inject the UV acrylate material into the mold cavity. The material will flow from the injection
port, down a shallow channel, into the recoat cavity. The plunger should be turned slowly to give the
material time to flow smoothly along the injection path.
Use the viewport in the recoat top to watch the material flow into the mold. Continue turning the plunger
until the acrylate material reaches both coating interfaces of the exposed section of fiber. A slight
migration of the acrylate material outside of the injection path between the two mold plates can be
expected. The bottom mold plate has an optical coating that prevents this material from curing and
forming a characteristic mold flashing. Excessive flashing flow indicates that the plates did not mate flush
together. This is generally caused by dirt particles on the mold plates and/or by trying to recoat a fiber that
has a larger coating diameter than the recoat mold.
Figure 10: Manual Recoat Injection

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4.2.2 Manual Remote Injection System
Make sure that the selection lever is in the inject position (lever up). Once the fiber has been captured in
the recoat mold assembly, the injection syringe should be screwed in (turned clockwise) to inject the UV
acrylate material into the mold cavity. The material will flow from the injection port, down a shallow
channel, into the recoat cavity. The syringe should be turned slowly to give the material time to flow
smoothly along the injection path.
Use the viewport in the recoat top to watch the material flow into the mold. Continue turning the injection
syringe until the acrylate material reaches both coating interfaces of the exposed section of fiber. A slight
migration of the acrylate material outside of the injection path between the two mold plates can be
expected. The bottom mold plate has an optical coating that prevents this material from curing and
forming a characteristic mold flashing. Excessive flashing flow indicates that the plates did not mate flush
together. This is generally caused by dirt particles on the mold plates and/or by trying to recoat a fiber that
has a larger coating diameter than the recoat mold.
Note: If the syringe end of travel is reached during the injection process, the syringe can be re-filled mid-
process by positioning the selection lever to the fill position (lever down) and un-screwing (turn counter-
clockwise) the syringe screw. Once filled, re-position the selection lever to the inject position (lever
horizontal) and continue injecting material into the mold.
Figure 11: Remote Manual Recoat Injection
4.2.3 Automatic Injection System
Once the fiber has been captured in the recoat mold assembly, press and hold the inject button on the top
plate of the unit. This will activate the injection pump and begin dispensing recoat material.
Use the viewport in the recoat top to watch the material flow into the mold. Release the button to stop
dispensing material once it has reached the coating interface.
A slight migration of the acrylate material outside of the injection path between the two mold plates can be
expected. The bottom mold plate has an optical coating that prevents this material from curing and
forming a characteristic mold flashing. Excessive flashing flow indicates that the plates did not mate flush
together. This is generally caused by dirt particles on the mold plates and/or by trying to recoat a fiber that
has a larger coating diameter than the recoat mold.

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Figure 12: Automatic Recoat Injection
4.2.4 Curing the Coating
The liquid UV acrylate material cures to a solid state when exposed to ultra-violet light. The necessary UV
radiation is provided by eight tungsten-halogen lamps located below the bottom mold plate. The optical
coating on the bottom plate ensures that any material which flows between the two plates will not cure and
form a flashing on the recoated section of the fiber.
WARNING
Do not look directly at the recoat assembly while the recoat lamps are on. The recoat lamps emit ultra-
violet radiation which can cause damage to the eyes. The mold top must be closed during recoat lamp
operation.
To cure the fiber coating, use the following procedures:
1. Make sure recoat material has been injected up to or beyond the coating interfaces.
2. Activate the cure process to turn on the UV lamps. The recoat lamps will shut off automatically
after the set cure time.
3. Raise both fiber holding block tops.
4. Raise the recoat mold top by lifting straight up at the two outside corners of the top. A slight force
is typically required to “pop” the top free.
5. Note: Do not lift by or exert any force on the injection port.
6. The fiber may remain tacked to either the top or bottom mold plate. In this case, it may be
necessary to gently pull on the fiber to release it. Try to avoid inducing any sharp bend to the
fiber.
7. Visually inspect the recoated fiber to make sure the recoat reached both interfaces and that there
are no voids or air bubbles in the recoat. The recoat can be gently wiped with a dry lens tissue to
remove any uncured recoat material or light flashing. Do not wipe the recoat with acetone.
8. Clean both top and bottom mold plates with a soft lint-free lens tissue and/or cotton swab soaked
in cleaning solution.
Note: Acetone is the preferred solution for cleaning the mold plates. Acetone cleans more
thoroughly than alcohol and will also soften and remove cured recoat material. The mold plates
can typically be cleaned of excess uncured recoat material with a single wipe from left to right
across both top and bottom plates. Take care to avoid contact with the uncured recoat material
(read “5.3.9Appendix A: Material Data Safety Sheet” before working with recoat material).

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Note: The top surface of the bottom mold plate has an optical coating that blocks the UV light. Great care
must be taken not to scratch or abrade this coating. Do not rub any hard objects across the surface of
the plates as this could scratch the optical coating or chip the edges of the mold channel and
degrade the quality of the recoat.
4.3 Recoat Diagnostics
Problem
Possible Cause
Solution
Fiber snaps when
mold top lowered. Fiber not loaded properly. See “4.1 Loading the Fiber”.
Recoat mold not
properly aligned to
fiber.
Refer to the “5.3.7 Replace and Align Mold Assembly”
section for instructions on realigning the recoat mold
assembly.
Channels of recoat
mold plate are
misaligned..
Contact Vytran for recoater servicing.
Material flows
excessively
outside of mold
cavity or does not
flow down mold
cavity (“puddling”).
Recoat mold plates
are dirty. Dirt between quartz mold plates will not allow them to lay flush, causing the acrylate to flow excessively outside the
mold cavity. The recoat mold plates should be cleaned as
described in the “5.2.1 Clean Mold” section.
Channels of recoat
mold plate are
misaligned.
Contact Vytran for recoater servicing.
Plunger turns
excessively when
injecting acrylate.
Bubbles in injector
port. Empty the recoat injector port (refer to the Maintenance section for instructions) and reload.
Flashing forms
along the length of
the recoat.
Cure time too long. This will increase the modulus of the coating and make it
stiffer. In the future, decrease the cure time. This flashing
can generally be removed by wiping the recoated section
with a dry lens tissue. Do not use a solvent!
Recoat feels tacky
or can be easily
rubbed off by
pulling the fiber
between fingers.
Cure time too short. Increase the cure time.
Recoat lamp(s)
burned out or old. Replace the recoat bulb (refer to the “5.3.8 Replace Tungsten Halogen Lamps” section for instructions).
Fiber sticks to
recoat mold
consistently.
Recoat mold plates
are dirty. Clean the recoat mold plates as described in “5.2.1 Clean Mold”.
Fiber snaps when
lifting the recoat
mold top.
Failed to first release
the holding fixture
tops before lifting the
recoat mold top.
If the recoat mold top is lifted with the holding fixture tops
closed, the fiber may stick to the recoat mold top and snap
or degrade the strength of the fiber. Always open the
holding fixtures before lifting the recoat mold top.