5
Step-by-Step Plastic Cable Connectoring Instructions
The following step-by-step guide describes how to termi-
nate plastic ber optic cable. It is ideal for both eld and
factory installation. Connectors can be easily installed
on cable ends with wire strippers, cutters and a crimping
tool.
Finishing the cable is accom plished with the Broadcom
AFBR-4594Z Polishing Kit, consist ing of a Polishing Fixture,
600 grit abrasive paper and 3 µm pink lapping lm (3M
Company, OC3-14). The connector can be used immedi-
ately after polishing.
Materials needed for plastic ber termination are:
1. Broadcom Plastic Optical Fiber Cable (Example: HFBR-
RUS500Z, HFBR-RUD500Z, HFBR-EUS500Z, or HFBR-
EUD500Z)
2. Industrial Razor Blade or Wire Cutters
3. 16 Gauge Latching Wire Strippers (Example: Ideal
Stripmaster
TM
type 45-092).
4. HFBR-4597Z Crimping Tool
5. AFBR-4594Z Polishing Kit
6. One of the following connectors:
a) HFBR-4501Z/4503Z Gray Simplex/Simplex Latching
Connector and HFBR-4525Z Simplex Crimp Ring
b) HFBR-4511Z/4513Z Blue Simplex/Simplex Latching
Connector and HFBR-4525Z Simplex Crimp Ring
c) HFBR-4506Z Parchment (o-white) Duplex Connector
and HFBR-4526Z Duplex Crimp Ring
d) HFBR-4516Z Gray Latching Duplex Connector and
HFBR-4526Z Duplex Crimp Ring
Step 1
The zip cord structure of the duplex cable permits easy
separation of the channels. The channels should be sepa-
rated a minimum of 100 mm (4 in) to a maximum of 150
mm (6 in) back from the ends to permit connectoring
and polishing.
After cutting the cable to the desired length, strip o
approxi mately 7 mm (0.3 in.) of the outer jacket with the
16 gauge wire strippers. Excess webbing on the duplex
cable may have to be trimmed to allow the simplex or
simplex latching connector to slide over the cable.
When using the duplex connector and duplex cable, the
separated duplex cable must be stripped to equal lengths
on each cable. This allows easy and proper seating of the
cable into the duplex connector.
Step 2
Place the crimp ring and connec tor over the end of the
cable; the ber should protrude about 3 mm (0.12 in.)
through the end of the connector. Carefully position the
ring so that it is entirely on the connector with the rim of
the crimp ring ush with the connec tor, leaving a small
space between the crimp ring and the ange. Then crimp
the ring in place with the crimping tool. One crimp tool is
used for all POF connector crimping requirements.
For applications with extreme temperature operation
or frequent temperature cycling, improved connector
to cable attachment can be achieved with the use of an
RTV (GE Company, RTV-128 or Dow Corning 3145-RTV)
adhesive. The RTV is placed into the connector prior to
insertion of the ber and the ber is crimped normally.
The connector can be polished after the RTV has cured
and is then ready for use.
Note: By convention, place the gray connector on the trans-
mitter cable end and the blue connector on the receiver cable
end to maintain color coding (dierent color connectors are
mechanically identical).
Simplex connector crimp rings cannot be used with duplex
con nectors and duplex connec tor crimp rings cannot be
used with simplex connectors because of size dierences.
The simplex crimp has a dull luster appear ance; the duplex
ring is glossy and has a thinner wall.
