FIBER OPTIC CLEAVING TOOL (GHC100-2TA)

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1 Fiber Optic Tooling DANIELS MANUFACTURING CORP., 526 THORPE ROAD, ORLANDO, FL 32824, USA PHONE (407) FAX (407) COPYRIGHT 2008 ALL RIGHTS RESERVED

2 FIBER OPTIC CLEAVING TOOL (GHC100-2TA) PRECISION Mirror quality finish of cleaved fiber endface with less than 1.0 degree endface angle makes additional polishing unnecessary. Ideally suited for cleave & crimp terminations. VERSATILITY Standard tool works on 172 micron, Polyamide coated, aircraft grade, optical fibers. ADJUSTABILITY Can be adjusted for various fiber sizes and bare fiber lengths. Instructions are included. RELIABILITY Gem-quality diamond scribe permits thousands of high quality cleaves without replacement. SPEED Fiber cleaving is performed in seconds. Stripping, clamping, and other preparation vary with application. DURABILITY Outstanding durability due to rugged metal frame construction. MIL-T-83523/10 (Ref.) GHC100-2TA The standard cleaving tool is designed to work with 172 micron, Polyamide coated, aircraft grade, optical fibers and most fiber optic connectors and splices. The rugged carrying case contains the cleave tool assembly plus accessories and instructions to calibrate the tool for exceptionally clean fiber cleaves. A precision lapped, gem-quality (diamond) scribe permits thousands of cleaves without the need for replacement. The stylus performs a scribing motion at the circumference of the fiber, while the fiber is under longitudinal tension. A controlled break occurs with a mirror quality surface. This makes additional fiber endface preparations, such as polishing, unnecessary in many applications. Endface angles are typically less than 1.0 degree from the perpendicular. The following patents apply to this tool: 4,530,452 4,627,561 COPYRIGHT 2008 DANIELS MANUFACTURING CORP., 526 THORPE ROAD, ORLANDO, FL 32824, USA PHONE (407) FAX (407) DMC@DMCTools.com ALL RIGHTS RESERVED 09/08 GHC100-2TA-SL

3 FIBER OPTIC CLEAVING TOOL (GHC100-2TA) SPECIFICATIONS DIAMOND DURABILITY 3,000 cycles without replacement (in typical applications). BLADE PROTRUSION 1/4 to 1/2 fiber diameter. TYPE OF FIBER Polyamide coated, aircraft grade FIBER DIAMETER RANGE 172 um. (with coating) FIBER PRE-TENSION 150g to 200g (standard). PRE-TENSIONING TIME 3 to 5 seconds. DIAMOND GEOMETRY Chisel, 60 to 85 degrees cutting edge. DIAMOND EDGE PERPENDICULARITY TO THE FIBER AXIS + or -0.5 degrees. BARE FIBER LENGTH.750/.875 Typical. TYPICAL END FACE ANGLE 0.3 to 1.5 degrees (See chart above) The cleave tool is a precision built tool utilizing a gem quality diamond cleaver. If properly cared for, it will perform thousands of proper cleaves. As with any precision tool, it is recommended that a periodic calibration verification program be followed to assure that the tool is still cleaving properly. Also, the diamond may become damaged, or worn, thereby requiring replacement and recalibration. Replacement and Recalibration of the tool by the user. Consult the user instructions supplied with the tool or contact DMC customer service for instructions. Cleave Tool Return The entire cleave tool may be returned to DMC prepaid for calibration and/ or complete refurbishment. The customer will be advised of the repair/ service charge upon completion of an evaluation of the cleave tool. Contact DMC Sales for the details of this program. TYPICAL CLEAVED FIBER ENDFACE This view represents a fiber endface as viewed by an interferometer (50/125 micron corning fiber core). The light/dark bands (fringes) indicate end face angle. COPYRIGHT 2008 DANIELS MANUFACTURING CORP., 526 THORPE ROAD, ORLANDO, FL 32824, USA PHONE (407) FAX (407) DMC@DMCTools.com ALL RIGHTS RESERVED 09/08 GHC100-2TA-SL

4 GHC100-2TA FIBER OPTIC CLEAVE TOOL DATASHEET GHC100-2 GHC100-2TA GHC100-BFRT GHC-SCR GHC100-2TA-DS Fiber Optic Cleave Tool with Case and the following: Fiber Optic Cleave Tool Broken Fiber Removal Tool Kit Styrofoam Cleaning Rod Kit Datasheet GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 1 of 12 REV. A 7/05

5 FIBER OPTIC CLEAVE TOOL GHC100-2TA 1. OPERATING INSTRUCTIONS a. Each Cleave Tool is factory adjusted and inspected by the DMC Fiber Optic technician prior to shipment. Additional inspection and documentation is performed by the DMC Quality Assurance Department. Figure 1: Side view of Fiber Optic Cleave Tool GHC100-2TA b. To open the fiber clamp and lock it in the open position push inwardly on the release knob as shown in Figure 2. Figure 2: Open clamp position ready to receive fiber c. Strip the jacket, strain member and buffer from the fiber to the specified length, leaving a minimum of 1.25 bare fiber. d. Remove the protective cap from the diamond. The diamond and drum assembly will be in the down position as shown in Figures 1 and 2. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 2 of 12 REV. A 7/05

6 e. Insert the fiber into the Cleaving Tool by passing the fiber through the drum/alignment tube until it stops as illustrated by Figure 3 and further described in Section 4a. Figure 3: Inserting a fiber into the Cleave Tool f. Clamping the cable release the cable clamp set screw (35), open the cable clamp by pressing down on the cable clamp lever (6). Place the fiber cable in the cable clamp opening and confine the fiber cable by releasing the spring loaded cable clamp lever. Use the cable clamp set screw (35) for additional pressure. g. Use the fiber clamp (4) to apply tension to the bare fiber by pressing inwardly and upwardly on the release knob (18); slowly lower the fiber clamp pad down onto the fiber. Leave at rest for five seconds to ensure stability of the clamped fiber, refer to Figure 4 and Section 4. Use tweezers to pre-tension the fiber, if necessary, before releasing the fiber clamp if loose fiber exists. Figure 4: Applying tension to the bare fiber prior to cleaving In order to assure that the rubber pad (19) on the fiber clamp (4) grips the bare fiber without slipping, it is necessary to wipe each bare fiber with a tissue dampened with an approved cleaner/solvent. In addition, if slipping is noticed wipe the rubber pad with alcohol or acetone. WARNING: Follow user safety instructions on alcohol and acetone containers. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 3 of 12 REV. A 7/05

7 h. To cleave the fiber, spin the drum (7) a number of times by using a rapid pulling tangential stroke of the index finger as shown in Figure 5. The number of turns required depends upon the fiber itself, the diamond position, and the fiber clamp spring tension. Figure 5: Rotating the drum to cleave the fiber i. Once a cleave is achieved release the cable clamp (6) and remove the cable. j. Release the fiber clamp (4) by pressing the release knob (18). Remove the excess fiber by a sliding motion of the index finger away from the tool as illustrated in Figure 6. Figure 6: Removing excess fiber after cleave k. Check the endface quality of the fiber if necessary recleave the fiber. (See cleave tool factory adjustment procedure in Section 3a.) l. Clean diamond frequently as described in Section 3c and as illustrated in Figure 7. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 4 of 12 REV. A 7/05

8 Figure 7: Cleaning the diamond 2. APPLICATION NOTES a. The proper cleaving of an optical fiber is achieved by the combined effect of the diamond scoring of the fiber and the tension applied to the fiber through the fiber clamp spring force. Each cleaving tool is adjusted by DMC to provide a mirror surface cleave and an endface angle that is suitable for the intended operation. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 5 of 12 REV. A 7/05

9 Figure 8: Exploded view of Fiber Optic Cleave Tool 1. Base 24. Pin 2. Handle 25. Bearing 3. Bracket 26. Torsion Spring 4. Fiber Clamp 27. Spring 5. Cable Clamp 28. Spring 6. Cable Clamp Lever 29. Pin 7. Drum 30. Pin 8. Shaft 31. Set Screw 9. Diamond Cleaver 32. Pin 10. Alignment Tube (bare fiber) 33. Pin 11. Not used in model GHC100-2TA 34. Screw 12. Cover 35. Cable Clamp Screw GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 6 of 12 REV. A 7/05

10 13. Spacer 36. Screw 14. Spacer 37. Spring Plunger 15. Bushing 38. Nut 16. Collar 39. Nut 17. Positioner 40. Set Screw 18. Release Knob 41. Set Screw 19. Pad 42. Nut 20. Pad 43. Protecting Cap 21. Nut 44. Set Screw 22. Rubber Washer 45. Pin Dowel 23. Nut 46. O-Ring Seal 3. DIAMOND CONSIDERATIONS The diamond in the cleave tool is a high precision gem quality chisel blade instrument which will last indefinitely with proper care. Do not allow the diamond to come in contact with hard or sharp objects such as a screwdriver or pliers. Should the diamond be damaged, the diamond cleaver (9) should be removed and replaced (see Section 9). a. Diamond position adjustments Adjustment of the diamond is to be accomplished with the drum assembly in place on the cleave tool as shown in Figure 9. The diamond cleaver is to be retracted by rotating the outer adjusting nut (21) clockwise until there is clearance so that a test fiber can be pre-tensioned in the tool impinging slightly on the diamond cleaver (no more than ¼ of the fiber diameter). Turn the inner adjusting nut counterclockwise applying pressure to the optional rubber washer (22) if present. Both adjusting nuts need to be tight in order to produce consistent results. Inspect the angle of the diamond blade to ensure it remains at a 90 position to the fiber. Rotate the drum. If the scoring is insufficient to obtain a cleave, and it is determined that the tension on the fiber is correct, turn the outer adjustment nut counterclockwise in small increments until a satisfactory cleave is obtained. Keep in mind that an adjustment with one adjusting nut warrants tightening the connection with the other adjusting nut. Examine the endface to assure that all aspects of the cleave are of acceptable quality. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 7 of 12 REV. A 7/05

11 Figure 9: Diamond position adjustment b. Diamond edge quality A sharp scoring chisel edge is provided by the precision gem quality diamond blade. The diamond should be examined regularly using a 10X magnification or greater power optical viewing device. If the diamond is chipped, dull or broken, remove the diamond cleaver (9) and replace with a new diamond cleaver. c. Diamond cleanliness The pressed Styrofoam cleaning rod has been specially produced in a quality that is suitable for cleaning the diamond cleaver (see Figure 7). Follow these instructions after each use. 1. Bevel the tip of the rod to a 45 angle with an oil-free single edge razor blade. 2. Dip the tip of the rod in absolute alcohol (ethanol) and shake off any excess. 3. Slightly press the diamond s cleaving edge into the cleaning rod as shown in Figure 7. The diamond edge and the rod edge are at 90 to one another. Pass the rod along the entire length of the diamond, cleaning both faces of the diamond simultaneously. 4. Repeat the process using a different portion of the rod. NOTE: Although it may not be necessary to clean the diamond after each cleave, it is imperative to keep the diamond clean. Operator discretion is advised. 4. FIBER TENSION a. Fiber pretensioning Fiber pretensioning is necessary to hold the fiber taut during the scoring/cleave cycle. This tension is accomplished by spring (28) when fiber clamp (4) is released (see Figure 4). The spring force can be set by adjusting set screw (41) and lock nut (42) within the range of 150 to 250 grams. This spring force is set by DMC during the initial adjustment process. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 8 of 12 REV. A 7/05

12 b. Spring adjustment/replacement Remove fiber clamp (4) from tool base (1) by releasing top set screw (31). Gently pull the fiber clamp (4) outwardly and replace spring (28). Reverse the procedure to reassemble. Readjust set screw (41) and lock nut (42) to the desired spring force (see Figure 10). Figure 10: Fiber clamp tension adjustment 5. CLAMPS a. Fiber clamp force Spring (27) (see Figure 8) provides the fiber clamping force. This spring has been installed during manufacturing and covers a broad range of fiber optic cleaving applications from 125 to 425 microns. b. Fiber clamp lock mechanism Fiber clamp (4) opens and locks by pressing on knob (18). If readjustment of the locking mechanism is desired release lower set screw (31) and relocate collar (16) (see Figure 8). c. Cable clamp adjustment The cable clamp lever (6) opening is adjusted by cable clamp screw (35). If additional pressure is required to secure the cable and prevent fiber slippage in the cleaving area, cable clamp screw (35) may be used to apply additional pressure to grip the cable tighter. Your cleave tool can be adjusted to accept a wide variety of fiber optic cables. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 9 of 12 REV. A 7/05

13 6. DRUM ADJUSTMENTS a. Drum concentricity The procedures described in this section are intended for use within a Fiber Optic Laboratory when the most exacting drum alignment is required. To check for concentricity of the drum and cleaving mechanism follow this procedure: Strip the fiber optic cable in accordance with strip lengths indicated in the termination specification or process being used (1.75 minimum bare fiber required) and insert it into the drum assembly. Keep fiber clamp (4) open by not releasing knob (18). Rotate drum (7) so that the diamond cleaver (9) is in a horizontal position as shown in Figure 11. When the diamond cleaver is adjusted to the fiber, the diamond will impinge upon the fiber approximately ¼ of the fiber diameter. Figure 11 illustrates the deflection of the fiber as the drum is rotated 180 from positions a to b. Figure 11: Setting up drum for concentricity test Referring to Figure 12, visually examine the deflection under 10X magnification. If there is a visually detected difference between C1 and C2 follow this procedure to bring into alignment. Release nut (39) and rotate shaft (8) in small increments until C1 and C2 are equal. Retighten nut (39). Any minute differences in concentricity will now be balanced by the fiber clamp (4). Figure 12: Concentricity test GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 10 of 12 REV. A 7/05

14 b. Clearing and changing fiber alignment tubes Alignment tubes can be cleared and/or replaced if they become blocked by debris. DMC supplies a Broken Fiber Removal Tool Kit (GHC100-BFRT) which can be used to clear a blockage prohibiting fiber insertion (see Section 7b). If debris is unable to be cleared the alignment tube may be replaced. 7. CURVED FIBER a. Curved Fiber Occasionally a fiber exhibits a permanently induced curvature from spool winding. If a curved fiber is to be cleaved it must be positioned with the curved end of the fiber pointing down into the fiber clamp (4) as illustrated in Figure 13. Figure 13: Cleaving a curved fiber b. Jamming If alignment tube (10) becomes obstructed, the broken fiber removal tool (GHC100-BFRT) should be used to clear the obstruction. When the condition is encountered, make sure the diamond cleaver (9) is fully protected before attempting to clear the tubes. Use the removal tool to probe from either end through the alignment or entry tube until the obstruction is removed. IMPORTANT: Do not attempt to place any object larger than Ø.009 into the drum/alignment tube. c. Retractable handle To release the handle, pull plunger 37 and pivot the handle (2) to the extended hand held position. Set screw (40) provides a stop for the handle in the open position (see Figure 8). d. Serial number All Fiber Optic Cleave Tools are serially numbered when manufactured. This number should be referenced when corresponding with DMC regarding your unit. e. Diamond protection When the Cleave Tool is not in active use, always protect the diamond by sliding on the protective cap (43). GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 11 of 12 REV. A 7/05

15 f. Warranty Limited Warranty Daniels Manufacturing Corporation warrants each new unit sold by it to be free from defects in material and workmanship under normal use and service. Its obligation under this warranty is limited to the free correction or, as its option, the refund of the purchase price of any such unit which proves defective within ninety (90) days after delivery to the first user, provided that the unit is returned to it with all transportation charges prepaid and which shall appear to its satisfaction, upon inspection by it, to have been defective in material or workmanship. This warranty shall not cover any damage to such products, which in the opinion of Daniels Manufacturing Corporation, was caused by normal wear, misuse, improper operation or accident. DANIELS MANUFACTURING CORPORATION IS NOT LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY NATURE OR KIND RESULTING FROM THE USE OF ANY OF ITS PRODUCTS. This warranty is in lieu of all other warranties express or implied. No warranty, expressed or implied, is made or authorized to be made or assumed with respect to products of Daniels Manufacturing Corporation, other than that herein set forth. GHC100-2TA-DS 2005 Daniels Manufacturing Corporation Page 12 of 12 REV. A 7/05

16 Miniature Open Frame Crimp Press (UDT3) DMC Introduces the Ultimate Portable Crimp Press for Fiber Optic Assembly and Electronic Cable Crimping. The UDT3 crimp tool features a system of interchangeable dies which eliminate the need of separate fixed die crimp tools for each and every different application. The versatile UDT3 can be used as a bench top press or as a hand tool. It accepts DMC s common X series dies (M22520/10 Series), which are snapped into the tool frame and retained in place by internal spring clips. Dies may be permanently secured, if desired, by driving a roll pin into the holes provided. Hexagonal crimp dies are available in a variety of combinations having single, double, and even triple cavity design. Consult DMC for Die part numbers. Dies in various crimp patterns are also available for insulated and uninsulated terminal lugs, wire splices and end caps. The UDT3 is 9 in length and weighs 11 oz. Many maintenance and manufacturing concerns have been standardized on this model, eliminating the cost associated with maintaining and calibrating bulky inventories of single purpose tools. As new requirements evolve, a new set of dies is all that s required to meet the demand. A truly modern concept which will not require major change with time only simple additions. The tool frame is equipped with a positive ratchet assembly which controls complete handle movement in both directions. DANIELS MANUFACTURING CORP., 526 THORPE ROAD, ORLANDO, FL 32824, USA PHONE (407) FAX (407) DMC@DMCTools.com COPYRIGHT 2008 ALL RIGHTS RESERVED 09/08 UDT3-SL

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19 HT260-2N FIBER OPTIC RETENTION TESTER SET This tool set meets all requirements of NAVY Drawing The DMC Standard Fiber Optic Retention Tester for testing the proper seating of fiber optic termini in aircraft fiber optic systems. COPYRIGHT 2008 DANIELS MANUFACTURING CORP., 526 THORPE ROAD, ORLANDO, FL 32824, USA PHONE (407) FAX (407) ALL RIGHTS RESERVED 09/08 HT250-2N-SL

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