FO Plug Assembly Tool Kit PSM-HCS-KONFTOOL for

HCS Quick Mounting Plug PSM-SET-FSMA/4-HCS

2. Introduction

1. Introduction

What was previously a matter for the FO specialists, is
now available for general use: The on-site assembly of
F-SMA plugs to HCS cable. These cables are the pre-
ferred choice in polymer ber transmission systems
when the range of the system is no longer sufcient.
Using the HCS ber technology (ber cross-section
200/230 m), a distance of up to 400 m can be covered,
depending on the transmission system used.
The on-site preassembly of this cable as is now possi-
ble, is as simple to handle as the familiar polymer ber
technology. Using the new tool set and the correspon-
ding F-SMA plugs, all that time-consuming and pre-
viously usual work can be dispensed with:
crimping
glueing
and polishing
The time needed per plug is thus cut from 20 minutes to
a mere two minutes. The remaining
work to be done:
stripping the bers
pushing on the individual plug components
screwing in the plug
scoring and breaking the bers on the top of the
plug
If necessary (in the case of system extensions or altera-
tions), the plugs can be removed and reconnected.
For technical questions you can reach us at:

PSM-HOTLINE:+49/(0)52 35 / 3 - 19890
FAX: +49/(0)52 35 / 3 - 19899
e-mail: interface-service@phoenixcontact.com

Headquarters:

Phoenix Contact GmbH & Co. Flachsmarktstrae 8-28 32825 Blomberg Germany
Phone +49-(0) 52 35-3-00 Fax +49-(0) 52 35-3-4 1200 http://www.phoenixcontact.com

25
cm
24
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3
2
1
cm
0

2.2. Scope of delivery

'

Multi-purpose knife


^

Stripping tool for single core

Wire-Stripper

Aramide scissors

I

F-SMA plugs

I

Microscope 100x



I

Fiber scoring tool

I

Tape
Operating instructions
Hard-top case

2. Order Data

Type Order No.

Pcs.
Pkt.

HCS plug assembly tool kit

for F-SMA quick mounting plug
PSM-HCS-KONFTOOL 27 99 52 6 1

F-SMA plug set

for DIY assembly,
consisting of 4 quick mounting plugs (HCS ber)
PSM-SET-FSMA/4-HCS 27 99 48 7 1

HCS cable

indoor use
duplex, 200/230 m, outdoor use
PSM-LWL-HCS ...
PSM-LWL-HCSO ...

2.1. Technical Data

Plug type
Cross section
Length incl. bend protection sleeve
Suitable ber type
Insertion loss
Assembly technique
Extraction forces
Torque
Working temperature
Insertion/withdrawal cycles
F-SMA, Type 905 n. IEC 874-2
8.1 mm
63.3 mm (when assembled)
200/230 m step index with single core 2.9 mm
< 2 dB
Triple clamping when plug is screwed together
min. 100 N
min. 0.2 Nm, max. 0.5 Nm
- 20C to 70C
> 250

PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7

PHOENIX CONTACT page 2 of 8

Fiber scoring tool

I
Multi-purpose knife '
Stripping tool for
single core ^
Wire-Stripper
Aramide scissors
F-SMA plug I
Microscope I

Tape

I






3. Assembly instructions

When working with FO cable, please do not fail to obser-
ve the mechanical characteristics as prescribed by the
manufacturer. If the values for the bending radii are lo-
wer and the max. permissible tractive forces are excee-
ded, or if the fibers are trapped, this can result in the
fibers breaking. The relevant details for the Phoenix
Contact cables can be found in the appendix.

Note:

The measure strip printed on the first page can help
you to strip the fibers to the correct lengths.

3.1. Connecting the plug

The FO cables have a complex construction to protect
the fine fibers. The fibers must be freed from these insu-
lating/protective layers for assembly. When assembling
the plugs, please proceed in the order prescribed, so as
to achieve a good and steady quality. Since the con-
struction of the cable varies from manufacturer to manu-
facturer, certain steps may be dispensed with.

3.2. Removing the external sheath

The external sheath of the cable must be removed over
a length of at least 200 mm. The multi-purpose knife

'

is used for stripping. Make sure that only the external
sheath is slit. The extremely sharp blade can easily da-
mage the individual core.
Depending on the type of cable, the next step is to cut
the strain relief yarns, the rodent protection elements
and the stuffing material with the external sheath, using
the aramide scissors

.

PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7
Min. 200 mm
External sheath
Single core
Aramide strain relief
Stuffing material
Rodent protection

must have cross sections of 2.9 mm. (see PHOENIX CONTACT cable PSM-LWL-HCS ... )

The quick connection system described here is suitable for cable lengths of up to 400 m. The individual cores of HCS cables

PHOENIX CONTACT page 3 of 8

.


PHOENIX CONTACT page 4 of 8

3.3. Preparing the plug

Dismantle the plug completely. To do so, hold the plug
in a vertical position, with the bend protection sleeve at
the bottom, and unscrew the plug.
Ensure that you do not lose the core clamper B. It lies
loose in the plug! Also remove the protective cap.

3.4. Pushing on the bend protection sleeve and
clamping nut C

Push the bend protection sleeve together with the clam-
ping nut C over the individual core up to the external
sheath.

3.5. Stripping the individual core

The individual core is stripped using the stripping tool

^

in position 1.6 mm (second notch from the left). Remove
the core sheath over a length of at least 60-70 mm.


3.6. Removing the
protective coating of the fibers

The coating is removed along the entire length using the
wire stripper (can be adjusted 30 = 0.3 mm). First thread
the fiber through the front aperture of the tool and push
it in until stopped by the sheath of the core (pull the ara-
mide yarn to one side!). Press the handles of the pliers
firmly together and hold, then strip the coating from the
fiber along the axis, with a sudden motion.

Caution:

Do not bend the fiber over much after remo-
ving the protective layer.
It can easily break!
1.01. 6 2.0 2.83. 2
1.6

PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7

3
0
30
min. 60-70 mm
Strain relief
Fiber without coating
Coating
Coating
Strain relief
bend protection sleeve
with
Basic body A
Core clamper B
Clamping nut C
Protective cap

PHOENIX CONTACT page 5 of 8

3.7. Cutting the strain relief to length

Shorten the strain relief yarn to a length of
approx. 5 7 mm using the aramide scissors

.

3.8. Pushing on the core clamper B

Slide on the core clamper B, with the clamping slits fa-
cing away. The aramide yarn must also be thread throu-
gh the core clamper B. This procedure can be facilitated
by twisting the clamper whilst sliding it onto the core. It is
sufficient to thread through at least 60% of the aramide
yarn. The core clamper B is pushed onto the individual
core as far as it will go and the core insulation must be
visible through the clamping slits.


3.9. Screwing on the basic part A of the plug.

Carefully thread the fibers into the basic body A. Screw
together the basic body A and the clamping nut C and
tighten the connection firmly (torque + 0.2-0.5 Nm).
To avoid damage to the fibers, the basic body A should
be held firmly during the procedure and the clamping nut
screwed tight.
.


PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7
5-7 mm
Coating
Strain relief
Fiber without coating
Fiber without coating
Coating
Strain relief
Core clamper B
Fiber
Clamping nut C Basic body A

PHOENIX CONTACT page 6 of 8

4. Scoring and Breaking the Fibers with
the Fiber Scoring Tool

Attention:

This tool is a mechanical precision instrument!
Avoid any force, jolts, battering or contamination.

4.1. Preparing the fiber scoring tool

I

Before the plug is screwed in, the tool must be be adju-
sted to the start position.

Important:

Fiber tensioning wheel must be turned towards OPEN.
The fiber scoring wheel must also be turned fully to
OPEN (0). The fiber tensioning wheel is lowered during
this procedure.


4.2. Screwing in the plug

Along the axis, carefully thread the plug in with approxi-
mately 5 cm protruding fiber on the lower side of the tool.
The fiber must travel freely through the tool and exit
through the hole on the opposite side in the fiber tension-
ing wheel. Screw the plug onto the thread as far as it will
go.

4.3. Fixating and tensioning the fibers

Tension the fibers by turning the fiber tensioning wheel
clockwise toward CLOSED.

4.4. Scoring and breaking the fibers

The fiber is broken by slowly turning the fiber scorer from
position OPEN (0) through position (1) to position SCO-
RE (2). The fiber tensioning wheel must remain free to
move (do not hold it or press it). When operating the fiber
scorer between positions 1 and 2, the fiber breaks (con-
trolled) and the fiber tensioning wheel moves on visibly
by approx. 2 mm.
The procedure is now finished and the fiber remnants
can be removed after releasing the tensioning wheel.
The F-SMA plug can be unscrewed.

Attention:

The broken fiber remnants pose a serious risk of injury.
Dispose of them in a container.

PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7
F
a
s
e
n
r
it
z
w
e
r
k
z
e
u
g
0 1 2
Auf
Open
Ritzen
Cleave
Z
u
L
o
c
k A
u
f
O
p
e
n
0 1 2
Auf
Open
Ritzen
Cleave
Z
u
L
o
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k A
u
f
O
p
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n
0 1 2
Auf
Open
Ritzen
Cleave
Z
u
L
o
c
k A
u
f
O
p
e
n

Fiber tensioner
Fiber scorer

OPEN (Pos. 0)

Plug socket
Fiber tensioner

CLOSED

Fiber scorer

Scoring
OPEN

PHOENIX CONTACT page 7 of 8



5. Cleaning the Assembled
Connector

After the assembly, remove residual fiber gently using
the tape supplied with the set. If the connector is not
plugged in immediately, use the yellow protective cap to
protect the connector from dirt.

6. Quality Control

To check the quality of the work, the top of the plug must
be viewed with the microscope

I

. The miscroscope is
unfolded and the F-SMA plug is pushed into the special-
ly designed aperture. The individual strength can be set
using the lateral focusing device.

6.1. Assessment

a) Example of good quality.
b) Dust or residual fiber on the fiber or the connector
increase the attenuation of the of the assembled
connector. Refer to Section 5 for correct cleaning.
c) The odd splintering along the edge of the fiber
hardly impairs the optical performance.
Technical testing of the optical attenuation is,
however, recommended.
d) Furrows, scratches or extensive
splintering raises the attenuation to
non-permissible values. The procedure must
be repeated.

Note:

In extensive FO installations, it is advisable to document the optical attenuations of the cables laid in the installation
plans.
An easy-to-use measuring instrument is available from PHOENIX CONTACT under the following designation:

Design.: PSM-FO-POWERMETER Order No.: 27 99 539
PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7
Focusing screw
Direction viewed

3
0
x

a)
b)
c)
d)
Fiber
Plug surface
Scoring notch

Duplex HCS fiber cable for interior routing
PSM-LWL/HCS...
Fiber

200/230 m step index profile

Attenuation at

660 nm 9.0 dB/km
850 nm 8.0 dB/km
-
-

Individual element 2 complete strands for direct connection of FO plug

Material copolymer [FRNC] flame res., halogen-free
Color red/green
Core cross section 2.9 mm (for 3 mm crimping)
Strain relief elements non-metallic, aramide yarns

External sheath

Material copolymer [FRNC] flame res., halogen-free
Color orange
Dimensions 3.9 x 6.6 mm
Rodent protection -
Water-proofing -
Marking J-VHH 2K200/230 9A17 + 8B17
and running length in m

Weight

28 kg/km

Temperature range

-20 .. + 70 C

Mechanical properties

Bending radius short-term min. 30 mm
continuous min. 50 mm
Tensile strength short-term max. 1000 N
continuous max. 200 N
Lateral pressure short-term max. 100 N/cm
continuous max. 50 N/cm
Impact strength max 1.5 Nm/3 impacts

Material properties

halogen-free; flame-resistant;
free from substances impairing the
paint-wetting performance, in acc. with
chloroform test in acc. with VW-AUDI-SEAT
central standard 57 650

Duplex HCS fiber cable for external routing
PSM-LWL/HCSO...

200/230 m step index
660 nm
at 25 C 10.0 dB/km
at -25 C 14.4 dB/km
850 nm 8.0 dB/km
copolymer [FRNC] flame resistant, halogen-free
gray, with identification of individual cores
2.9 mm (for 3 mm crimping)
non-metallic, aramide yarns
PE
black
11.9 x 11.9 mm
glass fiber yarn
with stuffing material
marking PHOENIX CONTACT FIBER OPTIC CABLE
AT-VQH(BN)2Y 2K200/230 10A17 + 8B20 LG
and running length in m
90 kg/km
-25 ... + 70 C
short-term 300 mm
continuous 300 mm
short-term min. 1000 N
continuous min. 200 N
short-term min. 500 N/cm
continuous min. 300 N/cm
min. 1.5 Nm/3 impacts
UV-resistant;
free from substances impairing the
paint-wetting performance, in acc. with
chloroform test in acc. with VW-AUDI-SEAT
central standard 57 650
PHOENIX CONTACT page 8 of 8

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7. Appendix

7.1. Technical Data
Inner cable Outer cable
PSM-HCS-KONFTOOL Order No.: 27 99 52 6
PSM-SET-FSMA/4-HCS Order No.: 27 99 48 7
7.2. Standards applied

Max. tensile load capacity IEC 794-1-E1 (10/96), proc. 501
Min. bending radius IEC 794-1-E11 (10/96), proc. 513
Lateral pressure capacity IEC 994-1-E3 (10/96), proc. 504
Impact strength IEC 794-1-E4 (10/96), proc. 505
Temperature IEC 794-1-F1 (10/96), proc. 601
Chloroform resistance VW-AUDI-SEAT central standard 57 650
Halogen-free DIN VDE 0472 Part 813
Water-proofing DIN EN 187000-605; 3m, 3d
External sheath
Core sheath
Optic fibers
with primary protection
(coating)
Aramide strain relief
Blind element PE
External sheath PE
Central supporting element
Fiber with coating
Aramide yarn as strain relief
Glass fiber yarn as rodent protection
Stuffing material