HUBBELL HKE_AI502 FibreEx Connector Instruction Manual
- June 12, 2024
- Hubbell
Table of Contents
FIBRE OPTIC CONNECTOR TERMINATION
HOOK UP PROCEDURE
(AI502 Rev
F – June 21)
Images are for illustration purposes only. Product supplied may differ
slightly from that shown.
AI502 – FIBRE TERMINATION PROCEDURE
IMPORTANT NOTE – PRODUCT SAFETY
Read through the entire Assembly Instruction Sheet and any MSDS (Material
Safety Data Sheets) before installing the connectors.
Always wear safety glasses when handling glass fibre. Dispose of glass fibre
debris in a safe manner. Serious injury can occur from loose shards of glass
lodging into skin or eyes.
Protect eyes and skin from exposure to uncured epoxy or alcohol. Be sure all
containers are labelled and sealed properly.
Never view fibre ends if they are illuminated, eye damage may result. Verify
that fibres are not “live” before viewing ends with the microscope.
CP / CR PROCEDURE
- Unscrew the middle nut and back nut from the connector body and remove the armor clamping ring, spigot and insert. If you have purchased a connector with the optional blackout clamp and / or flange, slide these down the cable now (clamp first).
- Remove the two seal assemblies from the box and choose the required seal to suit the diameter of the cable outer jacket.
- Insert the seal into the blackout, ensuring that the flange on the seal goes past the thread as shown.
- Screw the back nut onto the middle nut. Do not compress the seal at this stage.
- Slide the middle nut, blackout and armor clamping ring over the cable ensuring that the clamping ring is pointing in the required direction for the size of armor / braid. The alternative ring is supplied in the box.
RING PART NO.| ARMOUR / BRAID THICKNESS
---|---
ORIENTATION 1| ORIENTATION 2
Os / 0| 0.8-1.25| 0.0 — 0.8
A| 0.8-1.28| 0.0 — 0.8
8| 1.25 —1.6| 0.0 — 0.7
**
CABLE PREPARATION**
IMPORTANT NOTE
The information below is for guidance only.
It is recommended that all cable preparation and polishing procedures etc.
involving fibre optics should be carried out by qualified personnel,
therefore, the following instructions assume that the installer is an
experienced fibre optic professional.
Pin & Socket Inserts
(repeat Pin Insert steps when preparing Socket Insert, taking note of the
differing strip back lengths)
- Strip back the outer sheath, armor and inner sheath of the cable to the same point to reveal the fibre cables as shown below.
- Slide heat shrink over the cable. Using the buffer strip tool, remove the secondary coating then the buffer (primary coating) in small increments (1/4” to 3/8”) to the specified length.
Cable Strip Lengths| Socket| Pin
---|---|---
Secondary (A)| 34.0 ± 0.75| 29.0 ± 0.75
Buffer (B)| 17.8 ± 0.75| 11.0 ± 0.78
Strength Member, if any (C)| 5.85 ± 3.8| 5.85 ± 0.75
Be careful not to damage glass fibre. Follow the direction of the arrow marked
on the fibre strip tool and ensure all bits of buffer are cleaned from the
tool before each length of buffer is stripped.
Note: Check the expiration date of the anaerobic adhesive before using.
Discard any adhesive that is expired. Adhesive should be kept warm in cold
temperatures to facilitate injection into the connector.
- Clean the exposed bare fibre with a wipe saturated in reagent grade alcohol (Isopropyl Alcohol IPA). While cleaning, bend fibre slightly to check for nicks. Fibre will break easily if nicked; remove any residue on the surface.
TERMINAL PREPARATION
For the Socket Only
-
Unscrew the Stainless Steel socket tube and remove the ceramic sleeve. Sockets now ready to be glued and assembled.
-
Using a syringe, insert the base adhesive to fill the inside of the pin / socket (Fig. A). Purge out any air bubbles. Insert needle fully into connector. Tip downward and inject adhesive until a small dot of adhesive appears out of the ferrule tip (See Fig. B). Then pull back slowly while continuing to fill the pin / socket. Place the fibre optic into the Activator Solution (Loctite 648 Retaining Compound). Carefully push the fibre optic through the contact until secondary coating prevents it going further and hold in place for a few seconds until the glue sets.
Note: Adhesive cures rapidly.
Note: Pull back the syringe plunger to aerate the adhesive when not in
use. Adhesive will cure without aeration in a syringe (bottle allows air to
penetrate).
-
The fiber is now ready to be cleaved.
It is recommended that the polishing process of each terminal is completed before moving onto the next.
IMPORTANT NOTE DO NOT OVERPOLISH
Over polishing can create fiber undercutting resulting in expensive rework and product replacement
POLISHING
-
a) Using 9 micron diamond film, remove adhesive (No pad)
b) Then change to 3 micron diamond film to polish (Use pad).
c) Change once again to 1 micron diamond film for the final polish (Use pad).
d) For single mode only, finish by using 65-70 shore rubber pad with a 1 or 3 micron diamond film. -
Replace stainless steel sleeve and secure with Loctite 222
ARMOUR / BRAIDED CABLE
-
Strip back the outer jacket of the cable to expose the armor / braid as shown below.
-
Push the spigot over the inner sheath of the cable and spread the armor / braid over the spigot until the end of the armor / braid is up against the shoulder of the spigot. Position the armor clamping ring onto the armor / braid. If the armor / braid extends over the spigot shoulder then make the necessary cuts on the armor / braid.
-
Place the connector body over the spigot engaging the octagonal portion of the spigot. Move the middle nut up to meet the connector body. Place spanner on the flats of the connector body and hold it in position. Hand tighten the middle nut to the connector body then tighten a further ¾ turn with spanner.
-
Unscrew the middle nut and visually inspect the armor has been successfully clamped between the armor spigot and the clamping ring.
-
Insert the terminals into the required location using the slotted insert retainer, fibers slot in through side channels.
-
Slide the insert cover over the terminals ensuring the insert locater is
aligned, firmly push the insert together. If you are terminating an 8-way
Fiber connector, fit the retaining screw at this point.
-
Slide the insert into the connector body aligning the half round key on the rear contact retainer with the required half round key in the connector body. (The colour coded or numbered keying position is shown on the front of the connector body. Note: No colour coding or numbering for default 12 o’clock position). It should also be noted that the colour coded and numbered connector bodies are mutually interchangeable. Push the octagonal portion of the spigot into the connector body.
-
Slide the middle nut over the clamp / spigot and hand tighten onto the connector body. Further tighten ½ to ¾ of a turn with spanner while holding the front shell with a spanner.
-
Tighten the blackout to form a seal around the cable. Further tighten 1 to 1 ½ turns with a spanner while holding the middle nut with a spanner.
-
If the optional mounting flange is required, slide the flange over the blackout and position on the middle nut. Align the grub screw with one of the flats and tighten. If the flange is used on a CR connector, it may also be placed on the connector body as shown below.
-
If the optional cable clamp has been purchased, tighten the screws on the clamping bars equally until the clamping bars tough the cable. Tighten each screw a further 2 to 4 turns or until adequately clamped. DO NOT OVERTIGHTEN as this could damage the cable.
If the cable clamp is used with unarmored cable, the connector should be earthed via the crimp with a 4mm² conductor.
-
Screw the cap back onto the connector. Stick the corresponding round colour coded / numbered sticker onto label in the circular space provided.
(NB: White = 12 o’clock / Position 1, this is the default position).
SCHEDULE OF LIMITATIONS
- The protective caps shall be fitted immediately following separation.
- The Type BR Bulkhead connectors may be fitted to Exd or Exe enclosures where the interface temperature does not exceed 80°C. The integral cables shall be mechanically protected by the enclosure, or equally effective means.
- The Type CP/CR In-line connectors are intended for use with resilient cables only, capable of withstanding axial loads in excess of 30N without damage.
- When used in dust environments, or fitted to increased safety enclosures, the Type BR bulkhead mounting thread shall be sealed in accordance with the installation code of practice to ensure that an ingress protection level of IP6* is maintained.
- Units coded Ex [op is] shall only be supplied from a separately certified optical source marked with coding to include ‘Ex op is’. The marked gas group and ‘T’ rating shall match (or exceed) those marked on the optical source, as limited by the maximum specified radiated power/irradiance levels (prescribed by Table 2 of IEC 6007928).
- Flameproof joints are not intended to be repaired.
- User / installer must check for the presence of external substances that may cause damage.
- User / installer is responsible for ensuring external forces do not damage / interfere with equipment.
- Ex op pr connector must be isolated from the supply before any attempt is made to remove cap or separate the two halves. (Do Not Open When Energised).
- Single Mode – Fibre Size 9/125, Cladding 126
- Multi Mode – Fibre Size 30/125 & 62.5/125, Cladding 127
TECHNICAL SPECIFICATION
Certification:
II2GD Ex op pr IIC Gb, Extb IIIC T85°C Db
Alternative markings include the following:
Ex[dbe] op pr IIC T6 Gb – for bulkhead / box mount version
Ex[op is] IIC T3 Ga – with separately certified ‘op is’ source
Tamb: -40°C to +60°C
Certificates: Baseefa16ATEX0030X IECEx BAS16.0032X
IP Rating: IP66 / 67
Note: Caps to be fitted to maintain IP ratings when the connector halves
are separated.
Deluge Rating: DTS01
Outer Seal Range:| Os
O
A
B| 5.5 to 12mm
9.5 to 16mm
12.5 to 20.5mm
16.9 to 26.0mm
---|---|---
Armor /Braid Sizes: 0 to 1.6mm
Keying Positions:| Op pr CP / CR
Position 1-5
Op is CP / CR Position
6| BR
1-5 factory set
BR
6 factory set
---|---|---
Fiber Type: Single mode and Multi mode
Ratings: 8Way
Maximum number of make and break operations 500 cycles (clean after 100
mattings) Storage Temperature: -40°C to +70°C
Ex op is
Radiated Power mW| IIA| 118| IIC
Up to 15| T6
Up to 35| T6| T4
Up to 150| T3| N/A
Irradiance Power mW/mm2| IIA| 118| IIC
Up to 5| T6
Up to 20| T3| N/A| N/A
CLEANING DEVICE
A 1.6mm
ferrule cleaning device required. Hawke recommends IBC Cleaner M16 – 13309.
This device is used to maintain a clean dust/dirt free surface on the polished
end of the contact. To ensure that this surface is kept in optimum condition,
it is essential that the cleaning stick is used before every engage and after
each disengage. When the connector pair are not mated, it is imperative that
the protective cap is used to maintain the IP rating of the connector. Not
fitting the cap will render the contact useless if left unprotected. The cap
must only be removed before engagement.
To use the cleaning stick you must first select the appropriate nib for the
contact concerned.
| For pin contacts: | For sockets: |
|---|---|
| Slide the attached nib on to the end of the cleaning stick. | The nib should be |
removed.
Place the cleaning stick on to the contact and with one smooth move, push
towards the contact until you hear a click. Once back in its original position
move on to the next contact. Should further cleaning be required repeat the
process.
Declaration of Conformity in accordance with European Directive 2014/34/EU and
UK
Statutory Instrument 2016/1107
Manufacturer: Hawke International
Address: Oxford Street West, Ashton- under- Lyne, OL7 0NA, United Kingdom
Equipment: Fibred Connectors
Provisions of the Directive fulfilled by the Equipment:
Group II Category 2GD Ex op is IIC Gb, Extb IIIC Db – IP66
Group II Category 2GD Ex op pr IIC Gb, Extb IIIC Db – IP66
Notified Body for EU-Type Examination: SGS-Fumiko 0598 Helsinki Finland
EU-type Examination Certificate: Baseefa16ATEX0030X
Notified Body for production: 0598
Notified Body for UK-Type Examination: SGS-Baseefa 1180 Buxton UK
UK-type Examination Certificate: BAS21UKEX0056X
Notified Body for production: 1180
Harmonised Standards used: EN 60079-0:2018, EN 60079-1:2014,
EN 60079-7:2015+A1:2018, EN 60079-28:2015, EN 60079-31:2014
On behalf of the above name d comp
any, I declare that, on the date the equipment accompanied by this declaration
is placed on the market, the equipment conforms with all technical and
regulatory requirements of the above listed di receives.
A. Reid
Technical Manager
Hawke International
UK Office,
Oxford Street West,
Ashton- under- Lynne,
Lancashire.
OL7 0NA. UK
Sales: +44 (0) 161 830 6698
Technical: +44 (0) 161 830 6697
Fax: +44 (0) 161 830 6648
E-mail: sales@ehawke.com
Connection Solutions
www.ehawke.com
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