Author: Fiber-MART.COM
How to Create a Cat 6 Patch Cable
Don’t Tell Us Connector Cleaning Does not Matter!
A high-performance fiber optic network requires low attenuation and low reflectance values to obtain the necessary bit error rate level. Unfortunately, all it takes is one contaminated or damaged connector to slow down or disrupt a transmission system.
In the images below, see how cleaning connectors significantly reduces insertion loss and reflectance and the effects of cross contamination.
Cleaning Makes a Difference!
These two dirty connectors are not an uncommon thing! We mated them ‘as is’ and tested for insertion loss and reflectance.
We then cleaned the connectors with a dry one-click cleaner, mated them again, and ran the same test. Connector images and results have improved dramatically.
Contamination from a Dirty Test Lead
Below is a clean connector – one end of your link where you’ll connect your test cord for optical loss testing.
This could be a test lead that someone carries around in their test equipment bag or tool kit. The technician may have lost the dust cap or even wiped it on their shirt. They plug that test lead in and mate it to your clean connector.
Ouch! See what your clean, undamaged connector looks like now? Cross-contaminated by the dirty test lead!
It is important to recognize the difference between contaminants and end face damage. To do so requires a good inspection scope with the digital video ones being the safest and most versatile. Inspecting and cleaning both ferrules and adapters is essential as cross contamination from one dirty plug can contaminate its mating plug.
OTDRs Never Go Out of Style
The optical time domain reflectometer (OTDR) is now thirty-six years old and aging gracefully.
While fiber optic cables had been installed in North America since 1977, one major concern was and still is: how do we accurately locate a fault? This is the major reason that OTDRs exist. Fortunately, as the communications industry has matured, so has the OTDR.
Why Use It?
Today’s OTDRs address quality control (QC), quality assurance (QA) for optical fibers and cables as well as acceptance testing and troubleshooting installed links in the field. Fiber and cable manufacturers make use of the OTDR’s QC features to perform attenuation and length measurements at a variety of wavelengths based on the type of fiber being tested. These tests are more common in factory settings, often in conjunction with optical switches to allow quick and efficient testing of large numbers of optical fibers.
As fiber counts in cables have increased, the level of automation has paralleled this growth, providing opportunities to increase the OTDR’s value to service providers by incorporating optical switches to monitor live and dark fibers.
The OTDR’s dominant role for service providers and contractors is in QA roles — which is far more extensive and complex than QC testing. Modern OTDRs must address multiple tests and measurement tasks focused mostly around attenuation, but as the critical nature of reflections and their impact on system performance increase, the OTDR is essential for these measurements. It must also be able to perform length measurements for approximate physical locations of events such as splices, fiber stress points (macrobends and microbends), passive devices such as splitters and fiber breaks.
The OTDR is also the easiest instrument to use to measure component reflectance and span optical return loss (ORL) values. The importance of reflection testing cannot be overstated. Reflectance and ORL values are critical for achieving desired bit error rates, as Fresnel reflections from connectors can disrupt the efficient operation of the laser diodes in fiber optic transmitters.
Transmitter manufacturers define the quality of signal based on the level of attenuation and the ORL values for fiber spans. A single contaminated connector can affect the component reflectance, which in turn affects the span’s ORL value. Component reflectance and ORL testing should be requirements for all end-to-end OTDR tests on single-mode fibers.
New Challenges
As system data rates increase, the need for fiber characterization (FC) continues to challenge the industry. In some cases where optical amplifiers are installed, identifying, locating and re-terminating high-loss connectors and splices is required due to higher reflection and attenuation issues with legacy terminations. Older terminations were limited by two issues: fiber tolerances and the type of polish on the connectors. Single-mode fiber tolerances for core, cladding dimensions, ovality and concentricity continue to improve. Older fibers simply have more opportunity for higher loss connections.
Many legacy connectors had either flat polishes or original physical contact (PC) polishes with reflectance levels of 30-40 dB. Even the improved super PC (SPC) polishes of the late 1990s with most ST and SC connectors have much greater reflectance levels (45 dB) than the 50-65 dB reflectance levels for today’s ultra physical contact (UPC) and angled physical contact (APC) polishes.
Identifying high loss splices and connectors as well as high reflectance connectors can easily be performed by the OTDR. However if the readings are too high to meet today’s standards or system performance levels, these older terminations may have to be replaced with UPC or APC connectors.
The Chicken and the Egg Question
Is the technology driving the development of improved OTDRs? Or are the users driving their needs? Each group will have their own perspectives. The manufacturers have done a great job at developing smaller, lighter, less costly instruments. They have done so while improving technical requirements: greater dynamic range options, shorter and longer laser pulse widths, increased waveform and data storage, longer battery life, and interfaces for exporting data via Bluetooth or Wi-Fi. At the same time maintaining an instrument that is easy to operate.
OTDRs have also grown from AC powered mainframe OTDRs to handheld mini OTDRs.
The development of modular OTDR platforms allows for greater flexibility to add various optical tools such as power meters, visual fault locators, inspection scopes or other modules for advanced fiber testing, wifi or copper testing.
Test Cables Don’t Last Forever
I frequently hear customers complain that although nothing has changed in their fiber optic cable assembly production process, the measured Insertion Loss (IL) and Return Loss (RL) values of their product aren’t as good as they once were. Is something wrong with the measurement equipment? Well, it’s possible but unlikely.
Obviously something has changed. If it’s not the measurement equipment, then it must be either the product or the measurement setup. Over time the production process can become a familiar, perhaps boring, routine. Operators may become less meticulous in cleaning, use polishing film longer than appropriate, or even take shortcuts. Eventually this takes a toll and yield suffers.
Let’s suppose you’ve eliminated this possibility with a clean sweep of procedures and a reset to rigorous production guidelines. Yet the problem persists. A “gold-standard” product is useful at this stage – a “known-good” example of the best of your previous production, carefully kept, with very good IL and RL values recorded. Using your current rigorous procedures, re-measure this gold-standard product. It should still look good. If it doesn’t, read on …
I have written that IL and RL tests on a product cannot be made in isolation. Remember, we are measuring connector loss, and the device under test (DUT) needs to be connected to a test cable (aka jumper cable, reference cable, or test lead). It’s important to note that the quality and condition of test cables have a direct bearing on the measured product’s IL and RL measurements.
Assess the quality and condition of test cables.
Firstly, ensure the test cable’s connectors are clean. Next, take a close look to ensure they are in good condition. Keep in mind that both connectors and coupling sleeves don’t last forever. They will degrade with use, and it’s not just scratches and pits. Sliding surfaces wear out. As the fit becomes loose, alignment will suffer.
How many matings can a test connector undergo before it should be replaced? It would be nice to have a definitive number to work with. However, it’s difficult to give a definite answer as it depends on the type and quality of the connectors and the skill of the operators.
Suppose replacing all the test cables and couplers restores your gold-standard product to the previous good measured values. This is useful information. Take a minute to determine approximately how many matings these particular test cables have undergone. What number did you arrive at? Now you know how many couplings are too many!
Identify a usage limit and determine a replacement schedule.
I propose you set usage limit at, say, half the above number. Weigh the ongoing cost of replacement and time required to replace test cables. How does this compare with the cost if you let products go to the failure stage?
A regime of frequent monitoring of the gold-standard device might help nail down the test cable usage limit. (Don’t do this too frequently, or your gold-standard cable will degrade.) This monitoring regime will help you create a reasonable replacement schedule.
Here’s a helpful tip: If you use the Viavi MAP/PCT system, it can track measurement jumper usage and warn if the cable exceeds a user-defined limit. If you use another test instrument, I encourage you to look into whether it can track usage and provide this type of warning as well.
Implement robust process controls.
Test cables do have a finite useful working life. And this lifespan will vary. For example, one improper mating or cleaning can potentially damage a test cable’s end-face enough to render it unusable.
Implementing robust process controls will go a long way to extend the test cable’s life and identify when it needs to be replaced. As discussed, I recommend:
- Frequently inspecting test cable end-faces between matings
- Adhering to good cleaning practices
- Using a “known-good” cable for troubleshooting
Here’s another tip: Telcordia’s GR-326 specification provides excellent guidance on this topic. It is highly recommended that any cable assembly manufacturer procures a copy and, at minimum, adheres to the requirements of Section 8.0.
If you are seeing degraded IL/RL results with your fiber optic cable assemblies, I recommend you first establish rigorous production controls. Next, follow the guidelines in this article to implement procedures to assess the condition of test cables, track usage, and create a reasonable replacement schedule.
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