SELECTION GUIDE TO FIBER-OPTIC CONNECTORS

BY Dennis Horwitz, Vice President RIFOCS CORPORATION

One of the most critical components of a fiber-optic system is the connector. A fiber-optic connector joins two fibers together such that light passes from one fiber to the other. The main requirements are to minimize signal loss, and reflections, and to provide a connection that is stable both mechanically and optically. Achievable losses for various connector types are in the range of 0.25 to 1.5dB. A fiber-optic connection consists of three components: two of which are the male connector plugs which are joined together through a coupling (or inline adapter). Unlike electrical connectors, all simplex fiber-optic connectors are only available as male plugs (there is no female version). The connector plug consists of a precision ferrule, cable or fiber strain relief support and housing. The coupling device allows two connectors to intermate through a bulkhead or panel. It offers female receptacles on each end and incorporates a precision sleeve, or bushing, to align two mated connectors. When choosing a connector and coupling for a particular application, the designer must consider the fiber type, required optical performance, operating environment and installation and maintenance of the system as well as cost. If an existing system is being modified or expanded, intermateability with existing components must also be considered. The selection process should address the following topics: 1. 2. 3. 4. Contact Type (i.e., NC, PC, SPC, APC) Connector Type (i.e., SMA, Biconic, ST, FC, SC, DIN, etc.) Termination Type (i.e., Epoxy/Polish, Epoxyless, etc.) Material Types (i.e. Ferrule and sleeve composition)

Contact Types While there are a multitude of connector styles, there are three variations in the way a connector ferrule can be prepared: non-contacting (NC), physical contact (PC) and angled physical contact (APC). The selection of one of these options based upon performance requirements is the most crucial first step in

connector selection. The NC finish is either a flat or concave polish which results in an air gap between two mating connectors. This was the original termination method for fiber-optic connectors. Overall insertion loss (IL) and return loss (RL) is substantially higher than either the PC or APC types. Insertion loss range is 0.5-2dB; typical return loss is 15-25dB. Not recommended for laser applications. The improved optical performance of PC connectors rose from the development of keyed connector designs combined with convex polishing techniques. Non-keyed connectors were subject to large variations in insertion loss performance because the fiber rotated into a different position during each mating. Keyed connectors can only be inserted into the bulkhead in one orientation and exhibit substantially improved repeatability over non-keyed types. A small dome or radius at the end of the ferrule allows a physical, or point, contact between connectors with an internal spring usually controlling fiber contacting pressure. The PC connector offers the substantially lower insertion loss (0.2-1dB) versus its older NC counterpart. Regarding return loss performance, a standard PC connector offers 30-35dB return loss; a high performance SPC (Super PC) version offers RL>40dB. Applying an 8 degree angled convex polish produces an APC connector. The minimum 60dB return loss is required for reliable operation of high speed digital, analog, CATV and microwave-onfiber applications. APC technology can only be incorporated into keyed connector designs and requires special couplings due to its critical alignment tolerances. Connector Types The SMA connector was the first "standard" fiber-optic connector in the industry. This multimode connector was developed by Amphenol as an adaptation of the popular microwave connector to fiber-optics. It is an unkeyed, threaded connector in which mating connectors do not make contact (flat polish). There are two types: the straight ferrule 905 style, and the stepped ferrule 906 style. The stepped ferrule allows for more precise alignment of connectors within a special ferrule sleeve, and is the preferred type for use in bulkheads. The newer FSMA version is a somewhat more precision version of the standard SMA. It is still a popular multimode connector in LAN and military systems. The BICONIC connector was originally developed by AT&T for the telecommunication industry. With both connectors fully threaded into the bulkhead, springs control the fiber contacting pressure (important in all contacting connectors). Because of the conical shape, taper length must be precisely controlled during the termination process. Unfortunately, this aspect of the termination process is the step most often ignored and violated by installers. Insertion loss variance can be quite substantial in the range of 0.3-2dB; return loss range is 15-30dB.

The ST-PC connector was developed by AT&T as a higher performance alternative successor to the Biconic connector. It introduced the familiar bayonet coupling with keying to ensure consistent connector orientation within the bulkhead. It is spring loaded, allowing two connectors in the bulkhead to maintain face contact with the same pressure. This eliminated the need to manufacture to a precise length, unlike the sensitive Biconic design. Inside the bulkhead the connectors are aligned within a straight ferrule sleeve. However, these sleeves can be made of different materials (polymer, ceramic, phosphor bronze, copper, tungsten carbide), with widely differing effects on overall connector performance. A low cost connector, the ST connector can be quite sensitive to vibration and susceptible to accidental optical disconnect. The FC-PC connector is an improved FC or D3 connector, originally developed by NTT in Japan. The outer collar crews onto the bulkhead with little mechanical coupling to the inner fiber and ferrule. This connector was one of the first keyed designs and offers excellent repeatability. An internal spring controls the fiber contacting pressure. It offers excellent overall performance and is one of the most robust designs in the industry in use in a wide range of applications. An FC-APC version is available for applications requiring high return isolation. The D4-PC connector was originally developed by NEC (Japan) and is somewhat similar to the FC-PC connector but features a 2.0mm OD ferrule. It does not offer the mechanical isolation from the cable as does the FC. Therefore, it can offer variable performance due to accidental cable pull and tension. It is commonly seen only in telecommunication applications, particularly central office equipment manufactured by NEC. The DIN-PC (DIN 47256) connector is a threaded coupling design originated by SIEMENS for the German telecommunications industry. Originally known as Deutsche Industry Norm (DIN) 47256, this connector is an IEC standard and is popular in many parts of Europe and Asia. The DIN connector is also the smallest overall connector with optical performance and reliability equivalent to the FC-PC connector. Unlike the other connector types mentioned in this article, the extended DIN "family" include blind-mating (back plane) versions as well as a DIN/AVIONICS model for commercial/military avionics and high vibration applications. The SC-PC connector is a more recent addition to the connector market by NTT. Unlike the previous connectors, the SC has a rectangular cross section and push-pull instead of threaded coupling. It is primarily plastic, occupies very little space, and can be packed very densely into a panel. It is also keyed, with an internal spring to snap positively in and out of place and maintain contact pressure. It has recently been recognized internationally by ISO and IEC as the proposed standard for all future premises wiring in voice and data communication applications. Any designer should seriously consider this connector for all new applications. An SC-APC version is also available for critical RL applications.

Material Options Once a given style has been selected, the design engineer must also be concerned with the performance variations found in a multitude of material options. Connector performance and reliability is most directly influenced by the materials used in the fabrication of the ferrules and alignment sleeves. There is always a cognizant cost/performance tradeoff in what may seem an unimportant (certainly unexciting) detail. Ferrule options include molded plastic polymer, brass, stainless steel, ceramic, zirconia and tungsten carbide. A disposable application may deem a polymer or stainless ferrule acceptable as a compromise of cost and performance. More demanding telecommunications applications may dictate of connectors with more expensive yet more reliable ferrule designs such as ceramic (100-200 matings), zirconia (200 matings) or tungsten carbide (over 1000 matings). High wear, precision applications should as test and measurement equipment should possibly consider only the most durable tungsten carbide variety. Choice of couplings are no less important. Inside the bulkhead the connectors are aligned within a straight ferrule sleeve. These sleeves can also be made of different materials and manufacturing processes, with widely differing effects on quality. Sleeve materials can include polymer, ceramic, zirconia, phosphor bronze, copper and tungsten carbide. Process variations (and related performance) are more evident in medium-priced phosphor bronze and copper sleeves where material can be cold rolled, laser cut or formed. Termination Options Most connectors require epoxy/polish termination. After the fiber is stripped to the proper dimension, it is attached with epoxy to the connector. Strength members are then crimped to the connector body and finally, the fiber/ferrule end is polished to a fine finish. Epoxyless connectors, which have been the object of much research and development over the last fiver years, exhibit performance generally comparable to standard epoxy/polish connectors in field applications, but significantly lower installation cost. Various types of epoxyless connectors are either directly derived from "crimp-and-cleave" or mechanical splice technology. While multimode versions are now in common use and very popular, singlemode variations have still yet to be fully proven and accepted by the telecommunications industry. A third termination option is splicing, either by fusion or mechanical methods. It is becoming the preferred method of "termination" in the outside plant (OSP) environment of telecommunications. A high quality, factory-terminated pigtail can be more efficiently spliced into a system than to mount an epoxy/polish connector in the field which is subject to installer

variances. Summary Connector selection is certainly not a trivial design decision. Remember that the connector is the most common site of failure and is potentially the weakest link in the system. The old caveat - "You get what you pay for" - is as true for fiberoptic connectors as anything else. In general, the choice of more expensive, higher quality connectors can actually save money when overhead support and failure costs are considered over and above the initial price of a lower quality connector. In general, the system designer would be best served by restricting his scope to the various PC and APC offerings. This automatically guarantees a reasonable expectation of low insertion loss. SUPER PC is the industry norm in telecommunications where minimum RL of 40dB is needed for high bit rate digital systems. Critical WDM digital systems as well as analog designs, generally require the higher return loss isolation (RL>>45dB) offered by APC connector technology.

MULTIMODE CONNECTORS
TYPE Insertion Loss -+ ++ o ++ ++ ++ Return Loss -+ ++ + ++ ++ ++ Repeatability Strain Relief Stress + + o ++ ++ + - Poor o Neutral Vibration Temperature Cycling -o + + + ++ + + Good ++ Very Good Contamination Performance + o + o + + o PERFORMANCE SUMMARY -o + o + ++ +

SMA Biconic ST FC-PC D4 DIN DIN/AVIO SC

-o ++ o ++ ++ ++ -- Very Poor

-o o + o + ++ +

SINGLEMODE CONNECTORS
TYPE Insertion Loss -+ ++ o ++ ++ ++ Return Loss -+ ++ + ++ ++ ++ Repeatability Strain Relief Stress o + o ++ ++ + - Poor o Neutral Vibration Temperature Cycling o + + + ++ + ++ Very Good Contamination Performance o + o + + o PERFORMANCE SUMMARY o + o + ++ +

Biconic ST FC-PC D4 DIN DIN/AVIO SC

-o ++ o ++ ++ ++ -- Very Poor

o o + o + ++ + + Good

CONNECTOR IDENTIFICATON GUIDE