User Manual Version 06102011

Large Diameter Splicer (LDS)

User Manual

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Table of Contents

Copyright Notice _______________________________________________________________________ 6

Introduction __________________________________________________________________________ 7

LDS Features and Options _______________________________________________________________ 8

High Performance Splicing Package: _____________________________________________________________ 8

PM Splicing Package: _________________________________________________________________________ 8

Tapering Package: ____________________________________________________________________________ 8

Extended Translation Stage Package: ____________________________________________________________ 8

Integrated Cleaver Package: ___________________________________________________________________ 8

Fiber Bundling Package: _______________________________________________________________________ 8

Safety Warnings and Precautions _________________________________________________________ 9

LDS Transportation & Storage ___________________________________________________________ 11

Components _________________________________________________________________________ 12

Initial Setup __________________________________________________________________________ 13

Identification ______________________________________________________________________________ 13

Power Specifications ________________________________________________________________________ 14

PC Communications Settings ____________________________________________________________ 15

LDS Setup Tab ________________________________________________________________________ 16

Splice Setup Tab ______________________________________________________________________ 21

Splicing Tab __________________________________________________________________________ 24

PM Alignment ________________________________________________________________________ 28

Taper Setup Tab ______________________________________________________________________ 30

Tapering Tab _________________________________________________________________________ 34

Cleaving Tab _________________________________________________________________________ 37

Service Mode Tab _____________________________________________________________________ 41

Saving/Loading_______________________________________________________________________ 47

LDS Splicing Process Chart ____________________________________________________________________ 48

X & Y Motor Movements _______________________________________________________________ 49

Arc Counter __________________________________________________________________________ 50

Passwords ___________________________________________________________________________ 51

Changing the Default Passwords _______________________________________________________________ 51

Fiber Diameter Scan ___________________________________________________________________ 52

Fiber Diameter Scan Graph ___________________________________________________________________ 52

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Performing a Scan ___________________________________________________________________________ 52

Camera Windows _____________________________________________________________________ 53

Measurement Tool ____________________________________________________________________ 54

Measuring a Fiber ___________________________________________________________________________ 54

Zooming In ________________________________________________________________________________ 55

Zoom to Fit ________________________________________________________________________________ 55

Clearing a ROI Box __________________________________________________________________________ 55

Performing a Splice ___________________________________________________________________ 56

Aligning the top view ________________________________________________________________________ 58

Performing a PM Splice ________________________________________________________________ 64

Auto Mode PM Splicing ______________________________________________________________________ 64

Manual Mode PM Splicing ____________________________________________________________________ 65

Performing a Taper ___________________________________________________________________ 70

Performing a Taper after a Splice ______________________________________________________________ 70

Performing a Taper without a Splice ____________________________________________________________ 70

Performing a Cleave ___________________________________________________________________ 71

Cleaving ___________________________________________________________________________________ 71

Anvil _____________________________________________________________________________________ 71

Auto Anvil _________________________________________________________________________________ 71

Manual Anvil _______________________________________________________________________________ 72

Auto Cleave ________________________________________________________________________________ 72

Manual Blade Control________________________________________________________________________ 72

Bundling ____________________________________________________________________________ 73

Introduction to the Capillary Speed Loader (CSL) __________________________________________________ 73

The CSL Rail at a Glance ______________________________________________________________________ 74

Powering the CSL ___________________________________________________________________________ 75

Ultrasonic Cleaner Button ____________________________________________________________________ 75

Ultrasonic Cleaner LED _______________________________________________________________________ 75

Ultrasonic Time & Amplitude Adjustment _______________________________________________________ 76

General Use _______________________________________________________________________________ 76

Preparing the Ultrasonic _____________________________________________________________________ 77

Preparing the Tube __________________________________________________________________________ 78

Loading a Honeycomb (optional steps) __________________________________________________________ 79

Loading a Capillary __________________________________________________________________________ 80

Funnel Fixture ______________________________________________________________________________ 81

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Stop Fixture ________________________________________________________________________________ 82

Pre-cleaning Individual Fibers (optional steps) ____________________________________________________ 83

Loading the Fiber in the Honeycomb ____________________________________________________________ 84

Loading the Fiber ___________________________________________________________________________ 85

Refilling the Water __________________________________________________________________________ 90

Optimization _________________________________________________________________________ 92

Optimizing Splicing Programs _________________________________________________________________ 92

LDS Setup _________________________________________________________________________________ 92

Optimizing _________________________________________________________________________________ 92

Optimizing the ROF Splice Location _____________________________________________________________ 92

Setting the Gap _____________________________________________________________________________ 92

Optimizing the Pre-fuse Time and Power ________________________________________________________ 93

Optimizing the Arc Time 1 and Arc Power 1 ______________________________________________________ 93

Optimizing the Arc Time 2 ____________________________________________________________________ 93

Optimizing the Pull Time and Pull Power ________________________________________________________ 93

Maintenance & Calibration _____________________________________________________________ 94

Adjusting the X & Y Manually (Mechanically) _____________________________________________________ 94

Manual Motor Control via GUI ________________________________________________________________ 95

Electrode Measurement Guide ________________________________________________________________ 95

Electrode Removal __________________________________________________________________________ 96

Cleaning Electrodes _________________________________________________________________________ 97

Option 1 (Recommended Option) ______________________________________________________________ 97

Option 2 __________________________________________________________________________________ 98

Adjusting the Position of the Plasma Field _______________________________________________________ 99

To Fine Align the ROF Module _________________________________________________________________ 99

To Adjust the ROF Module Height _____________________________________________________________ 100

Check Camera Alignment Calibration __________________________________________________________ 100

Cleaning the Lens __________________________________________________________________________ 101

Advanced Communication & Control ____________________________________________________ 102

Direct Communication with LDS Hardware ______________________________________________________ 102

Overview of the LDS Splicing System Communication _____________________________________________ 102

DMU Control ______________________________________________________________________________ 103

Arc Unit Control, Communication with ADU Unit _________________________________________________ 104

Direct-Access Setting Protocol (used when arc is off) ______________________________________________ 105

Arc State Controls __________________________________________________________________________ 106

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Miscellaneous Controls _____________________________________________________________________ 106

Probe Arc Feature __________________________________________________________________________ 106

Other Outputs from the ADU _________________________________________________________________ 107

Explanation of the Parameters and Effects ______________________________________________________ 107

The H (phase) Parameter ____________________________________________________________________ 107

Modes of Power Control ____________________________________________________________________ 108

X and Y Alignment Motor Movements _________________________________________________________ 108

Electrode Reconditioning Tool __________________________________________________________ 110

Introduction to the AEC _____________________________________________________________________ 110

Unboxing the AEC __________________________________________________________________________ 111

The AEC at a Glance ________________________________________________________________________ 111

Accessories Included _______________________________________________________________________ 112

Optional Accessories _______________________________________________________________________ 112

General Use ______________________________________________________________________________ 113

Replacing the electrode cleaning disc __________________________________________________________ 114

Replacing the batteries _____________________________________________________________________ 115

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Copyright Notice 2011 3SAE Technologies Inc. All rights reserved. Reproduction of this manual in any form requires written permission from 3SAE Technologies, Inc.

Introduction

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Introduction The Large Diameter Splicer (LDS) is designed for splicing optical fibers and other optical devices that are beyond the capability of conventional optical fiber splicers. The LDS is a semi-automated fiber processing station that provides far more range of positioning adjustment than conventional optical fiber splicers. Depending on options selected, up to ten separate angular and positional axes can be controlled, allowing unprecedented adjustment of the geometry of the splice. A sophisticated GUI, in conjunction with two high magnification, 2 MP, telecentric cameras, provides detailed real-time feedback of fiber position and shape both before and after the splice. The exclusive 3SAE Ring of Fire technology provides a highly controllable plasma field that completely surrounds the fibers for even heat distribution. Sufficient power is available to splice silica fibers up to 2.5mm in diameter. Similarly-sized optical devices such as lenses and prisms can also be spliced, with appropriate fixturing. Both the positioning features and the Ring of Fire unit are controlled by a well-documented serial protocol that allows unprecedented user access to all aspects of the units operation, either manually or in conjunction with user-created software. This manual is intended to instruct the user in the routine use, adjustment, and maintenance of the LDS.

Features and Options

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LDS Features and Options The LDS accompanying this manual may be equipped with some of the optional features described below. Additional documentation may be provided separately for some options.

High Performance Splicing Package:

Additional Z-axis fine positioning stage, implemented by a piezo-controlled flexure stage on the left stage

Allows vibration-free gap-closing step for highest splice quality and lowest loss

PM Splicing Package:

Adds alignment stages Third camera with additional software features for end-face inspection and alignment

Tapering Package:

Allows ramping of motor speed in programmed patterns and/or real-time load cell feedback. This enables the creation of highly accurate and repeatable fiber tapers in a variety of geometries

Includes additional clamping hardware and software functions for taper shape analysis

Extended Translation Stage Package:

Increases all Z-axis motions (Left fiber, Right fiber, Ring of Fire) from 30mm to 90mm of travel. This allows very long tapers or fiber bundles to be created

Includes upgraded stage hardware and compatible software

Integrated Cleaver Package:

Provides in situ cleaving of fibers while still clamped in the positioning stages

Allows creation of cleaved-splice end-caps, mode adapting tapers, and combiner fabrication

Cleaving position optically located to high precision

Includes retractable, piezo-driven diamond cleaving blade and compatible software

Fiber Bundling Package:

Provides support features for the creation of 2,3,4, and 7-fiber pump and signal combiners, with bundle diameters up to 1800um

Includes bundle handling fixtures, tooling, and compatible software

Safety Warnings and Precautions

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Safety Warnings and Precautions

READ THE INFORMATION BELOW!!! Many of these safety considerations are not obvious!

No coating materials containing fluoropolymers (such as PTFE or fluoroacrylates) or fluorine in any form should ever be exposed to high temperatures or electrical plasmas (such as in the LDS unit), as Hydrogen Fluoride and other highly toxic materials will be produced.

It is the responsibility of the user to determine the chemical makeup and decomposition products of materials to be used in the LDS. Use appropriate protective measures as needed.

Operate only in a well-ventilated area. All flames and plasma discharges in air produce ozone and nitrogen oxides in some amount. Sufficient ventilation must be provided for operator protection.

Do not touch the electrodes or adjacent areas while the unit is powered on or connected to the power supply. The electrodes produce high voltages and high temperatures that can cause burns and electrical shock, possibly causing serious injury or death.

Fiber containing electrically conductive materials, such as carbon coating or metallization layers, should not be used without specific consultation with 3SAE Technologies Engineering Personnel. Electrically conductive fibers may cause a shock hazard, due to the high voltages employed in the unit.

The positioning motors of the unit can be operated with the cover open. These positioning stages move very slowly, but can develop high forces due to the gear ratios involved. Keep clear of pinch points and keep hair, jewelry, and clothing away from moving parts.

If required, an external safety panic button may be connected so as to disconnect power from both of the AC adapters of the LDS. Interruption of power will not damage the LDS. Be aware that a motor reset will occur when power is reapplied.

The LDS is equipped with a safety interlock that requires the lid to be closed before the LDS can fire an arc. The LDS is also equipped with a thermocouple to prevent the unit from overheating.

The LDS power supply is rated for UL and CE

Overvoltage Protection: Typical 125% max

Overload Protection: 120-150% hiccup/trip & restart mode with auto restart

Short Circuit protection: Continuous

Temperature Coefficient 0.04%/C

Efficiency: 85% typical at 230 VAC & 100% load

Safety Approvals: EN60950-1, UL1950-1, CSA C22.2 No. 60950 cUL

Do not attempt to defeat or circumvent the safety interlock on the top cover. Also, do not rely on the interlock: disconnect the power supply entirely when working on or near the electrode block assembly.

The use of safety glasses is recommended. Fragments of fiber can cause injury if they come into contact with eyes.

Observe all safety precautions common to the handling of optical fibers and dispose of fiber scraps safely.

Do not operate the LDS in the vicinity of flammable vapors or liquids. Operation of the unit in such an environment may increase the risk of fire or explosion.

The LDS is designed to splice optical glass fibers. Operation of the unit in applications other than the intended use can cause damage to the unit.

Safety Warnings and Precautions

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Use only the A/C adapters that are supplied with the LDS. Using an improper power supply may permanently damage the LDS.

Do not modify or disassemble the LDS or any of its accessories, including the power supplies.

Turn the LDS off when not in use.

Never plug in a power supply to the cameras. All cameras are powered through the USB cable.

Do not expose any portion of the LDS to water or other liquids.

The use of compressed gas or canned air to clean the LDS can cause damage to the unit. These products can contain flammable materials or contaminants that may ignite during the electrode discharge.

Use only factory specified electrodes; the use of non-factory electrodes can potentially damage the LDS.

Applications for the LDS should be developed only by persons with a full technical understanding of the materials to be used (fibers and coatings). These persons must give full consideration to the safety implications of the process to be used.

Use of the unit should be restricted to personnel that: Have been appropriately trained in the handling of optical fiber and related materials. Have read, understood, and will follow all usage and safety instructions in this manual.

Note: It is the responsibility of the user to use this product for its intended purpose and according to this manual. 3SAE Technologies cannot be responsible for damages or injury resulting from failure to follow these instructions.

Transportation & Storage

[11]

LDS Transportation & Storage After receiving and opening the LDS, store all original shipping containers for future use. Always use the original shipping crate when transporting the LDS. Also, when transporting the LDS from a cold to warm environment, allow approximately one hour prior to use. Avoid storing the LDS in the following environments:

Temperatures that exceed 54C (130F)

Humidity that is greater than 95% (non-condensing)

Components

[12]

Components The LDS contains the following components:

LDS System

LDS Electrode Cover

Power Supply (quantity 2) 1. 15V, 6.0A, 90W 2. 24V, 6.3A, 150W

Power Cord (quantity 4)

PC

Monitor

Keyboard

Mouse

USB Cables (quantity 6)

Serial cable

Fiber holders

Spare electrodes (1 set)

LDS Toolkit

Electrode tweezers

0.9mm Allen key

Optional LDS Components:

EFI (End Face Inspection) unit

Ring Light

3rd

Camera for end-cap viewing(through the splice)

Initial Setup

[13]

Initial Setup The LDS will arrive shipped in a crate. The PC and monitor will arrive together in one box. The remaining LDS accessories will arrive shipped in up to 3 additional boxes. 1 Un-crate and place the LDS in an appropriate, well-ventilated work space 2 Un-box the PC and monitor and place alongside the LDS 3 Connect the mouse, keyboard, power cord, and monitor to the PC 4 Connect both power supplies from the LDS to an outlet (labeled 8 & 9) 5 Connect the USB cables from the PC to the LDS 6 Connect the serial cable from the PC to the LDS

Identification

1 Com 1; connect to Com 1 on motherboard via serial cable 2 USB labeled 1 is used with a motor; connect to the PCI USB card 3 USB labeled 2 is used with a motor; connect to the PCI USB card 4 USB Side Camera; connect to the USB on motherboard 5 USB Top Camera; connect to the USB on motherboard 6 Power connection 1 (15V, 6.0A, 90W) 7 Power connection 2 (24V, 6.3A, 150W) 8 Power switch

Initial Setup

[14]

Power Specifications

Power supply 1: 15V, 6.0A, 90W max Power supply 2: 24V, 6.3A, 150W max

PC Communications Settings

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PC Communications Settings The LDS system includes a PC that is pre-configured for connection to the unit. If it is necessary to operate the unit from a different computer, or different serial port, the following settings must be set in Control Panel/ System/ Hardware/ Device Manager/ Ports (COM & LPT)

Serial Port Parameters 19200 bps 8 data bits 1 stop bit No parity Flow Control: NONE FIFO buffers-disabled

LDS Setup Tab

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LDS Setup Tab

Tab Status: Password Protected

Com Port This setting adjusts the serial port communication port through which the program communicates with the LDS. Data Top Level Folder This is the location on the PC where all the saved information goes. The information is saved in the Operations Folder Marker folder. Operations Folder Marker This is the name of the folder on the PC where all the saved information goes. This folder name came be changed. Current Data Path This is the location of the file created by the LDS for the saved data, i.e. taper, splice. The LDS automatically increments the saved file for every splice (or taper) created. Angle Text Color This is the color of the view angles/cleave angles during the splicing operation. HWSerialNum X This value is factory set and should not be changed. This value represents the serial number of the stepper motor that has been installed in the LDS. HWSerialNum Y This value is factory set and should not be changed. This value represents the serial number of the stepper motor that has been installed in the LDS.

LDS Setup Tab

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Global Arc Power This a DC power offset that will be added or subtracted if a negative value is entered to the splicing powers and manual arcing powers. This feature is commonly used to calibrate multiple splicers to one another. The default is 0, but will accept -255 to +255 values. Camera Speed This controls the frame rate that the cameras are recording. Typically 1/2 speed is suggested. 0=full speed, 1=half speed, and 2=1/4 speed. Full speed has a frame rate of 15 frames per second. Piezo Factor This value is a DC offset to the Piezo Distance Moves, i.e. if there is a Piezo Move of 60 and a Piezo Factor of 0, the Piezo should move 60, but if measured and the Piezo does not move 60, instead it moves 55, the Piezo Factor should be changed to 5. Piezo Home Piezo home is the piezo location of the left platform when the fast align is activated. The purpose of advancing the piezo forward is so the piezo can move backward, if needed, when setting the gap. Theta Zero Position This is only available with PM functionality. This is the calibrated theta rotation that represents how far from the home it takes to reach 0. This is calibrated at the factory and again during installation of the LDS. This should only be done with a calibration kit. Load X & Y Motors When toggled green, it will load the X and Y motors when the software is played. When toggled red, the X and Y motors will not be loaded. Check Box in the Load X & Y Motors This check box, if checked, will home the X and Y motors when the software is played. Fiber Vision Factor Top This multiplier is used to correlate pixels to microns. This parameter should never be adjusted unless the cameras or lenses are replaced or modified. It is suggested to write down your settings before using the splicer. This can be adjusted by placing a fiber in view of the camera of a known diameter and use the measuring tool to draw a box around the O.D. of the fiber. You can select the magnifier tool to zoom in to ensure the ROI (region of interest) box is accurately drawn on the fiber. You will need to right click and click "Zoom to Fit" to zoom out for the measured numbers to appear. Adjust the vision factors until the measured value displayed matches the know fiber diameter. Default with Doublers is 2.18 Default without doublers is 1.09 Fiber Vision Factor Side This multiplier is used to correlate pixels to microns. This parameter should never be adjusted unless the cameras or lenses are replaced or modified. It is suggested to write down your settings before using the splicer. This can be adjusted by placing a fiber in view of the camera of a known diameter and use the measuring tool to draw a box around the O.D. of the fiber. You can select the magnifier tool to zoom in to ensure the ROI (region of interest) box is accurately drawn on the fiber. You will need to right click and click "Zoom to Fit" to zoom out for the measured numbers to appear. Adjust the vision factors until the measured value displayed matches the know fiber diameter. Default with Doublers is 2.18 Default without doublers is 1.09 ROF Speed This is the default speed that the ROF Module run during homing and some sub routines. This speed should be defaulted to 1200 um/sec. ROF Home This is the default home position of the ROF Module. If your LDS has a cleaver installed the home position should be ~14500. If you do not have a cleaver, it will be 0.

LDS Setup Tab

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ROF Arc Position ROF arc position is the position that the ROF will move to during splicing, tapering, and when the "Arc Position" button is pressed. The default position is ~20000. Load Cell Cal This is a multiplier used for calibrating the load cell to grams. Default values range from 0.40 to 0.70. Load Cell Command X0 is load cell off X3 is used with an analog load cell X4 is used with a digital load cell Load Cell Digit Count This is the number of digits that the load cell is outputting from the DMU to the Lab View software. The default setting is 5. Password 1 This is the current set password for the LDS Setup Tab, Splice Setup Tab, and Service Mode Tab. You can change the password back to default by clicking the PM Alignment page and pressing F5. Stop the program and restart it for this change to occur. Cleaver Blade First Position The "Cleaver Blade First Position" is the lowest blade elevation (in arbitrary units) that successfully will cleave a fiber. This is used to calibrate the elevation after installing a new blade or cleaver module. Master Gain This is the master gain of the LDS and controls both cameras.

Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program. Cleave Save Saves current cleaving program. ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views.

LDS Setup Tab

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Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default. Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Note: Closing the program by any other method is likely to cause error messages both during the shutdown and the subsequent restart of the program Configuration File (Save/Load) This saves the every variable from each tab of the LDS so that they can be loaded at later time. The factory default Configuration File is provided with on disc as a backup. Note: Programs will over right the Configuration File Tension Offset DC offset that will be added to the load cell. Most always this parameter will be 0. Tension Speed Motor speed in microns per second of the left and right stepper motors. Default is 10. Tension Overshoot The amount in grams that the tensioning process will over shoot prior to setting the desired tension. Default is 5. Tension Delay Wait time (each unit is equal to 10 ms) after the overshoot tension has been reached, but before adjusting the desired load. Default is 30. Tension Window Plus/minus window of acceptable tension. Default is 10. PM Mirror Installed This box should be checked if there is a PM mirror installed on the LDS. By checking this box, the right motor will not move closer than the set limit of the box below labeled "mirror/right stage limit". This limit is designed to prevent the right fiber holder from crashing into the mirror arm. ROF / Right Stage Limit This is a variable that will not allow the arc to fire when the distance between the ROF and the right stage is less than the variable set. Most splicers do not use this unless they are equipped with custom fiber holders that are longer than the original. Side Align Offset This will automatically add an X offset to the fusion splice in microns after the X and Y alignment is completed. Top Align Offset This will automatically add a Y offset to the fusion splice in microns after the X and Y alignment is completed. Arc Boost Arc boost is an increased arc power that is used to initialize the plasma field. Select Low when using a small electrode gap and a low power. $J10 and $S25 Select Normal when using a small to medium electrode gaps at low to medium power levels. $J20 and $S50 Select High when using large gaps and anytime the arc is inconstantly firing. $J40 and $S100

LDS Setup Tab

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LED Calibration This can be performed every time the LDS is powered on, but only needs to be performed every 100 splices or once a month. This will auto adjust LED brightness to be at the correct value for splicing. Close cover and make sure there are no fibers installed and click LED Calibration. The LED calibration will run automatically and beep when the sequence is completed. If the LEDS are not properly calibrated, it can change fiber diameters, alignment accuracy, and other subroutines. Top/Side Displays the top calibration value and side calibration value; both values range from 1-254. Top LED Displays the current top LED setting. The range is from 100-65550. Side LED Displays the current side LED setting. The range is from 100-65550. Camera Calibration This performs a check to verify that both cameras are vertically aligned to each other. See Check Camera Calibration in the Maintenance section. Note: If the difference between Top Camera Cal and Side Camera Cal is greater than 15 pixels, an error will be displayed letting the operator know that this calibration needs to be performed.

Splice Setup Tab

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Splice Setup Tab

Tab Status: Password Protected

ENG Notes This allows the program designer to create notes for the operator. This is displayed when a program is loaded. Master Gain This is the master gain of the LDS and controls both cameras.

EFI Gain This is the master gain of the EFI camera. Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program.

Splice Setup Tab

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Cleave Save Saves current cleaving program. ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views. Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default. Plasma Clean Gain This is the gain setting of both cameras during the clean operation. Plasma Clean Time This sets the arc time for plasma cleaning. Plasma Clean Power This sets the arc power for plasma cleaning. Splicing Gain Adjusts the camera gain during the splice, to see fibers during splice, large fibers use hot arc. Adjust as needed (use Hot arc, Med arc, and Low arc). Pre-fuse Time This is the amount of time in seconds that the arc will be on prior to the fibers driving together. Pre-fuse Power This is the power setting of the arc prior to the fibers being pushed together. Arc Time 1 This is the amount of time in seconds that the arc will be on during the fiber push. This value can, and should exceed the actual push time. Arc Power 1 This is the amount arc power applied during the fiber push. Arc Time 2 This is the amount of time in seconds that the arc will be on after the fiber push but before the fiber pull. Arc Power 2 This is the amount of arc power applied after the fiber push but before the fiber pull. Pull Time This is the amount of time in seconds that the arc will be on during the fiber pull. This value can and should exceed the actual pull time. Pull Arc Power This is the amount of arc power applied during the fiber pull.

Splice Setup Tab

[23]

Push Distance This is the travel distance in microns of the left fiber during the push stage of the splice. Some systems are equipped with a piezo drive that is used to create this motion but the standard LDS system will drive the left Z stage this distance. This value should always exceed the Total Fiber Gap measured by the Get Data button. The Piezo can move as slow as 3um/sec and as fast as 788um/sec. The stepper motors can move as slow as 15um/sec and as fast as 3000um/sec. Pull Distance This is the travel distance in microns of the left fiber during the pull stage of the splice. Some systems are equipped with a piezo drive that is used to create this motion but the standard LDS system will drive the left Z stage this distance is a backward direction. Splice Mode Selects which pushing method during the splice; Piezo, left stepper, or both the left and right stepper motors. ROF Splice Offset This is the offset location in microns of the ROF during the splice. Unlike many splicers that move the fibers from the center of the screen for an offset splice, the LDS system can alter the heat source location of a splice to intentionally offset the heat distribution when splicing dissimilar fibers. This is useful because the fibers are still centered on the screen. For similar fiber splicing, the ROF location should be on the red center line. For a dissimilar splice, the ROF location should be altered from this center. Cleave Angle Limit This is the acceptable cleave angle limit for splicing. View Angle Limit This is the acceptable view angle (pitch/yaw) limit for splicing. Low/High Power This is the power range for the arc, i.e. for 1000um and smaller diameter fibers, Low Power is recommended and for 1000um and larger diameter fibers, High Power is recommended. Click on the box to toggle between Low Power and High Power. Low Power is considered higher resolution. Left Reset Position This is the home position for the fiber when Splice Reset is enabled. Right Reset Position This is the home position for the fiber when Splice Reset is enabled. Y Reset Position This is the home position for the fiber when Splice Reset is enabled. X Reset Position This is the home position for the fiber when Splice Reset is enabled.

Splicing Tab

[24]

Splicing Tab

Tab Status: Available

Auto Focus This will automatically focus the top view. Focus Jog buttons Adjusts focus up and down in fine and coarse distances that are defined on the splicing page under fine and coarse step sizes ^^ = Large steps of upward movement. ^ = Small steps of upward movement. v = Small steps of downward movement. vv = Large steps of downward movement. Camera Jog Buttons Adjusts the position of the top camera front to back in fine and coarse distances that are defined on the splicing page under fine and coarse step sizes. ^^ = Large steps of backward movement. ^ = Small steps of backward movement. v = Small steps of forward movement. vv = Large steps of forward movement. Blue Up/Down Buttons There are two sets of up/down buttons. The set located on the lower right hand side of the Top view screen control the front to back stepper motor which is the right Y stepper motor. The set located on the lower left hand side control the up/down movement of the right fiber which is the X motor. These jog distances are also variables that are defined on the splicing page.

Splicing Tab

[25]

Left/Right Arrow Keys The set on the lower right hand side of the top view control the left stepper in the Z direction. The set on the lower Left hand side of the side view control the right stepper in the Z direction. These jog distances are also variables that are defined on the splicing page. Master Gain This is the master gain of the LDS and controls both cameras.

Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program. Cleave Save Saves current cleaving program. ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views. Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default. End Cap Vacuum Toggles the solenoid on/off for the venturi when using the End Cap holder. Gap Shows the gap or the distance between the left and right fibers. Clicking Update All will re-estimate the gap. Cleave Angle L/R These fields display the left and right estimated cleave angle. Active Splice Program This displays the current program. ENG Notes Shows any notes regarding the splicing program. The notes cannot be edited in this tab.

Splicing Tab

[26]

Operator Notes When the data is saved, any notes in this window will be saved as well. This allows the operator to leave notes, i.e. forgot to clean fiber, saw an unsteady arc, etc. Arc Counter This is considered the life counter of the LDS. Every time the arc fires, either manually or automatically, this number will increase by an increment of one. Usage Counter This is an algorithm that multiplies the power level of the arc by the time the arc is on. This is used as an electrode life counter. This number will vary depending on how the LDS is used, i.e. tapering, large diameter splicing, PM splicing, etc. Reset Arc Counters This is used when a new set of electrodes is installed into the LDS. Update All Updates gap and cleave angle estimations. Home Y Homes the Y stepper motor. Home X Homes the X stepper motor. Fine X/Y Step Size (Blue Buttons) This setting adjusts the Fine Step Size of the jog function for both the X and Y motorized alignment. Course X/Y Step Size (Blue Buttons) This setting adjusts the Course Step Size of the jog function for both the X and Y motorized alignment. Set as Reset Position This saves the current motor positions as the new reset locations in the splicing program. You must save the splicing program for this to be saved. Fine Z Step Size This setting adjusts the Fine Step Size of the jog function for both the Z motorized alignment. Course Z Step Size This setting adjusts the Course Step Size of the jog function for both the Z motorized alignment. De-focus This is a parameter that will automatically de-focus the Top camera (lower it) in ms of run time. This can be used for another method of evaluating the image in the top view for a number of processes. Re-focus This will run the camera up for the set time of de-focus text box. Fast Align Fast Align will activate the left, right, X and Y stepper motors. The fast align is used to bring the left and right fibers ~200 microns from the center vertical line and align the right fiber to the left using the X and Y motors. This alignment is critical for the pitch/yaw measurement. Auto Splice Auto splice will automatically set left, set right, align x and y, and perform the splice permitting all splicing alignment criteria was met. You can also execute the left and right set fines, X and Y alignment, Plasma Clean, and splice manually working the subroutine from the left to the right. Pitch/Yaw

Splicing Tab

[27]

(Pitch) It is important that the LED calibration and camera gain settings are properly set and that the fibers are relatively in focus for this function to work. Some LDS systems are capable of making the adjustments on both the left and right fibers. The blue numbers below the fibers represent the pitch alignment in degrees. If your system only has the capability of adjusting only the right side, then the left Pitch displayed will always read zero. The box displays the value of pitch when the program stops. A checkbox will appear when running Pitch. Clicking the checkbox when running Pitch will move the fiber automatically to help adjust the pitch of the fiber. (Yaw) It is important that the LED calibration and camera gain settings are properly set and that the fibers are relatively in focus for this function to work. Some LDS systems are capable of making the adjustments on both the left and right fibers. Clicking the Yaw button turns on an algorithm that actively displays Yaw of the two fibers on the screen. The blue numbers below the fibers represents the Yaw Alignment in degrees. A checkbox will appear when running Yaw. Clicking the checkbox when running Yaw will move the fiber automatically to help adjust the yaw of the fiber. PM Opens the window for PM theta alignment Manual PM Opens the window for PM theta alignment Set Gap This setting controls the distance from the ideal splice point red grid line to the right fiber. 10 is the minimum distance that should be set. Plasma Clean This runs the plasma cleaning program that is defined on the "Splice Setup". If the check box is checked, the plasma clean will run during auto splice. Fine Align This is similar to fast align, but much more accurate. It does the x and y alignment at the same time (always aligning the right fiber to the left fiber). It will align to the accuracy of the value provided in the text box (025um is default value). It will run until the alignment measures less than the value and then stops. The last step in this process is the gap will be re-checked and adjusted if needed. Splice Executes the splice Abort Clicking abort will abort any of the steps in the splicing sub-routine. Splice Reset This button will automatically send the right fiber platform to the Right Reset Position, the left fiber platform to the Left Reset Position, and the ring of fire to the 0 or its home position, and home the X and Y motors. These Reset Positions are located on the Splicing Page.

Note: To prevent any mechanical collisions, make sure the fiber holders are closed prior to resetting.

PM Alignment

[28]

PM Alignment

Tab Status: Available (if PM package was purchased)

Three Images Starting with the upper left hand image and working to the right the images are light fiber image, image overlay of the left and right fibers, the right fiber image. Show End View Clicking show end view will automatically move the left and right fibers out and the top camera down based on the parameters defined in the text boxes below. Show Top View Clicking show top view will automatically move the left and right fibers in and the top camera up based on the parameters defined in the text boxes below. Manual Theta Controls Top Slider bar This setting adjusts the speed of theta motor. The setting ranges from 100 to 3000 with 1 increment. Moving the slider to the right increases movement speed in units of microns per second. Go Clicking this button activates the motor to move to set Position and at the speed set by the Speed Slider. Stop Stops the motor from moving. Location Slider This is the distance slider that ranges from 0 to 40 degrees. You can scroll the slider to the desired position or enter the position in the text field.

PM Alignment

[29]

Auto Theta Controls Bar Graph This creates a running average of acceptable "Good" data points. As long as the software is getting good readings on the stress rods, the bar will automatically graph the data. Once the bar graph is full, the theta can be moved to align the fibers. Theta Motor Button Align theta will move the theta motor so the stress rods are aligned. For a theta offset splice enter the desired offset on the text field, or 0 for a 0 offset splice. Auto X/Y Auto X/Y will automatically align the right X and Y motors so the fiber is always centered. This is beneficial when adjusting the right theta stage to within the 40 degree range of the goniometer. Mode Selecting one of the three modes will determine the running average used for the bar graph. Low Contrast=.5 Normal=1 Precision=5 User Controls This is setup for particular customer applications. Please contact 3SAE directly for more information. Theta This is the estimated theta offset between the left and right fibers. Left and Right Dia. When clicking on the fast align, the software will automatically measure the left and right fiber diameters and display the measurement in these boxes. This process is required to draw the ROI (region of interest) boxes for manual and automatic theta alignments. Manual Theta Controls Align Theta Motor Align theta will move the theta motor so the stress rods are aligned. For a theta offset splice enter the desired offset on the text field, or 0 for a 0 offset splice. Overlay Clicking Overlay will overlay the two stored images of the left and right fibers. Right Click Right after the ROI has been placed over the left fiber end face. This will pop-up a box to draw an annulus around each of the stress rods.

Taper Setup Tab

[30]

Taper Setup Tab

Tab Status: Password Protected

Master Gain This is the master gain of the LDS and controls both cameras.

Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program. Cleave Save Saves current cleaving program.

Taper Setup Tab

[31]

ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views. Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default. Heat Delay This is the amount of time (in seconds) that the arc is on before any fiber motion begins; it preheats the fiber before the taper begins. Heat Delay Arc Power This is the power setting that will be used during the heat delay and remain constant until the end of the Run-in. If power ramping is turned on the power will begin ramping down after the run-in is complete. For 125um the power should be around 20-35, furthermore, the load should peak at ~1-4grams. If there is more load, then the arc power should be increased. Run In This is the distance traveled (in microns) while the left and right platforms are moving at the Base Speed; no taper is made during the Run In. This is a transitional motion. Down Taper Start Arc Power This is the power setting that will be used during the down slope of the taper. If power ramping is enabled, the power will begin ramping down at the start of the down slope and end at the start of the waist. Down Slope Length This is the distance traveled (in microns) of the down taper; this is the change in diameter from the original Fiber Diameter to the Waist Diameter. Waist Length This is the distance (in microns) of fiber length that maintains the programmed Waist Diameter. Waist Arc Power This is the power setting that will be used during the Waist. There is no change or ramping of the power during this part of the taper. If power ramping is enabled, at the end of the waist, the power will ramp up to the power entered in the Up Taper Finish Arc Power. Waist Diameter This is not a variable and is calculated based on Dia Change (%). Up Slope Length This is the distance traveled (in microns) of the up taper; this is the change in diameter from the original Waist Diameter to the Fiber Diameter. Up Taper Finish Arc Power This is the power setting that will be used during the up taper. If power ramping is enabled, at the end of the waist, the power will ramp up to the power entered in the Up Taper Finish Arc Power and will remain the this power setting during the Run-out.

Taper Setup Tab

[32]

Run Out This is the distance traveled (in microns) while the left and right platforms are moving at the Base Speed; no taper is made during the Run Out. This is a transitional motion. Taper Sweep This will turn on/off the arc sweeping of the ROF module. This can be used during a taper to effectively widen the plasma field. Sweeping the arc is can be beneficial on fibers larger than 500um. Testing is still in process for smaller diameters. Taper Sweep Speed This is the speed at which the ROF will modulate during the taper. Taper Sweep Length This is the sweep distance that the ROF will translate left or right during the taper at the taper speed. Fiber Change in Cross Sectional Diameter This is not a variable and is calculated based on Fiber Diameter and capillary ID if applicable. Capillary Factor This is not a variable and is calculated based on Fiber Diameter and capillary ID. (OD/ID=Capillary Factor) Fiber Diameter This is the original estimated fiber diameter. Capillary I.D. This is the estimated starting I.D. Waist Diameter Enter the desired waist O.D. Waist Capillary I.D. Enter the desired waist I.D. Dia Change (%) This is a percentage of the diameter that will change as a result of the tapering program. Taper Program Name Displays the tapering program name. Eng Taper Notes This allows the program designer to create notes for the operator. This is displayed when a program is loaded. Taper Push This will enable the taper push. Taper push is a sequence that occurs prior to making the taper based on the push distance and then tensions the fiber until the desired preload is met at the pre-load speed. Find Minimum Position This feature will calculate the minimum positions for the left and right Z motors to minimize the span between the left and right fiber holders. Left Taper Reset This is the home position for the fiber when Taper Reset is enabled. Right Taper Reset This is the home position for the fiber when Taper Reset is enabled.

Taper Setup Tab

[33]

Push Distance Pushes the right fiber forward prior to pulling the left fiber to the left for pre-tensioning Pre-Load Pre Load is for tensioning the fiber prior to the taper. The Load setting will vary depending on the fiber diameter. 125um Cladding should be 5-10 grams. Setting to 0.0 will not use the preload option. Pre-Load Speed Pre Load speed is the speed of the left stepper motor in microns pre sec. The suggested speeds are 10 or 25 microns per second. Higher tensioning speeds may result in over tensioning the fiber. ROF Offset Location This offset parameter, in microns, will be added or subtracted to the ROF Splicing Position on the setup page. Ex. If the ROF arcing position (Located on the LDS Setup Tab) is at 20000 and you want to have the ROF to the right of the center line by 200um, set the ROF Offset Location to 200. If you want the ROF to be 200um to the left of the red line, set the ROF Offset to -200. Low/High Power This is the power range for the arc. Click on the box to toggle between Low Power and High Power. Most tapering applications less than 1.0mm are performed using low power. Ramping This will enable/disable the power ramping function. Base Speed This is the speed when the platforms are moving together, i.e. Run In and Run Out. During the taper operation, both platforms will start at the Base Speed and then the left platform will accelerate/decelerate while the right platform stays at the Base Speed. Slow is 40 um/sec. Medium is 64 um/sec. Fast is 100 um/sec. Note: When the Dia Change (%) is less than 34, you must use a medium or fast speed. The tapering process doesnt support large taper ratios at slow speeds. X Taper Reset This is the home position for the fiber when Taper Reset is enabled. Y Taper Reset This is the home position for the fiber when Taper Reset is enabled.

Tapering Tab

[34]

Tapering Tab

Tab Status: Password Protected

Run Executes the tapering program that is displayed on the Taper Setup page. Abort This stops the taper program. Taper Reset After a taper is completed and removed, This button will automatically send the right fiber platform to the Right Reset Position, the left fiber platform to the Left Reset Position, and the ring of fire to the 0 or its home position, and home the X and Y motors. These Reset Positions are located on the Tapering Page. Note: To prevent any mechanical collisions, make sure the fiber holders are closed prior to resetting. Zero Load Cell This button zeros the load cell. Active Program This displays the current taper program. ENG Notes This allows the program designer to create notes for the operator. This is displayed when a program is loaded. Operator Notes When the data is saved, any notes in this window will be saved as well. This allows the operator to leave notes, i.e. forgot to clean fiber, saw an unsteady arc, etc.

Tapering Tab

[35]

Pitch/Yaw (Pitch) It is important that the LED calibration and camera gain settings are properly set and that the fibers are relatively in focus for this function to work. Some LDS systems are capable of making the adjustments on both the left and right fibers. The blue numbers below the fibers represent the pitch alignment in degrees. If your system only has the capability of adjusting only the right side, then the left Pitch displayed will always read zero. The box displays the value of pitch when the program stops. A checkbox will appear when running Pitch. Clicking the checkbox when running Pitch will move the fiber automatically to help adjust the pitch of the fiber. (Yaw) It is important that the LED calibration and camera gain settings are properly set and that the fibers are relatively in focus for this function to work. Some LDS systems are capable of making the adjustments on both the left and right fibers. Clicking the Yaw button turns on an algorithm that actively displays Yaw of the two fibers on the screen. The blue numbers below the fibers represents the Yaw Alignment in degrees. A checkbox will appear when running Yaw. Clicking the checkbox when running Yaw will adjust the X and Y motors to continuously align the right fiber to the left fiber until the check box is unchecked. Note: It is important to remember to uncheck the check box and unclick the Pitch/Yaw when completed. Master Gain This is the master gain of the LDS and controls both cameras. Load This loads a taper program.

Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program. Cleave Save Saves current cleaving program. ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views. Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default.

Tapering Tab

[36]

Scan Speed This is how fast the taper is scanned. This controls two things, 1-how long does it take to scan, 2-how high is the resolution of the scan, i.e. the faster the speed, the lower the resolution; the slower the speed, the higher the resolution. 400um/sec is the default speed. Note: This scans at a fixed rate of 10 samples per second Taper Scan Distance This is the distance that is being scanned. Scan to Max This will scan the max distance or if unchecked, will only scan the distance that you input into the "Distance" box. Cleave Dia Enter the desired cleave diameter of a tapered fiber here. Scan Only/Stop For Cleave This button has two functions: Scan Only-Scans the fiber based on the scan distance. Stop for Cleave-Performs the scan and scans until the cleave diameter is reached. Taper Scan Right/Left This is the direction of the Taper Scan. Toggle this between Right and Left. Save Graph This saves the actual graph under C:/LDS/TaperData. Save Absolute Scan Data This saves the Taper Scan data. This data is saved at C:/LDS/TaperData Overlay Load Cell Data This overlays the load cell data and the absolute motor positions of the taper.

Cleaving Tab

[37]

Cleaving Tab

Tab Status: Password Protected

Cleaver LED Slider bar adjusts the LED setting. Settings range from 100-65550. Default is ~38000. This is how fast the taper is scanned. This controls two things, 1-how long does it take to scan, 2-how high is the resolution of the scan, i.e. the faster the speed, the lower the resolution; the slower the speed, the higher the resolution. Master Gain This is the master gain of the LDS and controls both cameras.

Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program.

Cleaving Tab

[38]

Cleave Save Saves current cleaving program. ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views. Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default. Blade Location Speed Slider (ROF) This setting adjusts the speed of the ROF (ROF motor). The setting ranges from 20 to 1700 with an increment of 1. Moving the slider to the right increases movement speed in units of microns per second. Go (ROF) Clicking this button activates the ROF to move to set Position and at the speed set by the Speed slider. Stop (ROF) Clicking this button stops motor movement. Position (ROF) This field contains the current absolute position of ROF. Values can be entered directly into this field, through using increment/decrement button or values can be controlled using the position slider. The field also displays current position values during automatic adjustments. Position slider (ROF) This setting adjusts the absolute position of the left fiber. Values ranges from 0 micron to 35000 micron. Cleave Position Text Field This is the cleave position in microns from 0. The default cleave position is ~1050. This is setup so that it matches the same location that the scan measurement occurs (The Red vertical line in the center of the top view) Cleave Position Button Toggling this button will move the ROF to the "Cleave Position". Blade Up This moves the Cleaver blade up to the cleaving location that is defined on the setup page. Blade Down This moves the cleaver down to the home position. Cleave Dia Text Field Enter the O.D. at the center vertical line and click calculate load to calculate the required tension for cleaving. You may also change the load manually if you wish to cleave under a different tension. Calculate Load Calculates the required cleaving tension based on the diameter set in the Cleave Diam. box. Auto Scan and Calculate Load This will measure the O.D. of the fiber at the center line to determine the required tension to cleave the fiber. It is imperative to make sure the vision factor (on the Setup Page) is correct.

Cleaving Tab

[39]

Load (g) Displays the load that the "Set Tension" will use in Grams. Load (n) Displays the load that the "Set Tension" will use in Newtons. Set Tension This button initiates the tensioning process based on the "Load Setting" and the "Load" values. Stop Stops the tensioning process. Run Load Cell This button runs the load cell. The load cell must be stopped before any other functions can be executed. Stop This button stops the load cell. Zero Load Cell This button zeros the load cell. Auto Anvil Anvil will automatically move forward and automatically stop when the camera measures the deflection set in the Deflection text field. Stop Stops the auto anvil. Deflection (um) The measured amount of deflection in microns of the fiber before the Anvil stops. Start Anvil The purpose of the Anvil is to create a "Backstop" to support the fiber and prevent it from bowing during the cleaving process. Ideally the backstop should touch the fiber, but not apply pressure. The procedure is as follows: Press "Start Anvil" and be ready to press "Stop Anvil" before the anvil touches the fiber. Press "Stop Anvil" before contact with the fiber Use the Jog buttons to incrementally jog the anvil to the fiber. Stop Anvil Stops the Anvil. Home Anvil Homes the anvil. Jog+ Jogs the Anvil forward towards the fiber. Jog- Jogs the Anvil away from the fiber. Auto Cleave Auto Cleave will automatically move the Piezo forward and retract the Piezo after the camera measures the deflection set in the Deflection text field. Stop Stops the Auto Cleave. Deflection (um) The measured amount of deflection in microns of the fiber before the Blade stops.

Cleaving Tab

[40]

Run Blade Initiates the Piezo movement forward towards the fiber. Press "Start Blade" and be ready to press "Stop Blade" before the blade touches the fiber. Press "Stop Blade" before contact with the fiber Use the Jog buttons to incrementally jog the blade to the fiber until cleaved. Stop Blade Stops The Blade from moving forward. Home Blade Homes blade. Jog + Jogs blade towards the fiber. Jog Jogs the blade away from the fiber. Cleaver Variables: Note: If changing this parameter, the "Load Variables" button must be pressed for the parameter to be updated. Please allow 3-5 seconds for the update to occur. Blade Position The Blade Positions are 0-20. 0 is the top of the blade and 20 is the bottom. Cleaver Motor Speed This is the speed that the cleaver motor moves up. The homing speed of this motor cannot be changed. The default setting is 1500. Anvil Rate This is an arbitrary value that represents the speed of the anvil. The higher the value the faster the movement. The default setting is 67. Anvil Jog Distance This is the distance (in microns) that the anvil will move when using the Jog buttons. This is an arbitrary value and the higher the value, the further the distance. The default setting is 20. Cleave Speed This is the speed that the piezo will travel. The higher the value the faster the movement. The default setting is 67. Amplitude This represents the amplitude of oscillation, or how aggressive the blade will swing. The default setting is 500. Frequency This represents the frequency that the piezo will use. The default setting is 521 for a "Thin" bender, and 800 for a "thick" bender. Please consult your technical representative for more information. Load Variables Button This button loads the variables labeled in purple. Please allow 3-5 seconds for variables to load after the button is pressed.

Service Mode Tab

[41]

Service Mode Tab

Tab Status: Password Protected

Master Gain This is the master gain of the LDS and controls both cameras.

EFI Gain This is the master gain of the EFI camera. Stop Program The Stop Program button properly stops the execution of the program by releasing computer resources related to the USB and serial interfaces. Splice Load Loads splicing program. Splice Save Saves current splicing program. Taper Load Loads tapering program Taper Save Saves current splicing program. Cleave Load Loads cleaving program. Cleave Save Saves current cleaving program.

Service Mode Tab

[42]

Password 2 This is the current set password for the Taper Setup Tab, Tapering Tab, and Cleaving Tab. ROF Home Clicking this button will move the ROF module to the home position that is defined by the "ROF Home" on the LDS setup page. Arc Pos Clicking this button will move the ROF Module to the Arcing position that is defined by the "ROF Arc Position" located on the LDS Setup page. Threshold This is the acceptable threshold of the focus values in the top and side views. Focus Clicking this button will turn on the fiber focus check and display the focusing values in the top and side view. If the value is less than the threshold, the value is displayed in green and displayed in red if higher than the threshold. The higher the number, the better the focus. 825 is the default. Update Z This updates the current location of all stepper motors. Ring Light This slider adjusts the Ring Light intensity. The higher the value the brighter the LED. Note: This is an optional accessory. +Alignment Jog/-Alignment Jog Clicking this button causes the side view camera to be moved for a pre-defined time period, in milliseconds, set by Jog Duration Slider. The move is displayed in real time in the display windows. +Focus Jog/Focus Jog Clicking this button causes the top view camera to be moved for a pre-defined time period in milliseconds set by set Jog Duration Slider. The move is displayed in real time in the display windows. Jog Duration Slider This setting adjusts the jog duration of the alignment and focus jog functions. The setting ranges from 50 to 500 milliseconds. Piezo Control The piezo is an optional accessory that is typically used for splicing. The piezo drives the fiber forward during the splicing process with no hysteresis during this movement. The overall range of movement is 30um -160 um. The piezo contains a set of controls for manual maneuvering and accurate positioning of the piezo. When the Forward button or Reset button is clicked, a control signal is sent to the system to move or reset the piezo. Speed Slider (Piezo Control) This setting adjusts the speed of piezo. The setting ranges from 50 to 1000 with 1 increment. Moving the slider to the right increases movement speed in units of microns per second. Forward (Piezo Control) Clicking this button activates piezo to move set distance and at the speed set by the Speed slider. Reset (Piezo Control) Clicking this button resets piezo. Distance (Piezo Control) This field contains the current absolute position of fiber. Values can be entered directly into this field with an optional decimal place, i.e. 130.1

Service Mode Tab

[43]

Theta The theta motor is an optional accessory that is used for PM splicing. Speed Slider (Theta) This setting adjusts the speed of theta motor. The setting ranges from 50 to 1000 with 1 increment. Moving the slider to the right increases movement speed in units of microns per second. Go (Theta) Clicking this button activates the motor to move to set Position and at the speed set by the Speed Slider. Position (Theta) This field contains the current position of the theta motor. Values can be entered directly into this field, through using increment/decrement button or values can be controlled using the position slider. The field also displays current position values during automatic adjustments. Position Slider (Theta) This setting adjusts the position of the theta motor. Values will vary depending on current location of the motor. Left Fiber This window contains sets of controls for manual maneuvering and accurate positioning of the left fiber. When the Go button or Stop button is clicked, a control signal is sent to the system to move or stop the left fiber motor and the response is immediate. The display windows update continuously to indicate current view. Speed Slider (Left Fiber) This setting adjusts the speed of the left fiber motor. The setting ranges from 6 to 1100 at an increment of 1. Moving the slider to the right increases movement speed in units of microns per second. Go (Left Fiber) Clicking this button activates motor to move to set Position and at the speed set by the Speed Slider. Stop (Left Fiber) Clicking this buttons stops motor movement. Position (Left Fiber) This field contains the current absolute position of the fiber. Values can be entered directly into this field, through using increment/decrement button or values can be controlled using the position slider. The field also displays current position values during automatic adjustments. Position Slider (Left Fiber) This setting adjusts the absolute position of the left fiber. Values ranges from 12000 micron to 29000 micron. Right Fiber This window contains sets of controls for manual maneuvering and accurate positioning of the right fiber. When the Go button or Stop button is clicked, a control signal is sent to the system to move or stop the right fiber motor and the response is immediate. The display windows update continuously to indicate current view. Speed Slider (Right Fiber) This setting adjusts the speed of the right fiber motor. The setting ranges from 6 to 1100 with an increment of 1. Moving the slider to the right increases movement speed in units of microns per second. Go (Right Fiber) Clicking this button activates the motor to move to set Position and at the speed set by the Speed Slider. Stop (Right Fiber) Clicking this button stops motor movement. Position (Right Fiber) This field contains the current absolute position of fiber. Values can be entered directly into this field, through using increment/decrement button or values can be controlled using the position slider. The field also displays current position values during automatic adjustments.

Service Mode Tab

[44]

Position slider (Right Fiber) This setting adjusts the absolute position of the left fiber. Values ranges from 0 micron to 35000 micron. Fiber Scan This window contains sets of controls for manual maneuvering and accurate positioning of fiber for scanning. When activated both fiber platform are moved simultaneously. This movement is a manual movement of both the left and right fiber platforms at the same speed. The default value is 0 and the range updates automatically showing how far the motors can move from their current location. This is a relative moment. Go (Fiber Scan) Clicking Go will initiate the scan sequence. Stop (Fiber Scan) Clicking the Stop button will stop the process. Position (Fiber Scan) This field contains the current position. Values can be entered directly into this field, through using increment/decrement button or values can be controlled using the position slider. Position Slider (Fiber Scan) This setting adjusts the position of the left fiber. Values will vary depending on current location of the motors. ROF This window contains sets of controls for manual maneuvering and accurate positioning of the ROF. When the Go button or Stop button is clicked, a control signal is sent to the system to move or stop the ROF motor and the response is immediate. The display windows update continuously to indicate current view. Speed Slider (ROF) This setting adjusts the speed of the ROF (ROF motor). The setting ranges from 20 to 1700 with an increment of 1. Moving the slider to the right increases movement speed in units of microns per second. Go (ROF) Clicking this button activates the ROF to move to set Position and at the speed set by the Speed slider. Stop (ROF) Clicking this button stops motor movement. Position (ROF) This field contains the current absolute position of ROF. Values can be entered directly into this field, through using increment/decrement button or values can be controlled using the position slider. The field also displays current position values during automatic adjustments. Position slider (ROF) This setting adjusts the absolute position of the left fiber. Values ranges from 0 micron to 35000 micron. Sweep Speed This is the speed at which the ROF will translate left to right. Sweep Length This is the sweep distance that the ROF will translate left to right during the taper at the taper speed. Run Sweep Click "Run Sweep" to initiate, and "Stop Sweep" to Stop. Stop Sweep Stops sweep. Radius Tool Toggle this button to turn on/off the radius tool. This tool is intended for measuring the radius of a ball term or a lens.

Service Mode Tab

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Right/Left Choosing left or right will determine the side that the tool is measuring. If "Right" is clicked, the right side of the screen will be "blacked-out" and it will measure the radius from the center line to the left of the screen. When setting up to measure the radius of a lens, place the fiber in the right fiber holder, position the fiber so the peak of the radius or the largest part of the radius is on the center vertical line, toggle radius to turn on, and toggle radius to turn off. Averaged Radius This is the combined radius averages of the Top and Side views. Arc Control This window provides control of the arc power and balance settings. Arc Gain The camera gain will automatically change to this setting when the arc is manually initiated by using Arc On. Arc On Turns the arc on based on the Arc Power setting. Arc On Click to turn on the arc manually based on the arc power and arc time settings in the arc control box. Arc Abort Turns arc off at any time when it has been initiated by Arc On. Arc Position Selects the Current or Arc Position. This is where the arc will initiate when the Arc On is pressed. Low Power This is the power range for the arc, i.e. for 1000um and smaller diameter fibers, Low Power is recommended and for 1000um and larger diameter fibers, High Power is recommended. Click on the box to toggle between Low Power and High Power. Low Power is considered higher resolution. Set Arc Balance This sets the Arc Balance after the slider has been moved to a new location. Set Arc Power This updates the Arc Power when changed. If you change the Arc Power you must click Set Arc Power before the change will be updated. Arc Power The minimum setting is 0 and the maximum setting is 255. However, the arc may not fire at 0 depending on the arc gap and the arc balance. Arc Time This is the arc time that will be used if the arc is manually initiated by arc on. The range is from 0.1 to 99.9. Arc Power This is the arc power that will be used if the arc is manually initiated by arc on. The range is from 0-255. Arc Balance Slider (side) This adjusts the arc balance or the intensity of the plasma field horizontally. To check the arc balance for LDF applications place a piece of ~1mm (or an operator preferred LDF fiber) across the V grooves and manually initiate the arc at a power level of 100. The light intensity should be symmetrical from top to bottom as the fiber is heating up in the Side View camera. If the arc is more intense on the top, lowering the arc slider would shift the intensity from the top to the bottom. The Default setting is 170. Note: This value should not need to be changed, but if changed, be aware that changing this value can change the overall power of the plasma field and a re-optimization and possible verification of the splicing program is suggested The Arc Balance values are saved in the Excel files for each splice.

Service Mode Tab

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Arc Balance Slider (bottom) This adjusts the arc balance or the intensity of the plasma field vertically. To check the arc balance for LDF applications place a piece of ~1mm (or an operator preferred LDF fiber) across the V grooves and manually initiate the arc at a power level of 100. The light intensity should be symmetrical from top to bottom as the fiber is heating up in the Top View camera. If the arc is more intense on the left or right, moving the arc slider either left or right would shift the intensity from the left to the right, or vice versa. Note: This value should not need to be changed, but if changed, be aware that changing this value can change the overall power of the plasma field and a re-optimization and possible verification of the splicing program is suggested The Arc Balance values are saved in the Excel files for each splice.

Saving/Loading

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Saving/Loading Splice & Taper programs can be saved and loaded for future use. There is no limitation to the number of programs that can be saved with the LDS. When performing the Save and/or Load function for a splice the following values are recorded:

Prefuse

Arc Time 1

Arc Time 2

Pull Time

Prefuse Power

Arc Power 1

Arc Power 2

Pull Power

Push Distance

Pull Distance

gap set

V Arc balance

H Arc balance

Plasma Clean power

Plasma Clean time

Right move (um)

Left move (um)

Focus move (ms)

theta distance 2

Auto Offset

Manual Offset

Theta

Cleave Angle Limit View Angle Limit Splice Mode ROF Offset Position Left Reset Position Right Reset Position X Reset Position Y Reset Position Operator Notes Engineering Notes Splicing Gain Prefuse Gain Power Level

Saving/Loading

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LDS Splicing Process Chart

The two charts below are Arc Power over time and Push Distance over time.

X & Y Motor Movements

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X & Y Motor Movements The motors have 12mm of travel and are settable in 0.1um increments. Each motor needs to be homed after the LDS has been turned on. If the software GUI is turned off and back on but the LDS is not powered down then homing should not be necessary. The reason that they are not homed automatically is that it is often not desirable to lose a fiber alignment each time the GUI interface is turned off. Once the motors are homed the operator should manually set the Y motor (up and down) to ~10mm and the X motor to ~6mm from home. Depending on the fiber and V-grooves being used, this should place the fibers approximately into the view of both cameras so that automatic alignment can occur when executed. The controllers and motors are from a third party and the information below is extracted directly from the manual of the motor controller. Digital Display This shows the position (in millimeters or degrees) of the motor. The motor must be homed before the display will show a meaningful value, i.e. the displayed position is relative to a physical datum, the limit switch. Home Y This sends the motor to its home position. Fine X/Y Step Size This setting adjusts the Fine Step Size of the jog function for both the X and Y motorized alignment. Course X/Y Step Size This setting adjusts the Course Step Size of the jog function for both the X and Y motorized alignment. Master Gain Splice This is the master gain of the LDS and controls both cameras. EFI Gain Splice This is the master gain of the EFI camera. Fine X/Y Step Size This setting adjusts the Fine Step Size of the jog function for both the X and Y motorized alignment. Course X/Y Step Size This setting adjusts the Course Step Size of the jog function for both the X and Y motorized alignment.

Arc Counter

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Arc Counter The LDS records the count of the electrodes installed in the unit as well as a life counter. Arc Counter This is considered the life counter of the LDS. Every time the arc fires, either manually or automatically, this number will increase by an increment of one. Use Counter This is an algorithm that multiplies the power level of the arc by the time the arc is on. This is used as an electrode life counter. This number will vary depending on how the LDS is used, i.e. tapering, large diameter splicing, PM splicing, etc. Reset Arc Counters This is used when a new set of electrodes is installed into the LDS.

Passwords

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Passwords The Splicing Tab and PM Alignment Tab are the only tabs that are not password protected. Note: If the PM Splicing package and/or tapering package were not purchased, then the tab will be grayed out and unavailable to use The default Taping Tab and Taper Setup Tab password is: taper The default LDS Setup Tab, Splice Setup Tab, and Service Mode Tab password is: engnr

Changing the Default Passwords

The default LDS password can be changed in the LDS Setup Tab. 1 Type in a new password The default Taper password can be changed in the Tapering Tab. 1 Type in a new password Note: The new password will take immediate effect

Fiber Diameter Scan

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Fiber Diameter Scan When executed, the Fiber Scan measures center of the screen and begins translating the left and right stages simultaneously in the direction selected; the fiber scan feature begins measuring the outer diameter if the fiber. This program is useful when analyzing Splice Push and Splice Pull parameters as well as taper and MFA mechanical results (if your unit has these functions) as well as quantifying the result of a taper. Both Top and Side views are scanned and plotted on the graph.

Fiber Diameter Scan Graph

The data collected during a fiber scan is displayed here. The graph can be saved checking the box Labeled Save Graph. You may also overlay the load cell data (image below doesnt have the load cell data present) by checking the box labeled Overlay Load Cell Data. The graph is also scaling the absolute stepper motor position.

Performing a Scan

1 Enter a scan speed in the speed text field. 400 (400um/sec) is the default speed. 2 Check Scan Max if you wish to scan the maximum distance of travel and stop at any time, or you can uncheck scan

max and enter in the distance you wish to scan. 3 If cleaving, toggle the scan only/stop for cleave button so that the stop for cleave is displayed and the button is

yellow. 4 Enter in the diameter that you wish to cleave at. 5 Select the direction that you want the motors to move during the scan. 6 Check save graph. 7 Check overlay load cell data. 8 Check save absolute scan data. 9 Click begin scan. 10 Wait for scan to stop or you may stop the scan at any time. 11 Save data as pop-ups are displayed.

Camera Windows

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Camera Windows The LDS has two orthogonal cameras and are displayed in two windows. Note: The images displayed in both windows can be saved by right clicking on the individual display and choosing Save Data. This function saves the image to the Windows Clipboard and can be pasted into most standard programs Note: Both views have the capability of Digital Zoom. The Digital Zoom can be accomplished by left clicking the mouse button in either the Top View or Side View. The window can be returned to the original size by right clicking in the window and selecting Zoom to Fit.

Measurement Tool

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Measurement Tool The LDS comes with a measurement tool built into the GUI. The measurement tool is available in the following tabs; LDS Setup, Splicing, Tapering, Cleaving, and Service Mode. The measurement tool is useful in measuring:

Fiber diameters

Lengths

Taper diameters

Cleave results

Measuring a Fibe