AFO-101-3 Fiber Optic Routing and Installation

Aerospace Fiber Optics
Aerospace
Fiber Optics
AFO 101, Session 3
Fiber Optic Routing and

Installation
© Everett Community College. All rights reserved. 1
Session Objectives
After completing this session you should be able to:
• Work safely with materials used for fiber optic

routing and installation.
• Properly handle fiber optic material during routing
and installation to prevent damage during the
installation process.
• Properly route and install fiber optic assemblies
with proper routing, protection, tying, support, slack
and drip loops.
• Properly install connector receptacles.
• Properly mate connectors.

Session Agenda
• Safety
• Material Handling
• Bundle Tying
• Support
• Mating Connectors
• Practice per Quality Requirements
• Written Test

Personal Safety
The light from functioning optical fibers is invisible
and can cause damage to your eyes.
• Do not look into the end of a connected
cable.
• Do a very through lock-out tag-out or disconnect
the cable at both ends and put on clean dust
caps.


Personal Safety
• If the fiber cable gets cut, the fiber may piston out
of the cut end and injure personnel.
• Fiber optic cable can cause skin punctures and
may separate below the skin following puncture.
• For fiber optic cables that inadvertently get cut,
place tape as flags on both cut ends to capture
any fiber that may piston out.


Ensure Cleanliness
Exposure to airborne contaminates causes light

loss. Protect fiber optic cables as follows:
• Ensure that the area is clean prior to opening
the dust cap or protective bag.
• DO NOT remove the dust cap from uninstalled
cables except to connect the connectors.
• Connect the connector immediately.
• DO NOT touch the end face with your fingers or
any tools.


Route For Protection

Protect Fiber Optic Cables During Routing and
Installation
• Install cables so that they do not rub or touch sharp surfaces
that could damage the assembly.
• DO NOT use protective wrap as a substitute for good routing
practices. When possible, reroute the cable to achieve
protection.
• When rerouting is not possible, install protective wrap or
sleeving to protect the cable.
• Fiber optic cables need to be held tightly in clamped so that
the cable cannot contact the structure, hardware, or
equipment.

Routing Precautions
• If possible, do not pull or push the cable.
• If direct installation is not possible:
• Make sure that the cable does not form a loop that may
develop into a kink.
• Make sure that the cable does not exceed the minimum
bend radius.
• DO NOT attempt to pull or push the cable if it does not
move freely.
• DO NOT apply stress to the area where the cable
attaches to the connector. This could damage the fiber-to-
terminus assembly.





Routing Precautions
Fiber optic bundle routing is the same as for

general wiring, as follows:
• Fiber optic cables need to be routed so that the
cable bundles are held tightly in supports so that
they cannot contact the structure, hardware, or
equipment.

Check Your Understanding
What safety practices help protect your

eyes and skin? Why are these necessary?
How can you ensure cleanliness in your

work environment?
What are important routing practices?

Bundle Tying Requirements
• Bundle Tie: A means of holding the components

of a cable bundle securely. Ties may be tape,
plastic, or string.
• Cable bundle ties must hold the components of
the bundles together securely.


Bundle Tie Spacing

• Tie cables using the minimum number of ties necessary to
provide support and to hold the bundle shape at bends and
breakouts, and to keep cables in place when installed
adjacent to moving parts.
• Space ties on cable groups and bundles a minimum of 8”
and a maximum of 12” apart.
• Use a maximum spacing of 36” to tie the individual cable
groups that are tied within a bundle. Leave the original ties
in place.
• Some bundles have wire groups tied separately to ensure
separation.
• Remove ties on the portion of the cable bundles installed in
conduit.
Cable Routing in the Bundle

• Untangle the cables and route them parallel to
each other as much as practical.
• It is only acceptable to cross cables within a
bundle when a cable needs to be routed for
termination or to a breakout to another bundle or
group.



Material Selection
• Tie bundles that contain ONLY fiber optic cables
with Scotch Super 20 adhesive tie unless
otherwise stated.
• For bundles that contain a combination of wires
and fiber optic cables, use either Scotch Super
20 adhesive tie or use four wraps of either
Permacel P212HD or Scotch 70 protection on
the cable prior to installing a plastic tie or string
tie.

Installing Adhesive Ties

Install the adhesive tie as follows:
Install the tie tightly around the cables with a
minimum overlap of 1 times the circumference of
the bundle and a maximum overlap of three times
the circumference.
Requirements:
• The end of the tape bonds to the surface of the layer
below it with no edges or corners folded back.
• The tie does not have any cuts or tears.
• The tie cannot move along the longitudinal axis of the
bundle.
• The maximum distance between the edges of the
tape is not larger than 0.05”.

Activity: Adhesive Tying Practice

Practice tying fiber optic cables together with Scotch
Super 20 adhesive tie.
 Are your edges less than 0.05” apart?

 Is your overlap between 1 and 3 times the
circumference of the bundle?
 Does the end bond securely to the layer below it?
 Does the tie stay securely in place?
 Were you able to prevent tears or cuts in the ties?
If not, try again.

Installing Plastic Ties

• When installing a plastic tie wrap on a bundle that
contains fiber optic cable in a wire bundle, use a
minimum of 4 wraps of Scotch 70 or Permacel P212HD
tape as protection under the plastic tie.
• The installed strap must grip securely so that it does not
slip along the bundle unless forced by hand, but does not
bind the bundle so tightly that it deforms the cable.
Important Note
• Do not use the German method for installing plastic ties.
29


Activity: Plastic Tie Installation Practice
Practice tying fiber optic bundles to other wire bundles

with plastic ties.
• Install protection under the tie.
• Install the tie.
• Does your tie grip securely so it doesn’t slip along the
bundle unless forced by hand? It should!
• Does your tie bind the bundle so tightly that it deforms
the cable? It shouldn’t!

Installing String Ties

• When installing lock stitch on a bundle that
contains a fiber optic cable, use a minimum of
4 wraps of Scotch 70 or Permacel P212HD
tape as protection under the string tie (lock
stitch).
• The installed tie must grip securely so that it
does not slip along the bundle unless forced by
hand, but does not bind the bundle so tightly
that it deforms the cable.
32


Activity: Installing String Ties

Directions for tying a clove hitch knot:
• Wrap string around bundle twice.
• Cross tail end over first end.
• Stick loose end through string cross over.
• Pull tight.
• Now tie a square knot with two string ends.


Activity: String Tie Installation Practice

Practice tying fiber optic bundles to other wire
bundles with String ties.
• Install protection under the tie.
• Install the tie.
• Does your tie grip securely so it doesn’t slip
along the bundle unless forced by hand? It
should!
• Does your tie bind the bundle so tightly that it
deforms the cable? It shouldn’t!

Cables with Expando Sleeves
• If the fiber optic cables have an Expando

sleeve, then use protective wraps the same as
you would for cables without sleeves. Place the
protection between the tie and the Expando
sleeve.
37


Bundle Tying Requirements
• When there is a breakout after a clamp

(cushioned) do not tie the cables together after the
clamp.

Describe an effective bundle tie?
Why is material selection an important

consideration in bundle tying?
What tying techniques and practices

are important in this work?

Breakout Points
• When there is a breakout after a clamp (cushioned) DO NOT
tie the cables together after the clamp.
• DO NOT include the fiber optic cable when installing the last
bundle tie before the breakout point.
• Tie the fiber optic cables and wire group together at a minimum
distance of 1.5” from the radius.
• When routing the fiber optic cable at the breakout, DO NOT

bend the fiber optic cables to a radius less than 1.5” (3” dia.).
• DO NOT use protective wrap as a substitute for good routing.

The tape will stiffen the fiber optic cable and cause kinks at
bends.


Support: General Requirements
• Support: A means of connecting fiber optic

cables and bundles to the aircraft structure,
such as clamps, ring posts, race ways, etc.
• Slack: The distance from the inside top of two

clamps to the top of the cable in the middle.

Support: Cable Protection

• DO NOT support or tie fiber optic cables without protection!
• DO NOT use plastic ties or lacing tape under support.
• Use a minimum of 4 wraps Scotch 70 or Permacel P212HD tape

to build-up the diameter of the bundle to provide secure support.
• DO NOT use filler rods with fiber optic cables.
• If filler is needed within the support, use Scotch 70 or Permacel

P212HD tape for fill.
• DO NOT apply Scotch 70 or Permacel P212HD tape

excessively. Use only one tape width at support point.

Support: Back Shells

Back shells are to be installed the same on fiber optic
cables as on all other wires.
• The protection requirements in back shells is the same

as for clamps and ring posts.
• Use a minimum of 4 wraps of Scotch 70 or Permacel

P212HD tape.

Support: Excess Harness Length
• Follow general wiring requirements for excess

harness length.
• Do not bend the fiber to a radius less than 1.5
inches.


Support: Drip Loops
• The drip loop requirement for fiber optic

cables is the same as it is for copper bundles.
One to three inches below the rear grommet.

Mating Connectors
General Requirements:
• DO NOT remove the dust cap from a connector until

you are ready to connect the connector.
• Verify that the connector is clean.
• Verify cleanliness prior to mating. (We will cover
this in a later section.

Mating Connectors
Procedure to connect an ARINC plug to a receptacle:
1. After verifying that the end face is acceptable. (To be completed
later)
2. Check that there are socket inserts in one and pin inserts in the
other.
3. Check that the polarization key-way on the plug and the
receptacle agree.
4. Align the connector shell.
5. Maintain alignment and push the plug toward the receptacle.
6. Use a torque screw driver with a 9/64” Allen hex head to tighten
the connector attach-screw clockwise until the screw driver
attains the correct torque (9 inch pounds)
Mating Connectors
Procedure to connect a circular connector:
1. After verifying that the end face is acceptable. (To be
completed later)
2. Remove the dust cap from the connector.
3. Align the keys on the plug to the keyways on the
receptacle.
4. Do not turn the plug more than half a turn in either
direction.
5. Push the plug into the receptacle until it stops.
6. Hand turn the coupling ring of the plug clockwise as seen
from the rear of the plug until the coupling ring is tight. DO
NOT use tools.
7. Examine the closure indicator on the receptacle shell – the
red indicator band should not be visible.
Exercise: Installation and Routing Practice

Part 1
Obtain the drawing and all of the supplies that you need to
route the cable assembly on the board.
1. Install the receptacle.

2. Route the assembly on the board.
3. Attach ties as needed.
4. Attach the assemblies to the supports.
5. Do Not mate the connectors.
When complete, ask your instructor to check your work and

record the results on your checklist.

Installation and Routing Practice

Part 2
Flag # Callout
1. Cushion clamp
2. Cushion clamp
3. Install Scotch 70 tape this location with string tie (Lock
stitch).
4. Butcher clamp
5. Install Scotch Super 20 tie tape this location.
6. Install Permacel P212HD or Scotch 70 tape this location
with Panduit tie.
7. Butcher clamp
8. Ring post & Panduit Contour tie (Cobra)
9. Ring post & Panduit Contour tie
10. Butcher clamp & Permacel P212HD or Scotch 70 tape Filler
11. Butcher clamp & Permacel P212HD or Scotch 70 tape Filler
12 Butcher clamp & Permacel P212HD or Scotch 70 tape Filler

Activity: Installation Rework
• If your routing and installation was not

acceptable in any area on the checklist, rework
the routing and installation until it meets all
requirements on the checklist.
• If your routing and installation was acceptable in

all areas of the checklist, you are ready for the
next lesson.

What are the most important points to

remember about support and its
requirements?
What can you say about installation

and routing?
What have we learned about breakout

points?

Review
How much do you remember?
By now, you should be able to:
• Identify the requirements for working with fiber optics

including:
• Cable protection
• Support
• Tie material selection
• Properly perform routing, installation, and connector

mating procedures.

Review Game
1. The instructor will divide the room into two teams.
2. The first team to X number of points wins the game.
3. Select a spokesperson.
4. Read the question.
5. Confer with your team. State an answer.
6. If you are correct, you get a point. If your answer is
incorrect your team loses two points and the other team
gets to try to answer for a point. If your team scored on that
round it is now the other teams turn.
7. Each team takes turns attempting to earn points.

Question:
What is the correct time to remove the dust caps from
connectors during the routing and installation process?
Answer:
Only remove the dust caps immediately before mating the

connectors.

Question:
What is the minimum bend radius for single fiber
optic cables?
Answer:
The minimum bend radius for a fiber optic cable
is 1.5”.

Question:
Why is it important to be cautious around
damaged fiber?
Answer:
The glass portion of a fiber optic cable can piston

out of a broken cable and cause personal injury.

Question:
How do you prevent eye damage while working
with fiber optic cables?
Answer:
Never look at the end of a fiber unless it is not

connected to a light source or the power has
been turned off.

Question:
True or False: When routing around sharp
objects, apply protective material to protect the
cables.
Answer:
False
It is better to re-route the cables so that they
don’t contact sharp objects.

Question:
True or False: If a cable does not move freely
during installation, hold the cable by the
connector to gently pull it into place.
Answer:
False
You should not pull or push fiber optic cables
that do not move freely during installation.

Question:
When is it acceptable to use plastic ties with
fiber optic cables?
Answer:
It is OK to use plastic ties when fiber optic cables

are bundled with other wires and to attach fiber
optic cables to designated support, but only with
protection.

Question:
True or False: Protective tape is always required
under fiber optic bundle ties.
Answer:
False.
Tape protection is needed under plastic and
string ties. It is not needed when you use Scotch
Super 20 Adhesive Tie Tape for the tie material.

Conclusion
Any Final Questions?

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Aerospace Fiber Optics

Fiber Optic Routing and

• Work safely with materials used for fiber optic

© Everett Community College. All rights reserved. 2

© Everett Community College. All rights reserved. 3

© Everett Community College. All rights reserved. 4

© Everett Community College. All rights reserved. 5

© Everett Community College. All rights reserved. 6

© Everett Community College. All rights reserved. 7

Exposure to airborne contaminates causes light

© Everett Community College. All rights reserved. 8

© Everett Community College. All rights reserved. 9

Route For Protection

© Everett Community College. All rights reserved. 11

© Everett Community College. All rights reserved. 12

© Everett Community College. All rights reserved. 13

© Everett Community College. All rights reserved. 14

© Everett Community College. All rights reserved. 15

© Everett Community College. All rights reserved. 16

Fiber optic bundle routing is the same as for

© Everett Community College. All rights reserved. 17

Check Your Understanding

What safety practices help protect your

How can you ensure cleanliness in your

What are important routing practices?

© Everett Community College. All rights reserved. 18

Bundle Tying Requirements

• Bundle Tie: A means of holding the components

© Everett Community College. All rights reserved. 19

© Everett Community College. All rights reserved. 20

Bundle Tie Spacing

Cable Routing in the Bundle

© Everett Community College. All rights reserved. 22

© Everett Community College. All rights reserved. 23

© Everett Community College. All rights reserved. 24

© Everett Community College. All rights reserved. 25

Installing Adhesive Ties

© Everett Community College. All rights reserved. 27

Activity: Adhesive Tying Practice

 Are your edges less than 0.05” apart?

If not, try again.

© Everett Community College. All rights reserved. 28

Installing Plastic Ties

© Everett Community College. All rights reserved. 29

© Everett Community College. All rights reserved. 30

Activity: Plastic Tie Installation Practice

Practice tying fiber optic bundles to other wire bundles

© Everett Community College. All rights reserved. 31

Installing String Ties

© Everett Community College. All rights reserved. 32

© Everett Community College. All rights reserved. 33

Activity: Installing String Ties

• Wrap string around bundle twice.

• Cross tail end over first end.

• Stick loose end through string cross over.

• Now tie a square knot with two string ends.

© Everett Community College. All rights reserved. 34

© Everett Community College. All rights reserved. 35

Activity: String Tie Installation Practice

© Everett Community College. All rights reserved. 36