Evaluation of High-power Endurance in Optical Fiber Links
by Koji Seo *, Naoya Nishimura *, Masato Shiino *,Ren'ichi Yuguchi * and Hirokazu Sasaki*2

The capacity of optical communications networks has increased rapidly in thepast several years with the introduction of wavelength division multiplexing(WDM) technology, and optical power in the optical fiber link has risen accordingly. However,when optical power rises, system reliability suffers, with problems like damage to the fiberor optical components, safety of the human body, etc. This paper reports experimental data
gathered on three problems generated by high optical power in optical communications, i.e.,
damage to the connector endface, the phenomenon known as fiber fuse, and damage to the fiber
coating.

ABSTRACT1.

INTRODUCTION

The capacity of optical communications networks has
increased rapidly in the past several years with theintroduction of wavelength division multiplexing (WDM)
technology, and optical power in the optical fiber link
has risen accordingly. For example, the optical power of
1400 nm band laser diodes (LD) has reached as highas 400 mW, and in distributed Raman amplification,
which has attracted attention in recent years, a flat gain
characteristic has been achieved over a broad band
while pumping light power even reaches 1 W or more 1).
However, when optical power rises, system reliability
suffers, with problems like damage to the fiber or opticalcomponents, safety of the human body, etc. We consider
these problems associated with higher power in four
categories.
The first is damage to the connector endface. It has
been reported that the endface will be damaged by highoptical power if there is contamination of the endface 2).
Specifically, it has been reported that phosphor bronze,
which is currently used in conventional FC connectors,
caused damage to the connector endface 3), and FC
connectors without phosphor bronze have now come intouse.
The second problem is so-called fiber fuse, aphenomenon in which only the core of the optical fiber
melts locally due to high optical power in the fiber and thedamage is propagated toward the light source, emitting
visible light. After propagation, the fiber typically showsa string of voids in the core region. It keeps propagating**2

Transmission Line Dept., FITEL-Photonics Lab.
Analysis Technology Center, Yokohama Lab.

until the light source is shut down or the optical power
drops below a certain threshold. Experimentally, fiber
fuse propagation lengths of more than 1.5 km have beenreported 4). Fiber fuse was observed in optical fibers in the
1980s 5), but none of the proposed theories could explain
all the observations 6).
The third problem is damage to the fiber coating. Thismay be caused by light leaking from the fiber when it isbroken or bent accidentally in a high power environment
with the introduction of a Raman amplifier. The leaked
light is absorbed by the fiber coating generating heat, andin the worst case, it may ignite.
The fourth problem is the safety of the human bodyunder laser light radiation when there is a fracture in
an optical fiber link or a separation of connectors. With
present technology, we can consider such methods asusing connectors with shutters, or detecting the reflected
light and shutting down the light source.
These problems are crucial to operating optical fiber
communications systems safely, and progress is being
made in creating guidelines aimed at international
standards 7). Accordingly, we report in this paper the
results of experiments carried out to investigate damage
to connector endfaces, fiber fuse, and damage to fiber
coatings.

2.

DAMAGE TO CONNECTOR ENDFACE

2.1 Experimental Method
Figure 1 shows an example of damage to the endface ofan FC connector due to high optical power with phosphor
bronze contaminating the endface. This is a result of
the fact that phosphor bronze is sometimes used in theadapter sleeve or the connector key in FC connectors,

Furukawa Review, No. 24

2003

17

Evaluation of High-power Endurance in Optical Fiber Links

Table 1
Conditionand may be ground into a powder that gets on theendface during connector connection. Even with otherconnectors that do not use phosphor bronze, however, thesame phenomenon may occur.
Accordingly, we made detailed investigations of cases inwhich the connector endface had scratches (by polishingetc.) or various kinds of contamination that would tend
to damage the connector. We used a 2-W light sourcewith a peak wavelength of 1480 nm, the same band as
the pumping light for EDFAs and Raman amplifiers. Test
samples were prepared FC connectors for single mode
fibers (SMF). We input 2-W laser light into the system,
and investigated the changes in the samples.
2.2 Effect of Scratches
In terms of scratches on connector endfaces, weevaluated three kinds of samples, (1) without scratches in
the core area, the level of products on the market, (2) withscratches in the core area due to inadequate polishingcondition, which did not adversely affect connection
loss, and (3) with scratches caused by a 5-μm file, which
adversely affect connection loss. Five samples of eachwere evaluated, with the results shown in Table 1. Nochanges in the endface state was observed for any of
the samples, and in those samples with large scratches
made by the 5-μm file, a temperature increase of morethan 50°C was observed. This temperature increase
was probably due to connection loss. Concerning therelation between connection loss and heat generation, it
is reported that to control the generation of heat within 10
degrees in MU connectors, the connection loss shouldbe 0.25 dB or less 8). and of the scratches are within therange in which they have no effect on connection loss,
heat generation will be so little that it unlikely to cause
endface damage.
2.3 Effect of Contaminants
We evaluated samples of seven kinds of contamination,
which are in practice likely to contaminate the endfaces.
The results are shown in Table 2. With the contaminantsof high transparency, such as (4) ethanol, (5) oil fromthe hand, and (6) index-matching oil, no damage tothe endface was observed. Only in the case of index-

Results (n=5)

0.12 dB

No change: n=5

 Polishing scratches

0.18 dB

No change: n=5

 5- µ m file scratches

0.78 dB

Temp. increase: n=5

Condition

Damage to connector endface.

Typical connection loss No scratches on core

Table 2

Figure 1

Effect of scratches.

Effects of contaminants.
Typical connection loss

Results (n=5)

 Ethanol

0.14 dB

No change: n=5

 Oil from hand

0.21 dB

No change: n=5

 Index matching oil

0.64 dB

Epoxy resinwith carbon

No change: n=2
Temp. increase: n=3
No change: n=10.67 dB

Temp. increase: n=2
Endface damaged: n=2

 Ni plating

1.39 dB Oil-based black ink

0.24 dB Phosphor bronze

1.12 dB

Temp. increase: n=2
Endface damaged: n=3
Endface damaged: n=4
Fiber fuse: n=1
No change: n=1
Endface damaged: n=3
Fiber fuse: n=1

matching oil did a temperature increase sometimes
occur, probably due to a larger connection loss, causedby air bubbles in the oil, which is not usually used in
FC connectors. With light absorbing contaminants likemetals or black compounds, such as (7) epoxy resinwith carbon, (8) Ni plating, (9) oil-based black ink, or (10)phosphor bronze, when the connection loss was small,
endfaces were damaged and in some cases fiber fuseoccurred. Specifically with phosphor bronze, the endfaces
were damaged only at 50 mW. On the other hand, somesamples of epoxy resin or phosphor bronze caused nodamage to the endfaces, but when the samples wereobserved after the experiment, it was found that thecontaminants were not present in the core area.
2.4

Consideration of Endface Damage andCountermeasures Adopted
The experiments showed that only those contaminants
that absorb optical power easily produce damage to fiber
endfaces. However, even when scratches in the corearea do not directly result in endface damage, they are
better avoided because they may trap such contaminants.
The use of index-matching oil should also be avoided
in a high-power environment, because it easily traps air
bubbles and contaminants.
It has also been found that endface damage may occur
even with so little contamination that it has no effecton connection loss. Thus the most effective method of
preventing endface damage is to clean it carefully every
time a connection operation is performed. Cleaning during
the emission of high power light should be avoided,
however, because experiments have shown that it might

Furukawa Review, No. 24

2003

18

Evaluation of High-power Endurance in Optical Fiber Links

damage the endface whether alcohol is present or not,and it may also be dangerous to the human body.
Therefore, connectors exposed to high-power lightneed careful handling, and cleaning and checking of theendface should only be carried out with the light source
turned off.

laser source until fiber fuse stopped, and measured thatpower level which is the threshold value. This threshold
power for fuse propagation is determined solely by fiber
type and laser light wavelength, and is independent of themethod of fuse initiation. And since this threshold power isthe level below which fiber fuse cannot propagate, we also
believe it to be the point below which it cannot be initiated.

3.

3.2 Threshold Power of Fiber Fuse Propagation
Figure 4 shows the power threshold for fuse propagation
measured at two wavelengths for SMF and ITU-T G.653
dispersion shifted fiber (DSF). The fact that the power
threshold is lower for DSF than for SMF is thought to be
due to the higher power density because of the smaller
mode field diameter (MFD). Figure 5 shows the threshold
power for several fibers with different MFD, measured ata peak wavelength of 1467 nm. The fibers used weredispersion compensating fiber (DCF) for SMF, DSF, andlocally core expanded SMF (diameters of 20 μm and 30μm). For SMF, DSF, and DCF, the actual measured values
are plotted and for the core-expanded fibers is shown asa range, the value at which the fuse passed the expanded
part plotted as maximum and the value at which it stopped
as the minimum.
Against our expectations, the result showed that thepower threshold is in proportion not to effective area (Aeff ),but to MFD. If the power were in proportion to Aeff , the

3.1 Experimental Method
Fiber fuse is a phenomenon in which voids are formed
typically having the shape of bullets in the core area, andpropagate as shown in Figure 2. Propagation continues
as long as optical power is provided until the light sourceis shut down or the power drops below a certain threshold,and may eventually reach the light source and damage it.
In this work, we measured the threshold power at which
fiber fuse stops propagating.
Figure 3 shows the test setup. We used two lightsources with peak wavelengths of 1064 and 1467 nm.
The point to be noted here is that fiber fuse does notnecessarily occur, even under high light power. It has
been reported that the silicon fiber itself can withstandover 10 GW/cm2 and generally SMF is sufficiently durable
to withstand light intensities in the order of several Watts.
If, however, there is some trigger to initiate fiber corefusion at some point, from which it will propagate toward
the light source. In actual light transmission paths, lightabsorption by contaminants adhering to a connector
endface, or the concentration of light energy by multirefection at fiber breaks can constitute such a trigger. The
probability of fiber fuse initiation thus tends to increaseas optical intensity rises, but the probability and threshold
power for the initiation of fiber fuse differ dramaticallyaccording to what the trigger is.
During this investigation, in order to increase theprobability of fiber fuse easily, fibers carrying 5 W of laser
light power were heated locally by arc discharge to over
1000°C. Once fiber fuse occurred, we decreased the lightintensity level gradually by adjusting the bias level of the

2.0
SMF

Power threshold (W)FIBER FUSE

1.5

DSF

1.0

0.5

0

800

1000

1200

1400

Figure 4

Wavelength dependence of power threshold for fiber
fuse propagation.

λ =1467 nm

Optical fiber after fuse propagation.

Optical fiber(10~20 m)

Heating by arc discharge

Direction of light power
propagation

Light source
1064 nm, 5 W
1467 nm, 5 W

4.0

3.0

2.0

1.0

0

Power meter
Direction of fiber fuse propagation

Figure 3

Power threshold (W)5.0

Figure 2

Setup for testing fiber fuse.

1600

Center wavelength (nm)

0

5

10

15

20

25

30

35

MFD ( µ m)

Figure 5

MFD dependence of power threshold for fiber
fuse propagation.

Furukawa Review, No. 24

2003

19

Evaluation of High-power Endurance in Optical Fiber Links

Consideration of Fiber Fuse andCountermeasures Adopted
All that is necessary to assure that fiber fuse is notinitiated is to keep the optical power of the light source
below the propagation threshold. For example, we havefound experimentally that at 1467 nm, the pumping lightwavelength, the power threshold of SMF is approximately
1.5 W, so that it is certainly safe with respect to fiber
fuse when operated below this level. However, since thepower levels in fiber optic communication networks may
rise to more than 1.5 W, technology for stopping fusepropagation is also needed.
Detecting optical output power and turning off the laser
light source is the most effective method to stop fiber
fuse propagation. When fiber fuse is initiated, output
power decreases precipitously, as shown in Figure 6,so, if the drop is detected and the laser source turned
off immediately, the propagation will stop, because thepropagation speed is several meters per second at most.
Especially, an automatic power reduction (APR) system,
which is described in ITU-T as a method for shutting down
the light source in case of fiber breakage, is effective not
only in terms of safety to the human body, but also of fiber
fuse.
There is also another technique that is effective inproviding an area of expanded MFD in the optical path.
For example, we made SC connectors using fibers withpartially expanded MFD, as shown in Figure 7. The lengthof the expanded part is about 4 mm, the expanded MFD
is 30 μm, and the MFD at the endface is 10 μm, so theseconnectors are compatible with standard SC connectors.
It was confirmed experimentally that they can stop fusepropagation at 4-W transmission at a peak wavelength of
1467 nm.

4.

DAMAGE TO FIBER COATING

4.1 Experimental Method
Tight bending of optical fibers is not conducive to longtime reliability, but in actual systems fibers may be tightly
bent. When tightly bent the light is radiated to the fiber
coating, which is heated particularly under high power
conditions. We have investigated damage to the fiber
coating induced by tight bending under high power
conditions in the short term.
Figure 8 shows the test setup for the investigation.
We used a 1480 nm high-power light source having amaximum output power of 3 W. The fibers tested wereG.652 fiber, with coating of 0.25 mm UV curable resin(transparent, white, and green) and 0.9 mm tight buffer(white nylon). The bending diameters of the fibers were
30 mm, 20 mm, 10 mm, and less than 5 mm. The ambient
temperature was approximately 25°C.

4Light power (W)

3.3

5

3

Fiber fuse initiated here

2

1

0

0

1

2

3

4

6

5

Time (min)Figure 6

Power meter readings on changes in output power
for tests according to Figure 3.

20
15
10

MFD ( µ m)

plotted data would not be on a straight line, but on thelocus of a quadratic equation. However, we were able toconfirm that expanding the MFD is an effective way toraise the power threshold for fiber fuse propagation.

5
0
-5
-10
-15
-20
0

1

2

3

4

5

6

7

8

9

10

11

12

Distance from connector endface (mm)Figure 7

Profile of MFD.

Fiber bending diameter:
φ 30, 20, 10, 5 mm

Light source
1480 nm,
3 W maximum
Coating on SMF:

Figure 8

UV (transparent, white, green),nylon (white)

Setup for testing damage to fiber coating.

First, the temperature changes at a point on fibers bent
to a 3-mm diameter were measured at 3 W input power,
as shown in Figure 9. This shows that heat equilibrium isreached within 5 minutes, so in our experiments the tested
fibers were exposed to high input power for 5 minutes.
4.2 Evaluation of Damage to Fiber Coatings
The experimental results after 5 minutes exposure areshown in Table 3. We distinguished the conditions ofcoating damage qualitatively into four stages: “deformed”
means that the coating resin is hardened by the heat;“discolored” means that, in addition, the color of coating
becomes dull; “melted” means that a part of the coating
melted; “ignited” means that the coating burst into flameand burned.
In the case of bending diameters of less than 5 mm, thenylon coatings were melted at 1 W and ignited at 3 W, andFurukawa Review, No. 24

2003

20

Evaluation of High-power Endurance in Optical Fiber Links

P=3 W, φ =3 mm120

Temperature (°C)

100
80
60
40

UV white
20
0

UV transparent
0

2

4

6

8

10

Time (min)Temperature change in fiber coating at bending
diameter of 3 mm and input power of 3 W.

Table 3Fiber coating

Diameter

1480 nm(mm)

UV transparent

φ 30

No change No change No change No change

φ 20

No change No change No change No change

φ 10

No change

Deformed

Deformed

Deformed≤φ 5

No change

Deformed

Discolored

Meltedφ 30

No change No change No change No change

φ 20

No change No change

Deformed

No change

φ 10

No change

Deformed

Deformed≤φ 5

Discolored Discolored Discolored

Ignited

3W

UV white

Deformed

UV green

Nylon white

the UV coatings also had became discolored at all levels.
Thus it is considered that diameters of less than 5 mmconstitute a very dangerous region. In the case of bending
diameters of 10 mm for up to 3 W, the nylon and colored
UV coatings were deformed. In the case of 20 mm at 3
W, one of the green coatings was deformed. Diameters ofless than 10 mm for up to 1 W and less than 20 mm up to
3 W should therefore also be avoided.
From these experimental data, ignition is not likely tooccur up to 3 W as long as the fiber is not bent to lessthan a diameter of 5 mm. However, in order not to lower
transmission path reliability, the diameter of fiber bends
must be more than 20 mm up to 1 W, and 30 mm up to
3 W. Lastly, it was determined that transparent UV wasmore durable than colored UV.
4.3

Consideration of Coating Damage and a Modelfor Heat Generation
We also measured the surface temperature of bent fibers
by means of a thermo-viewer, as shown in Figure 10. The
maximum temperatures were measured and plotted on
the graph in Figure 11. The temperature of nylon reached
160°C, which is almost the melting point but less than theignition point. It is therefore considered highly probablethat fiber coating ignition in Table 3 occurred because thenylon melted leading to reduced coating strength and fiber
breakage and to radiation of light from broken fiber.

λ =1480 nm, P=3 W

200

Result of tests for fiber coating damage.

Power

1W

Figure 10 Observation by thermo-viewer.

Temperature (°C)

Figure 9

150

100

50

Nylon white
UV transparent

0

25

20

15

10

5

0

Bending diameter (mm)Figure 11 Dependence of maximum coating temperature
on bending diameter.

We also attempt to provide theoretical support for
the temperature changes obtained experimentally. We
assume that bending loss occurs due solely to lightleak and that all the light leakage is absorbed by thefiber coating and converted into heat. In addition, if it isassumed that the heat generated does not escape fromthe inside the fiber coating, the average temperature
increase may be represented as follows.

∆T =

Pαη
Cpφπ2 (r2 2 –r1 2 )ρ(1)

where: P is light intensity, α is bending loss, η isabsorption index of the coating resin, and ρ is the specificheat of the coating resin, φ is bend diameter, and r 1
is the inner radius and r 2 the outer radius of the fiber
coating. Since a state of thermal equilibrium is reached,
the approximation described above is valid for only a few
tens of seconds. Taking, for example, the transparent UV,with P of 3 W, α of 95 %, and φ of 5 mm, the temperature
is calculated to reach about 105°C after 10 seconds,
from an ambient temperature of about 25°C. The value
measured in the experiment was 95°C, which wassubstantially in agreement with the calculated result.

Furukawa Review, No. 24

2003

21

Evaluation of High-power Endurance in Optical Fiber Links

5.

CONCLUSION

The capacity of optical communications networks has
increased rapidly in the past several years with theintroduction of wavelength division multiplexing (WDM)
technology, and optical power in the optical fiber link has
risen accordingly. However, when optical power rises,system reliability suffers, with problems like damage tothe fiber or optical components, safety of the human body,etc. This paper reports experimental data gathered on
three problems generated by high optical power in opticalcommunications, i.e., damage to the connector endface,
the phenomenon known as fiber fuse, and damage to thefiber coating.
This time, the qualitative tendency and a certain
quantitative prospect were obtained about three highpower problems. More data must be accumulated inorder to reach a conclusion as to reliability or guaranteedvalues. We plan to continue these evaluations andwant to contribute to the development of an optical fiber
communications system with products of higher power
durability and safety.

REFERENCES
1) Y. Emori, Y. Akasaka and S. Namiki, “Less than 4.7 dB noise
figure broadband in-line EDFA with a Raman amplifier-1300
ps/nm DCF pumped by multi-channel WDM laser diodes,” inTech. Dig. OAA ’98, Vail CO, July ’98, paper PD3.
2) M. E. De Rosa, V. A. Bhagavatula, Q. Wu., K. Matusick,“High optical power testing of physical contact connectors at
1550nm,” OFC’01, Technical Digest, TuI7-1.
3) J. Nakajima, H. Takara and S. Nishi, “Temperature increaseof optical connector end face due to spot heated by highpower light,” IEICE’91, B-574
4) Raman Kashyap, “Self-propelled self-focusing damage in
optical fibers,” Electronics Letters 7th, Jan.1988, Vol24,
No.1.
5) D.P. Hand and P. St. J. Russell, “Solitary thermal
shockwaves and optical damage in optical fibers: the fiber
fuse,” Opt. Lett. V13 p767 (1988).
6) D . D . D a v i s , S . C . M e t t l e r a n d D . J . D i G i o v a n n i , “ Acomparative evaluation of fiber fuse models,” SPIE 2966,592-606 (1997).
7) “Optical safety procedures and requirements for opticaltransport systems,” in ITU-T, G.664
8) S. Yanagi, S. Asakawa and R. Nagase, “Characteristics
of fibre-optic connector at high-power optical incidence,”
Electronics Letters 15th, Aug.2002, Vol38, No.17.
9) Stolen R H, “Optical fibre communications,” Miller S E &Chynoweth A G, eds., Academic Press, 1979.

Furukawa Review, No. 24

200322