Development of the New Fusion Splicer Series S123/S153/S178
Junichi Kazama *, Takeshi Nagao *, Fumihiro Yabe *, Seiryo Mishima *, Hisanori Yonenaga *Norifumi Yamazaki *, Tomohiro Akiyama *, Yoshihide Nakayama *, Satoshi Nagao *, and Shoichi Yoshinaga *As the transmission volume of information increases in the 2000s, wavelength
multiplexing in optical communications has been implemented along with theupgrading of the communication speed. Such advancement has made optical fiber fusion
splicers one of the essential industrial equipment for the implementation of the communication
networks and the manufacturing of optical components. Also, in the non-communication fields
present in sensing technology using strains in optical fibers and laser technology for powertransmission, the use of optical fiber is rapidly growing. The fusion splicers are used in these
non-communication fields as well.
In light of this, we have been developing new fusion splicers with sufficient performance andfunctions to meet requirements from the special market segments in response to customers'
needs. Simultaneously, we have been developing new products that provide superior robustness
required from all market segments.
Recently we have developed, around the same time, seven models of fusion splicers in threeseries - namely S123, S153 and S178 in addition to our mainstay product of direct core
monitoring type. We have thus been successful servicing all of our customers in the different
segments by providing them with a range of applications with a state-of-the-art technology of
Furukawa Electric.

ABSTRACT1.

INTRODUCTION

In many high technology countries, the diffusion rate of
the fiber to the x (FTTX) has surpassed 20%, and it now
shows a steady growth despite its tendency to flattening
out. In developing countries, on the other hand, the diffusion rate is still low, and it will probably increase hereafter.
In terms of the use ratio of optical fiber in communication networks, (it is acknowledged that this index generally increases up to 50% rather smoothly), the use ratio is
below 50% in most countries worldwide, so that in thedeveloping countries in particular, the use of optical fiberin telecommunications trunk line networks is expected toincrease in the future.
In non-communications fields, on the other hand, thelaser and the sensor technologies are representative of
the areas of optical fiber use, and the use is anticipated toincrease hereafter as well.
These situations suggest that optical fiber use will definitely increase in the future and that all installation aspectsof the optical fiber ranging from the trunk line networks tothe premises wiring, along with all application fields of
optical fibers, will require their specific purpose-designed
fusion splicers, an important component to promote theoptical fiber use in communications fields as well as in the* FITEL Products Div., Telecommunications Co.

non-communications fields.
Seven fusion splicer models in three series have all
together been developed here to cover all these specificpurposes. Their features will be described in this paper.

2.

APPLICATIONS OF FUSION SPLICERS

The application areas of fusion splicers are diversified inaccordance with the application area of the optical fibers.
2.1 Trunk Line Construction
It refers to, as indicated by its name, the connection
scope of work of the optical fibers to build a trunk line network using optical fibers. The optical fiber cable contains
as many as 1000 fibers, and a multi-fiber splicing machine
is mainly used for the connection scope of work.
2.2 FTTX
This is a generic term referring to the branching networks
from the trunk lines down to every home, condominiums
and buildings, where a single-fiber fusion splicing
machine is mostly used. In the fiber to the home (FTTH),
extremely low splicing losses are rarely required, because
these sections are at the end portions of a communication network.

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Development of The New Fusion Splicer Series S123/S153/S178

2.3 Field-Installable Connector
In connection field sites for optical fibers, a connector
connection is sometimes adopted instead of fusion splicing. And in such connector connection, special fusion
splicing for the boot of a connector must be carried out to
set the connection length optimized for the site plan. A
single-fiber fusion splicing machine provided with a field
connector splicing function is typically used for this application.
2.4 Optical Components Manufacturing
In the manufacturing area of optical components that realize long-distance transmission and wavelength multiplexing by sophisticatedly combining optical fibers of various
characteristics, a single-fiber fusion splicer capable ofcore monitoring and core alignment is mostly used.

3.

Figure 1

Appearance of S123A.

Figure 2

Appearance of S178A.

OUTLINE OF FUSION SPLICERS

The outline of the seven models in three series of fusion
splicers are shown in Tables 1 and 2, and their picturesare shown in Figures 1 and 2.
Table 1 shows the outline of the fusion splicer with fixed
V grooves for the self alignment of the optical fibers, while
Table 2 shows those with movable V grooves enabling theadjustable alignment of the optical fibers.
Table 1

Outline of S123 Series with fixed V grooves.

Model name
Number of fibers
Observation method
Alignment method

S123A/C
1

S123M4
S123M8
S123M12
1－4
1－8
1 － 12
Cladding
Self alignment based on outer diameter

Specification of
splicing loss

SM: 0.05 dB

Main applications

FTTX
FTTX
Trunk line
Trunk line
Field
Trunk line
construction construction
connector construction

Table 2Outline of S153A and S178A with movable V grooves.

Model name
Number of fibers
Observation method

S153A

S178A
1

CladdingCore

Alignment method

Alignment based on
cladding

Alignment based oncore

Specification of
splicing loss

SM: 0.04 dB

SM: 0.02 dB

Main applications

FTTX

FTTX
Trunk line construction
Optical components
manufacturing

3.1 S123 Series
The S123 Series fusion splicers are characterized by the
fixed V grooves, on which a pair of optical fibers is placedin opposed positions for splicing. The fibers splicing consist of a fusion by arc discharge at their end faces, andbrought in touch with each other to complete the splicing.
3.1.1 S123AThis is a single-fiber fusion splicer specialized for FTTX,
featuring the lowest price among fusion splicers.
3.1.2 S123C
This is a single-fiber fusion splicer, suitable for FTTX andfield-installable connectors.
3.1.3 S123M4
This fusion splicer is suitable from a single fiber to fourfiber ribbons, thus suitable for splicing of a 300-fiber cableas well as for FTTX construction. Due to its superior portability, a splicer of this model can meet any splicing
scope of work, aerial or underground.
3.1.4 S123M8
Since this device is applicable to fusion splicing of a single fiber to eight-fiber ribbons, it is suitable for construction scope of work of trunk lines consisting of multi-fiber
cables. With its size slightly larger than that of S123M4,
this fusion splicer has two battery slots, whereby the number of fusion splicing cycles has increased.

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3.1.5 S123M12
This is a multi-fiber fusion splicer capable of simultaneous
splicing of up to 12-fiber ribbons. Except for the number
of applicable fiber counts, it has the same functions as
those of the S123M8.
3.2 S153A
This is a skill-less fusion splicer provided with an opticalfiber alignment function based on cladding monitoring.
By means of its alignment mechanism, axial misalignment
caused by dirt on a fiber is automatically adjusted to null,
thereby achieving low-loss splicing.
3.3 S178A
This fusion splicer is characterized by its optical fiberalignment mechanism based on core monitoring, whereby the core of an optical fiber is directly monitored formeasurement of axial misalignment to allow a low-loss
splicing of optical fibers. Moreover, in case two fibers tobe spliced are of different kinds, the conditions of the rightand left cores are evaluated by means of image processing, and the ark discharge is automatically repeatedbased on the prediction to minimize the splicing loss.
Furthermore, the splicer is provided with an attenuation
splicing function to realize an attenuation-controlling splicing procedure, as well as with a wide-range of fusion
splicing capabilities of the core diameter from φ80 μm toφ150 μm. Thus, the device is best suitable not only for
FTTX splicing scope of work but also for manufacturing of
the optical components.

4.

FEATURES OF FUSION SPLICERS

Features of the new products will be presented below,
including options developed here.
4.1 Size Reduction
While the conventional S177 used a 7.5-power objective
lens and a complementary metal oxide semiconductor(CMOS) camera with a cell pitch required for core alignment, the S178 uses a 3-power objective lens and a newly
developed CMOS camera, securing an optical resolution
required for core alignment. The reduction of lens magnification power has resulted in a smaller lens, succeedingin reducing the distance between the optical fiber and theCMOS camera.
This success has constituted a major factor in reducing
the size of the fusion splicer: depth from 260 mm of theconventional to 199 mm, and the height from 138 mm to
105 mm.
With respect to the width, all models have been reviewed
for the design of the optical fiber carrier called "Z platform"
along with its driving motor and the layout of the driving
mechanism, and in the multi-fiber fusion splicers, thewidth has been reduced from 140 mm of the conventional
to 127 mm.
As a result, the size of the S178 has been reduced by
43%. And the S123M8, S123M12 and S178 have thesmallest size in the world for this class of fusion splicers.

4.2 Weight Reduction
For the purpose of weight reduction, materials for the
structural components and exterior components of thefusion splicers have been changed from aluminum alloy
to magnesium alloy that provides superior specificstrength and specific rigidity.
With respect to the weight reduction of electronic components, the use of programmable logic devices such as
field programmable gate array (FPGA) has been expanded to reduce the number of electronic components andthe area of glass-epoxy substrate, resulting in a weight
reduction of 7% from the conventional device. The
S123M8, S123M12 and S178 have the lightest weight in
the world for this class of fusion splicers.
4.3 Reduction in Power Consumption
As a result of the implementation of a new central processing unit (CPU), the heat generated by the CPU has
been reduced from that of the conventional devices,which in turn has resulted in power reduction of coolingfans, thus making a contribution to reducing the secondary power consumption.
A new heater has been designed together with its control
program to realize a shortening of the shrinkage time forthe heating reinforcement (HR) sleeve, which has led to a
reduction in the power consumption per cycle of the HR
process.
A new motor has been considered eliminating the needfor an excitation current for holding the motor position,
leading to a reduction in the consumption of power.
As a result of these efforts, the power consumption has
been reduced by 29% from the conventional splicers.
4.4 Robust Design
Robust design has been carried out under the assumption of the outdoor use and the handling of a variety ofissues including shock due to falling, dust in the air,
impact of water such as rain and impact of wind. Efforts
were made to develop a splicer with sufficient mechanicalresistance against such adverse conditions.
With respect to protection against dust and water, thedevelopment was performed in compliance with the IP52
specified in the IEC60529 standard, equivalent to JIS C
0920. The IP5X is a standard for dust protection, which
stipulates that normal operation of the device under test
shall be assured when the test chamber is depressurizedby 2 kPa, and 2 kg of dust below 25 μm in granularity is
sprayed for 8 hr continuously.
The IPX2 is a standard for waterproofing property, which
stipulates that normal operation shall be assured when
the device is tilted back and forth and from side to side by
15°, and water is dripping to simulate a rainfall at the rateof 3 mm/min for 2.5 min at each tilt angle --for 10 min in
total.
With regard to falling, the splicer was designed inaccordance to the Telcordia standard which stipulates
normal operation after falling from a 760-mm height.

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4.4.1 Design to Shock ResistanceThe device was designed to be protected from damageon the assumption that it undergoes a fall from a 760-mm
height during transportation. A shock buffering material
was provided at each of the four corners of the splicer,
and as a result, splicing loss performance on opticalfibers showed no adverse effects after falling with its 5
faces down, excluding the top face.
In the case of falling with its bottom face down in particular, the shock buffering material provided with a temporalshock dispersion function was used to temporally disperse the falling shock, thereby reducing the shock loadon the fusion splicer. See Figures 3 an 4.

bottom case and top case on one hand and that of battery doors on the other hand has adopted the socket andspigot engagement mechanism. This design proved to bevery effective in preventing the ingress of water and dust
within the engagement portions.
The connector portion of the USB and the power supply,
used for external connections, was located on a recessed
wall, on which a backboard was provided to prevent
water creepage. Moreover, assuming an ingress of waterrunning down the wall to enter the connector, the design
provided a cap on the connector to prevent the ingress ofwater and dust.

300

Impact shock in gravity（G）

250
200
150
100

Figure 5

50
0
‑50

0

5000

10000

15000

20000

Time
（us）

Figure 3

Time vs shock chart (I). Symmetric rubber pad
without shock buffering function is applied.

300
250
Impact shock in gravity（G）

Conditions of the waterproof test.

200
150
100
50
0
-50

0

Figure 4

5000

10000

15000

20000

Time
（us）

4.4.3 Design for Wind Protection
In fusion splicing of optical fibers, an arc discharge isused to fuse the fiber ends, and then they are brought incontact with each other to be spliced. However, since thearc discharge is susceptible to wind, the affected arc discharge tends to show instability in intensity and directions, providing an insufficient function for splicing of optical fibers with a low loss. In the present design, a closed
space for arc discharge was provided in order to secure adischarge space that can be used under a wind speed of
10 m/sec, a general standard of wind speed adopted forsafe use in which for aerial work. To accomplish it, thehinge of the clamp arm mechanism for fiber holding was
kept mechanically independent from the arm of the windprotecting mechanism of the arc discharge, forming aclosed structure in which the canopy overlaps the top
case shield. This design succeeded in protecting the arc
discharge from the wind effects, allowing us to perform
splicing works without adversely influencing the splicing
losses even under a wind speed of 15 m/sec. Figure 6
shows in orange the overlapping portion of the canopy
and top case.

Time vs shock chart (II). Asymmetric rubber padwith shock buffering function is applied.

4.4.2 Design of Dust Protection and Water Proofing
Properties
Since ingress of dust is almost the same as ingress ofwater in phenomenology, if the water-proofing design of adevice is successful, it can be considered that the samelevel of success has been achieved in terms of dust protection design. Specific design examples will be presented below. The engagement portion between the body's

Figure 6

Canopy and top case structure for wind protection.

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Development of The New Fusion Splicer Series S123/S153/S178

4.5 Releasable Clamping Mechanism
Optical fiber ribbons or coated optical fibers accommodated in closures for a long time have on them a permanent bend because of their storage in the tray. Despite thepresence of the clamp lifting mechanism, it sometimes
poses a problem making it difficult to set the fiber on thefiber holder or V-groove at the time of fusion splicing.
Whereas, typically, the optical fiber was clamped concurrently with the opening and closing of the canopy, aclamp arm has been newly provided to enable fiber
clamping independently from the canopy movement. The
new function has been built while keeping the typicalfunction. By handling a clamp of a release-lever, an operator can select one of the two operations, one couples
the fiber clamping with the canopy movement, and theother uncouples the fiber clamping and canopy movement. In case the uncoupled operation is set, the operator
activates the clamping arm manually and closes the canopy after visually confirming that the fiber is securely
clamped.

Clamp release lever

Figure 7

Independent clamping action.

4.6 Heating Reinforcement Equipment
Since a fusion spliced portion has bare glass, it needs
reinforcement. The reinforcement method generally uses
a heat-shrinkable tube containing a reinforcing member ofglass or stainless steel to cover the portion where theglass is exposed. It subsequently heats the tube to shrink
it in order to prevent the displacement of the tube. As aresult, the rigidity of the reinforcing member prevents the
optical fibers from breaking. This sleeve structure is calleda heating reinforcing (HR) sleeve.
The HR sleeve must shrink without trapping of air bubbles, the shrinking is performed with purging the air fromthe center to the ends of the sleeve. And it is the heaterthat is required to perform the shrinking process in ashorter time. Specifically in recent years, because thesplicing time has been reduced to less than 10 sec, thereduction of the heat shrinking time holds the key to thework time reduction in a series of processes from opticalfiber splicing to strengthening.
4.6.1 Speeding-Up of Heating
Since, as mentioned in Section 4.6, the HR sleeve must
shrink from the center to end, the temperature distribution
over the whole length of the heater becomes importantalong with how to control the temperature distribution.

Furukawa Electric has adopted a heating method in which
the heat generated by supplying an electric current to ametal resistor is conducted to the HR sleeve. We have
optimized the resistor to achieve high-speed heating,thereby reducing the time loss at an early stage of reinforcement heating. Moreover, the heat-generating parthas been divided into three: the center and both end portions, enabling the precise heat control that leads to the
speeding-up.
We also provide our customers who demand higher
speeds with the pre-heating mode, in which the heater
automatically starts heating when certain conditions aremet, thus minimizing the initial time loss at heating. As aresult of all these design efforts, for all the models, thesingle-fiber HR sleeve has achieved the world's fastest 25
sec and the multi-fiber HR sleeve 35 sec, also the world's
fastest.
4.6.2 Auto-Start Heating
In ordinary heaters, after setting an HR sleeve, it is necessary to push a switch to start heating, and if one inadvertently forgets to push this switch, heating will not starteven if an HR sleeve is set on the machine. The newly
designed HR equipment, in contrast, is equipped with anautomatic start function in which the device automaticallydetects whether or not an optical fiber is set on thedevice.
It is a characteristic of this automatic start function that
it is based on the detection of an optical fiber's existence
rather than the detection of opening and closing of the lidor the fiber clamp of the HR equipment. Heating begins
as soon as an optical fiber is set, thereby minimizing theinitial time loss at heating.
4.6.3 Permanent Bend Removing Function
As mentioned in Section 4.5, an optical fiber ribbon or
optical fiber having permanent bends poses a problem inthat it often causes axial misalignment, which makes it difficult to set the fiber on the fiber holder. To solve this problem, the HR equipment originally implemented for the
purpose of heat shrinking the HR sleeve was modified toprovide a function to remove the permanent bends on the
optical fibers.
When the HR switch is pushed for a predetermined
time, the temperature rises to a temperature level optimized for permanent bend removal, and discontinues theoperation after a certain time to reset the permanent bend
removal operation. This removes permanent bends for 70
mm (the heater length, adequately longer than 50 mm
which is required for splicing of the optical fibers including the length for preprocessing).
4.7 Automatic Image Storage Function
Data on the splicing loss estimations and the cut angle atthe time of fusion splicing are stored for 2,000 times ofsplicing, and for the latest 50 times of splicing, the imagesof optical fiber after splicing in the X- and Y-axis views (100images in total) are automatically stored.
Because the fusion splicing conditions after the optical

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Development of The New Fusion Splicer Series S123/S153/S178

fiber splicing can be confirmed visually, this function
enables us to analyze troubles and to find out splicing
abnormalities at the time of fusion splicing.
4.8 Multiple Battery Slot
Multiple battery slots have been implemented in the
S123M8/M12, S153 and S178 by installing two batteryslots in each. Taking a fusion splicing and a heating reinforcement in one cycle, the S178 achieves 200 cycles
using two full-charged batteries, which is about threetimes that of the S177, the conventional model (70 cycles
for the S177). Compared with other fusion splicers of thesame class, this is the largest cycle numbers in the world.

Figure 8

4.10 Splicing of G.657 Fiber
As the implementation of the FTTX advances, there arises
a need for a fusion splicer capable of splicing the G.657
fiber.
The S178 pre-installs the procedure, on a standard
basis, the direct core monitoring program for the fusion
splicing of the Bend Bright XS made by DRAKA and theEZ-Bend made by OFS. Also, the procedure that enables
the fiber splicing after nulling the misalignment of thecladding center axis of the Clear Curve made by Corning,is pre-installed.
4.11 Work Belt
Work belt combines the function of a soft case for carrying a fusion splicer and that of a work table. It enables insitu fusion splicing by wearing its accessory strap on
one's shoulder and around the waist to secure the work
belt on one's body, and then undoing the zipper. In caseof aerial works where an aerial work vehicle can notaccess, the work belt makes it possible to transport afusion splicer to the working spot safely for subsequent
fusion splicing work.

Multiple battery slot.

4.9 Semi-Automatic Mode
To reduce the process time for fusion splicing, a semiautomatic mode coupled with the opening and the closing of the canopy has been installed, with which an optical fiber is automatically transported to near the fusion
splicing spot.
When the start button is pushed to start fusion splicing
after the optical fiber is transported to near the fusion
splicing spot, the fusion splicing is completed within 7 sec
for the S178. This is the world's fastest fusion splicing
time when compared with other fusion splicers of thesame class.
By using the semi-automatic mode, operator can view
the preprocessing situations of an optical fiber such as
the cut endface and cut angle before starting fusion splicing, and after confirming the adequacy of the condition,
the operator can then proceed to fusion splicing.
Conventionally, it was possible for the operator to confirm
such conditions only after fusion splicing began. If any
problems in the cut angle and cut endface are found, theoperator can restart the procedures before fusion splicing
begins, and this leads to a reduction in process time.
Thus, the semi-automatic mode contributes to reducing
the secondary process times as well.

Figure 9

Picture of work belt wearing.

4.12 Maintenance4.12.1 Electrode Rod
When discharge is repeated, foreign particles progressively adhere to the tip of the electrode rod. The foreign
particles can cause unstable discharge, resulting in adegraded splicing loss. Thus, the electrode rod necessitates regular cleaning.
While the electrode rod is tiny making its handling difficult, a large finger grip has been set up at the rear end of
the rod to make handling easier (Figure 10). An electroderod equipped with a non-circular finger grip is the first in
the industry.

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Development of The New Fusion Splicer Series S123/S153/S178

6.

Figure 10 Easy-handling electrode.

5.

PRODUCT SPECIFICATIONS

Table 3 summarizes the main specifications for threemajor models, the S123M4, S153A and S178A among theseven models in three series introduced here.
Table 3
Model
Applicableoptical fiber
Applicablefiber numbers

Specifications for major models.
S123M4

S153A

1－4

S178A

1
Single fiber: 0.1 － 1.0

Applicable
cladding dia. (mm)φ 0.125

Fusionsplicing time

15 sec or less9 sec or less7 sec or less

Splicing loss(dB)

SM : 0.05
MM : 0.03
DSF : 0.08

SM : 0.04
MM : 0.02
DSF : 0.06

SM : 0.02
MM : 0.01
DSF : 0.04

Reinforcement Single fiber : 25 sectime
Mutti fiber : 35 sec

φ 0.08 － 0.150

Single fiber: 25 sec

Splicing
program150

Reinforcement
program18

Heating
sleeve (mm)20/40/60

Storage of
splicing data

1500 splicing; forthe latest 50 timesof splicing, theimages of spliced
fiber in the X- andY-axis views areincluded2000 splicing; for the latest 50 times ofsplicing, the images of spliced fiber inthe X- and Y-axis views are included

History ofdischarge test

100 data

Fiber image
acquisition

24 views

Input-output
terminal

USB 2.0

Power supply

DC: 11 － 17 V
AC : 100 － 240 V

Outer
dimensions

127 (W) × 199 (D)× 81 (H) mm,
excluding shock
buffer material
159 (W) × 231 (D)× 104 (H) mm,
including shock
buffer material

Mass (excluding
battery)

1.4 kgTo develop the seven models in three series in a shorttime, we have utilized the concept of common platform tointegrate different designs among the series. As a result,a component sharing between the variations of the series
has progressed, achieving a sharing ratio of 86.7% in thecase of the S178.
With regard to the S153A based on a new concept, wehave been successful in foreseeing the trends of the market to deliver the new product.
In terms of the fundamental specifications for the fusion
splicers, we were able to provide our customers withproducts featuring the No. 1 specification and the first
specification in the industry.
In the future, we intend to continue to be a leader company contributing to society as an equipment manufacturer supporting the optical communications and the opticalindustry of the world.

SM, MM, DSF, NZD,
EDF, BIF/UBIF

SM, MM, DSF,
NZD, BIF/UBIF

Applicable coated dia. Single fiber: 0.25 － 0.9
or thickness (mm)Ribbon fiber: 0.28 － 0.4

CONCLUSION

127 (W) × 199 (D) × 105 (H) mm,
excluding shock buffer material
159 (W) × 231 (D) × 130 (H) mm,
including shock buffer material

1.7 kg

1.9 kgFurukawa Review, No. 38

20107