How to Use a Fusion Splicer: Step-by-Step Tutorial

Whether you're a seasoned fiber optic technician or just starting in the telecommunications field, mastering fusion splicing is essential for building reliable networks. Modern fusion splicers like the Comptyco series have become increasingly sophisticated yet user-friendly. This comprehensive guide will walk you through the entire process, from setup to perfect splice, with specific insights applicable to advanced 2025 models.

Understanding Your Fusion Splicer: Key Components Explained

Before diving into the process, let's familiarize ourselves with the common components across modern splicers like the Comptyco AUA-70F, L-90C, A-5, and FS-60E:

1. Fiber Holders/Clamps: Securely hold fibers in place during splicing (note the L-90C's unique flip-style design)

2. Electrodes: Create the electric arc that fuses fibers together

3. Microscope/Camera System: Provides magnified view of fiber ends (5-inch screens on these models offer excellent visualization)

4. V-Grooves: Precisely align fibers before splicing

5. Heater/Heat Shrink Oven: Shrinks protective sleeves over splices

6. Control Interface: Touchscreen (all models) with additional physical buttons (L-90C and FS-60E)

7. Battery/ Power Supply: High-capacity batteries (7800mAh on A-5, 6700mAh on FS-60E) enable extended field use

Pre-Splicing Preparation: The Foundation of Success

Step 1: Safety First

• Wear safety glasses to protect against fiber shards

• Ensure work area is clean, dry, and well-lit

• Keep the splicer on a stable, level surface

Step 2: Equipment Setup

1. Power On: Turn on your splicer using the power button. Models like the AUA-70F with their 5-inch touchscreen will guide you through startup checks.

2. Battery Check: Verify battery level, especially important for field work. The A-5's 7800mAh battery typically provides power for 300+ splices.

3. Initialize System: Allow the splicer to complete its self-test. The 6-motor systems in these models will calibrate automatically.

Step 3: Fiber Preparation

1. Strip the Fiber: Using a precision stripper, remove 30-40mm of the fiber's outer coating.
   Pro Tip: Avoid nicking the glass fiber as this can cause weak spots

2. Clean with Alcohol: Wipe the exposed fiber with 99% isopropyl alcohol and lint-free wipes.

3. Cleave the Fiber: Using a high-quality cleaver, make a perfect 90-degree cut. A proper cleave should be smooth and perpendicular.
   Critical: The quality of your cleave directly impacts splice loss. Inspect the fiber end under the splicer's microscope if possible.

The Splicing Process: Step-by-Step with Modern Equipment

Step 4: Loading the Fiber

1. Open Fiber Holders: Gently open the clamps on your splicer. For the Comptyco L-90C, use its convenient flip mechanism.

2. Place the Fibers: Insert each prepared fiber into the V-grooves, ensuring they stop at the positioning rods.
   Important: Keep the stripped portion clean and avoid touching the cleaved ends

3. Close the Lids: Secure the fibers according to your splicer's design. The 6-motor system will begin gentle auto-alignment on models like the FS-60E.

Step 5: Fiber Alignment and Inspection

1. Auto-Focus and View: The splicer's camera will automatically focus on the fiber ends. Use the touchscreen (all models) to zoom if needed.

2. Check Fiber Ends: Visually inspect both ends on the screen for:

   • Clean, perpendicular cleaves

   • No dirt or defects

   • Proper placement in V-grooves

3. Automatic Core Alignment: On advanced models like the AUA-70F, the 6-motor system automatically aligns the fiber cores with micron-level precision. For ribbon fibers or special applications, you may need to select specific programs from the menu.

Step 6: Performing the Splice

1. Select Program: Choose the appropriate program for your fiber type (single-mode, multi-mode, etc.) from the touchscreen interface.

2. Start Fusion Process: Press the "SPLICE" button. The splicer will:

   • Perform final precise alignment

   • Clean the fibers with a small arc (pre-fusion cleaning)

   • Execute the main fusion arc

   • Display estimated splice loss

3. Monitor the Process: Watch the screen as fibers fuse. Modern splicers typically complete this in 8-15 seconds.

Step 7: Splice Protection with Heat Shrink Sleeves

1. Open Heater Cover: Lift the heater lid once the splice is complete.

2. Position Splice Protector: Slide a heat shrink sleeve over the splice, centered on the fused point.

3. Close and Heat: Close the heater lid and press "HEAT" on the screen. The automatic heater will:

   • Shrink the sleeve evenly

   • Cool properly (typically 20-30 seconds total)

4. Remove Protected Splice: Once the heater beeps and the display indicates completion, carefully remove the reinforced splice.

Advanced Features and Troubleshooting

Utilizing Built-in Testing Capabilities

Modern Comptyco splicers offer integrated tools that streamline workflow:

1. Built-in Optical Power Meter (OPM): Available on AUA-70F, L-90C, and A-5 models

   • Connect the fiber after splicing

   • Select OPM mode from the menu

   • Measure and record splice loss directly

2. Visual Fault Locator (VFL): Integrated in AUA-70F, L-90C, and A-5

   • Connect the VFL port to your fiber

   • Use to trace fibers, find breaks, or verify connections

   • Particularly useful in the FS-60E for its built-in red light source

Troubleshooting Common Issues

• High Loss Alarms: Usually caused by poor cleaves, dirty fibers, or incorrect program selection

• Arc Failure: Check electrode condition and clean if necessary

• Alignment Issues: Ensure fibers are properly seated in V-grooves and clean the grooves regularly

Optimizing for Specific Models

• For Comptyco AUA-70F: Take advantage of its fully automatic features and high-precision 6-motor alignment for critical splices

• For Comptyco L-90C: Utilize the dual-operation mode—touchscreen for setup, physical buttons for field adjustments in bright light

• For Comptyco A-5: Leverage its long battery life for extended field work without power concerns

• For Comptyco FS-60E: Use the button/touch dual operation in harsh environments where touchscreens might be challenging

Post-Splicing Best Practices

Step 8: Documentation and Storage

1. Record Splice Data: Modern splicers store splice histories. Transfer data periodically for quality tracking.

2. Properly Store Splice: Place the protected splice in a closure or splice tray without excessive bending.

3. Clean Equipment: Wipe down the splicer, especially V-grooves and electrodes, after each use.

Step 9: Maintenance for Longevity

1. Regular Electrode Maintenance:

   • Clean electrodes weekly with electrode cleaning rods

   • Replace electrodes every 1,000-2,000 splices or when arc quality degrades

2. V-Groove Cleaning:

   • Use specialized cleaning tools and compressed air

   • Clean weekly or when contamination is visible

3. Software Updates: Check manufacturer websites for firmware updates that can improve performance

Pro Tips for Efficiency and Quality

1. Batch Processing: Prepare multiple fibers before starting to splice for continuous workflow

2. Environmental Considerations: Avoid splicing in dusty, humid, or windy conditions whenever possible

3. Regular Calibration: Follow manufacturer guidelines for periodic calibration, especially if splice quality changes

4. Use Quality Consumables: Invest in good cleavers, sleeves, and cleaning supplies—they significantly impact results

Conclusion: Mastering the Art and Science of Fusion Splicing

Modern fusion splicers like the Comptyco series have dramatically simplified what was once a highly skilled manual process. With their 6-motor precision, intuitive touchscreens, and integrated testing capabilities, these tools allow technicians to achieve consistent, low-loss splices with proper technique.

Remember that while the equipment is advanced, the fundamentals remain crucial: impeccable cleaning, perfect cleaving, and careful handling. Whether you're using the fully automatic AUA-70F, the versatile L-90C, the endurance-focused A-5, or the rugged FS-60E, the principles outlined in this guide will help you achieve professional results.