How to deal with a sticking out of a fusion splice pigtail

A sticking out or bulging fusion splice pigtail is usually caused by excess arc energy or fiber overlap, and can be corrected by trimming, re-cleaving, and re-splicing the fiber.

Identify the Problem

A sticking out pigtail, often called a fat splice, appears as a mound or bulge at the splice point. This occurs when too much arc energy is applied or when fiber ends overlap excessively during fusion, causing the glass to accumulate at the splice region . It can lead to high splice loss and may interfere with connector insertion or fiber routing.

Step-by-Step Fix

1. Inspect the Splice
   • Use the splicer's camera to check the splice visually.
   • Confirm that the bulge is not caused by debris or contamination.
2. Trim and Re-Cleave
   • Cut back the fiber past the bulging section.
   • Ensure the fiber is cleaned with 99% isopropyl alcohol and a lint-free wipe before cleaving .
   • Use a precision cleaver with a sharp blade to achieve a flat, perpendicular end.
3. Check Splicer Settings
   • Verify that the fusion program matches the fiber type (single-mode or multi-mode) and that the arc power is appropriate .
   • Perform an arc calibration if necessary to adjust for environmental conditions like temperature or humidity .
4. Re-Splice the Fiber
   • Place the freshly cleaved fibers in the splicer.
   • Ensure proper alignment in the V-grooves and avoid overlapping.
   • Execute the fusion cycle and inspect the splice for uniformity.
5. Prevent Future Bulges
   • Regularly clean V-grooves and electrodes to prevent misalignment .
   • Track electrode usage and replace them according to the manufacturer's recommended lifespan.
   • Avoid excessive arc energy and ensure fibers are properly prepared before splicing.

Safety Considerations

• Wear safety goggles and handle fiber shards carefully to prevent injury .
• Dispose of fiber scraps in a dedicated container to avoid contamination or accidents. By following these steps, a sticking out fusion splice pigtail can be corrected, ensuring low-loss, reliable fiber connections and preventing damage to connectors or equipment.