INSTALLATION INSTRUCTIONS FIBER OPTIC CABLE TO MINI-DNP MALE SIMPLEX PLUG MINATRONICS PART NUMBER 100

Tests have shown that the new MINI-DNP connectors are not only more reliable than the old style connectors, but they are much easier to install and use and particularly the female connectors will last far longer. There are no long ears to break off which was a major problem with the old style Duplex Female Bushing - the Quad unit.

Factory made Fiber Optic Cables with the MINI-DNP Simplex Plugs already attached are available in approximately one foot, three foot, and 25 foot lengths for those who do not wish to install the plugs themselves.

The factory uses a specially made cutting and heating hot plate that costs approximately $1000.00. However, there is a relatively simple and inexpensive method which is explained below that provides a quick way to accomplish a near perfect male plug attachment that is almost impossible to tell the difference between it and the factory made attachments.

What is needed is a glass top electric stove or a smooth top Electric Griddle such as the GE Item Stock Number 106733, or West Bend 12 inch Electric Skillet Item number 72192, or an inexpensive electric clothes iron such as a Sunbeam model 3980, all of which are sold at Wal-Mart. Any other Electric Skillet or Electric Griddle will work if it has a temperature control and a very smooth heating surface. It is also helpful to have a good pair of cable stripping tools such as the GB GS-70 that is sold at Home Depot. This tool not only has the wire gage size marked for accurate stripping, but has a double curved wire cutting surface that makes an excellent cut of the Fiber Optic Cable without crushing it.

1. Using the size 16 notch of the stripping tool, strip off about a half inch of the outer jacket of the Fiber Optic Cable making sure not to nick the inter center core of the plastic Fiber Optic Cable.
2. Slide the MINI-DNP Simplex Plug onto the Fiber Optic Cable so that the clear center optical cable protrudes out from the plug.
3. Depress the small metal retaining clip found on the male plug which actually is "U" shaped. It will cut the sides of the outer jacket of the Fiber Optic Cable and help hold the Simplex Plug in place.
4. Very carefully using either the cutters of the stripping tool or a very sharp knife, cut off the extra clear plastic Fiber Optic Cable that protrudes out from the Simplex Plug so that there is approximately only one millimeter or 1/32 inch of clear Fiber Optic Cable protruding out from the plug.
5. Preheat the Electric Griddle to 225 to 250 degrees Fahrenheit or set a clothes iron at the "wool" setting. The indicator light on the Electric Griddle or iron will go out when the proper temperature is reached.
6. Very carefully, making sure that your hand does not touch the hot surface of the Electric Griddle or the iron, and push the Male Simplex Plug vertically down against the hot surface of the Electric Griddle for about 5 seconds making sure that the plug is not being held at an angle. The clear end of the plastic Fiber Optic Cable will melt forming a small flat rivet at the end of the Simplex Plug which will prevent the clear plastic Fiber Optic Cable from retracting from the plug as the Fiber Optic Cable is later flexed during installation of the LightGard alarm system. A proper end will appear to look like glass and will not have any blemishes across the clear flat surface. With a little practice, the proper amount of time to hold the Simplex Plug and Fiber Optic Cable against the hot surface can be determined and proper attachments of the plug to the cable can be speedily prepared.

NOTE: If the Simplex Plug does not hold firmly when inserted into the Simplex Female Bushing, chances are that you tried to melt down too much of the clear plastic Fiber Optic Cable and have a rounded rivet, or you have held the male Simplex Plug too long on the hot plate and have melted some of the black plastic casing.

For assistance please call Minatronics Corporation at 412-488-6435 or email us.

MINI-DNP CONNECTORS, FIBER CABLE, AND THE ORIGINAL LIGHTGARD UNITS AS WELL AS THE NEW LIGHTGARD II UNITS CAN BE ORDERED ONLINE. PLEASE VISIT WORLDSECURITYCORP.COM/LIGHTGARD.HTM AND CLICK ON THE LIGHTGARD APPLICATION THAT YOU DESIRE.