3M MS2 Instructions Manual
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3M MS2 Instructions Manual

3M MS2 Instructions Manual

Modular splicing system
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MS
Modular Splicing System
2
™
Instructions
May 2001
78-8130-4094-2-A

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  • Page 1 Modular Splicing System ™ Instructions May 2001 78-8130-4094-2-A...

  • Page 2: Table Of Contents

    Contents: General ............................3 Module Description ........................3 2.1 Super-Mini ........................3 2.2 Super-Mate Pluggable ......................3 Tool Description ........................4 3.1 Main Splicing Rig Components ..................4 3.2 Rig/Kit Components ......................5 3.3 Hand Tools........................7 Accessories ..........................7 Use of Tools and Modules ......................10 5.1 Rig Set-up ........................10 5.2 Wire Placement in Module ....................11 5.3 Crimping Modules......................12 5.4 Basic Module Connections ....................13...

  • Page 3: General

    General These instructions describe MS 2™ Modular System Splicing, including modules, tools and applications. Module Description 2.01 3M MS 2 modules will: • Connect and trim off 25 pairs of conductors at one time without stripping insulation. • Accept 22-28 AWG (.6 - .32 mm) solid copper conductors insulated with PIC, pulp or paper with a maximum insulation O.D.

  • Page 4: Tool Description

    Tool Description Main Splicing Rig Components 3.1.1 The splice head allows you to arrange and hold conductors in their proper locations during the The 4041 Splicing Head is used with a support splicing procedure. The splice head will hold rig for: the following module combinations: •...

  • Page 5: Rig/Kit Components

    Rig / Kit Components Type of Rig or Kit 4020M 4021M 4021M-2 4022M 4025K 4046-AT 4046-B 4046-BT 4045K 4046A 4041 Splicing Head Assembly • • •• •• • • Pedestal • • • •• • Traverse Clamp Assy w/ Long Bar •...
  • Page 6 Type of Rig or Kit 4020M 4021M 4021M-2 4022M 4025K 4045K 4046A 4046AT 4046-B 4046BT 4052-T Check Comb •• •• •• •• •• • • • • • Carrying (Rig) Case • • • • • • • • • •...

  • Page 7: Hand Tools

    Hand Tools - 4255 Hand Presser 4051 Wire Insertion and Cut Off Tool Used for crimping covers or Individual conductors can be inserted into ele- bases on 4000-D Super-Mini ments by using the 4051 Wire Insertion and Cut Modules or for plugging com- Off Tool.
  • Page 8 4079-S Super-Mini Tagging Labels 4.11 4048-DPM CJ Super-Mate Module Probe Permits easy and accurate recording of pair Used to transition between test equipment and counts during tagging operations. modular spliced conductors. Field fabrication of the probe body is possible, but it should be done only in the configuration shown below: 76607 Note:...
  • Page 9 4.14 4041 Rear Spring Holder 4.18 4019 Check Comb Allows the addition of a second set of wire Used to detect splicing errors prior to module retaining springs to the back of the 4041 MS 2 crimping. Also used as a temporary module Splice Head.

  • Page 10: Use Of Tools And Modules

    Use of Tools and Modules 5.1.6 Insert pedestal in head clamp. Rig set-up as follows: 5.1.1 Attach support tube to cable. 75426 5.1.7 Splice back, bottom group first. 832593 5.1.2 Attach buckle. 75469 75470 For inline splicing, adjust head(s) to group being handled.

  • Page 11: Wire Placement In Module

    Wire Placement in Module TIP Colors Wire Guides Note: Follow Color Code. RING colors 5.2.1 Wire pair to right side of Pair corresponding color coded wire guide. Separators Separate pair over pair separator, TIP left and RING right. 843046 843436 5.2.2 Using Super-Mini –...

  • Page 12: Crimping Modules

    Crimping Modules 5.3.1 Hydraulic Crimpers 5.3.1.1 Hydraulic hose can face left or right. Rest crimper on splice head with legs angled toward you. 75442 5.3.1.2 Rotate the clamp until it is locked in an upright position by the detents. Detents can be adjusted Adjust for proper height for tightness 781167...

  • Page 13: Basic Module Connections

    Basic Module Connections 5.4.1 One Way Pluggable Connection Cover Super-Mate 4005-DPM This combination connects two conductor Body groups by plugging the Super-Mate Module to the body top of the Super-Mini Module. Body Super-Mini 4000-D Base Conductors can be terminated either in the body bottom or body top of the Super-Mini Module.

  • Page 14: Preterminated Module Connections

    Preterminated Module Connections Preterminated Super-Mate Modules can be used as pluggable units with: • Other modules during splice construction • Modules in existing splices Cover Body 5.5.1 Pretermination of one Super-Mate Module Insulator 843052 Cover Super-Mate 4005-DPM 5.5.2 Preterminated Super-Mate, plugged to a new Body Super-Mini splice.
  • Page 15 5.5.4 Preterminated Super-Mate Plugged to Cover Super-Mate Preterminated Super-Mini 4005-DPM Body (without insulator) Note: A stripped splice head may be used. Body Super-Mini 4000-D (without cover) Base 843054 4270-A Hand Presser 4255 Hand Presser Cover Super-Mate 4005-DPM Body 5.5.5 Preterminated Super-Mate Plugged to (without insulator) Preterminated Super-Mate Body...

  • Page 16: Applications

    Application 6.1.5 Place the check comb over the base and slide Note: Splice modules so that equal number of it to the left, only TIP modules will fall in each bank. conductors should show. Slide the check Inline Splicing (2 Bank) comb to the right, only RING conductors should 6.1.1 Splice opening must be that recommended for...

  • Page 17: Inline Splicing (3 Bank)

    Inline Splicing (3 Bank) Inline Splicing (4 Bank) 6.2.1 Splice opening must be that recommended for 6.3.1 Splice opening must be that recommended for closure used, with a minimum of 26" (66 cm) closure used, with a minimum of 34" (86.4 cm) for a 3 bank splice.

  • Page 18: Foldback Splicing (2 Bank)

    Foldback Splicing (Two Bank) 6.4.5 Set up splicing rig. 6.4.1 Splice opening must be that recommended for closure use. Free conductors length (each cable) = 2 X splice opening plus 6" (152 mm) 75442 6.4.6 Three measurements must be repeated for each 6.4.2 Identify all binder groups.
  • Page 19 THIRD 6.4.7 Bundle modules as they are being spliced. Adjust height of splicing head to prevent con- ductors from lifting out of wire channels before Plan first module location. module is crimped, and to assure easy removal of module from head after crimping. Splice first 100-pair group at proper location.

  • Page 20: Foldback Splicing (2 Person)

    Foldback Splicing (Two Person) Foldback Vertical Splicing (Two Bank) Set up two splicing heads using LONG traverse Mount support tube assembly to vertical cable. bar. Mount long traverse bar in top holes of traverse Put long traverse bars on two traverse clamps. clamp with 3/16"...

  • Page 21: Foldback Splicing (3 Bank)

    Foldback Splicing (Three Bank) 6.7.5 Splice first group, identify and bundle to the core. 6.7.1 Splice opening must be that recommended for closure use. 26" (66 cm) minimum 75463 Free conductors length (each cable) = 2 X splice opening plus 6" (152 mm) 6.7.6 Position head for second group.

  • Page 22: Unilength Splicing Using 4005-Dpm Super-Mate

    Unilength Splicing using 4005-DPM Super-Mate 6.8.1 Attach unilength hook to splice head as shown. Hook can be attached on either side depending on which side of the splice opening the cable is entering from. Note: Refer to Section 8.6.2 for a definition of unilength splicing.

  • Page 23: Bridge Splicing Using 4005-Dpm Super-Mate

    Bridge Splicing Using 4005-DPM Super-Mate to an Inline 4000-D Super-Mini Splice 893742 Note: Free conductor 2 times length of splice opening. 4005-DPM 4000-D 4000-D 4270-A Hand Presser Note: A stripped splice head may be used with a crimper instead of hand tools. 6.9.1 PIC Cable 6.9.2.3Begin pretermination stub by removing...

  • Page 24: 6.10 Bridged Foldback Splicing

    6.10 Bridged Foldback Splicing 6.10.1 Tie binder groups from branch cable to corresponding groups in the splice so that slack exists for future transfers. Tie Point 893742 Tie Point Tie Point (Optional to place at end opposite bridge cable) Tie Point 4270-A Hand Presser Note: A stripped splice head may be used with a crimper instead of hand tools.

  • Page 25: 6.11 Half Tapping Using 4008 Half Tap Module

    Layered cable must be counted and identi- tap a run or through cable without cutting the fied in 25-pair groups. Verify all spare conductors by using the 3M brand 4008 Half pairs. Tap Module. The base and body/bottom of the module are colored green and contain no cut-off blades.
  • Page 26 6.11.6 Use check comb. 6.11.11 Finish splicing 100-pair at this location and bundle. Keep slack toward leg to be removed. On larger pair count cables, gently fold excess slack behind the module while NEW C.O. bundling to keep splice diameter and shape as small and as uniform as possible.

  • Page 27: Half Tapping Using 4000-D Super-Mini And 4005-Dpm Super-Mate

    6.12.1 Open existing tap cable (new cable.) Provide cable that is in the Super-Mate Module. free conductor length and slack according to standard MS2 Procedures for Half Tapping. Mount splicing rig with one splice head on Old C.O. cables. New C.O.

  • Page 28: Half Tapping Using 4005-Dpm Super-Mate

    6.13 Half-Tapping Using 4005-DPM Super- 6.13.2 Lay tap (new) conductors into a 4005 Series Super-Mate Module in the unilength configu- Mate ration. Place a second 4005 Series Super- Mate into the splice head and crimp, using An alternative method of half-tapping exist- the back edge of the check comb as a tempo- ing cables, using only 4005 Series Super- rary cover and remove cut conductors.

  • Page 29: Slack Removal

    6.14 Slack Removal 6.14.3 Place body in head. Body Note: In 4000 Series Modules, connection is made in "U" contact before wire is cut. 893744 832629 6.14.4 Take conductors from other side of splice opening and place in body top. Body Top 6.14.1 Remove sufficient sheath so that once slack...

  • Page 30: Maintenance

    Maintenance 7.2.2 Align 4051 Tool with "U" contact and wire. The slot is aligned with the "U" contact and the Module Reentry groove with the wire. 7.1.1 Insert the blade side of a pair of snips under the cut corner area of the base or cover. (There are no latches in this immediate area.) A 4053 Cover Removal Tool may also be used.

  • Page 31: Splice Conversion To 4005-Dpm Modules

    Splice Conversion to 4005-DPM Modules 7.3.1.4 Fan C.O. wires into body and place excess wire into rear spring. When: • 50% or more of the conductors will be rearranged. • Deteriorated splices. FIELD Existing • Discrete connector splices. Connector • Splices already partially converted. Slack Requirements: •...
  • Page 32 7.3.4 Straight Through Conversion: 7.3.5 Straight Through Conversion (No Slack) (6" Slack Required) Using Two 4041 Splice Heads: 7.3.4.1 Separate color groups to be spliced, i.e., 7.3.5.1 Build a piece out jumper using the DPM white, red, black, etc., and begin with the pri- Modules.
  • Page 33 7.3.5.7 Insert conductors in contacts body/top using 7.3.6.3 The new DPM module must be placed in the 4051 Wire Insertion Tool. splice at the point between the cable butt and the first cable tie point. Tag and splice new DPMs here C.O.

  • Page 34: Engineering

    Engineering Rebuild Coding – Engineering, by chart com- putation, will determine how many module Job Planning – A major consideration while banks will be required to complete a specific planning is the maximum protection of the splice. Splice bank configurations and splice feeder plant network.

  • Page 35: Splice Planning

    Splice Planning 8.6.5 Splice Data Data in the following tables was obtained from 8.6.1 Splice sizing is necessary to determine the splices prepared according to the instructions in this proper sheath opening and the proper practice. When the Bundle O.D. is close to Splice splice closure size.
  • Page 36 8.6.5.3Maximum Bundle Size for Closures 8.6.5.3.1 26 AWG Two Bank Straight Splice* Straight Splice Measurement in Inline Configuration (4000-D Super-Mini Modules) Number of Pair Bridged (4000-D Super-Mini and 4005-DPM Super-Mate Modules) Main Cable Pair Count Zero 1200 1500 1800 2100 2400 2700 3000...
  • Page 37 8.6.5.3.3 26 AWG Four Bank Straight Splice* Straight Splice Measurement in Inline Configuration (4000-D Super-Mini Modules) Number of Pair Bridged (4000-D Super-Mini and 4005-DPM Super-Mate Modules) Main Cable Pair Count Zero 1200 1500 1800 2100 2400 2700 3000 VALUES IN INCHES 1200 1500 1800...
  • Page 38 8.6.5.3.5 26 AWG Three Bank Super-Mate Apparatus Splice* Straight Splice Measurement in Inline Configuration (4005-DPM Super-Mate Modules) Number of Apparatus Pairs Unilength Cofiguration (4005-DPM Super-Mate Modules) Main Cable Pair Count Zero 1200 1500 1800 2100 VALUES IN INCHES 1200 1500 1800 10.0 2100...

  • Page 39: Load Coil Splice "L

    Load Coil Splice "L" (Apparatus) This splice is utilized where any apparatus having an "in" and "out" is to be added (i.e., load coil, carrier.) Cover "OUT" Super-Mate Body "OUT" Body "FIELD" Super-Mate Insulator Cover "IN" "C.O." Super-Mate Body Body "IN"...

  • Page 40: Loading

    Loading By building the apparatus/load coil splice with Super-Mate modules, loading/deloading can be per- formed without interruption of service. 1. C.O. to FIELD spliced in Super-Mate Modules "OUT Apparatus " 2. Crimp load modules using 4270-A Tool: "IN" to C.O. Super-Mate and "OUT" to FIELD "IN"...

  • Page 41: Transfer - Access Splice/Facility Splice "F" (Modified Foldback)

    8.10 Transfer – Access Splice/Facility Splice "F" (Modified Fold Back Configuration) This splice provides a tagged access to a main feeder cable count by the use of a stub. Future distribution additions, transfers and rearrangements can be made without reentering main cable splices. Cover Super-Mate 4005-DPM...

  • Page 42: 8.11 Cable Transfer - Conductor Termination

    New cable – New conductor groups involved with a transfer must be terminated in Super-Mate Modules according to 3M MS 2 Splicing Procedures and local transfer plan. Existing splices – If these existing groups are terminated in anything other than a Super-Mate Module, they must be converted to Super-Mate Modules in numerical sequence or color code order.

  • Page 43: 8.12 Cable Transfer - Using The Module

    8.12 Cable Transfer – Using the Module The subscriber, existing and new C.O. count pairs, should be terminated in Super-Mate Modules. Existing FIELD Subscriber Existing C.O. "FROM" Count 843061 After testing has been completed, identify the proper pair count and crimp the new C.O. count (transfer "TO") module to the subscriber module using a 4270-A Hand Presser.

  • Page 44: 8.13 Taper Feeder Splice / Junction Splice "J

    8.13 Taper Feeder Splice / Junction Splice "J" This splice is used when circuits cannot be multiplied because of bridge tap (excessive conductor) and engineering restrictions. 19" 48.3 cm Unilength Splice Method, Spice Opening plus 2" (50 mm) Cover Super-Mate 4005-DPM Body Unilength Splice Method...

  • Page 45: Bridged Feeder Splice/Multiple Straight Splice "S

    8.14 Bridged Feeder Splice / Multiplied Straight Splice "S" This splice connects cables that run continuously from the beginning to the end of the main feeder area with the cable count multiplied at specific locations where bridged tap is not a concern. 19"...
  • Page 46 TY OR FITNESS FOR A PARTICULAR PURPOSE. If this product is defective within the warranty period stated above, your exclusive remedy shall be, at 3M’s option, to replace or repair the 3M product or refund the purchase price of the 3M product. Except where pro- hibited by law, 3M will not be liable for any loss or damage arising from this 3M product, whether direct, indirect, special, inciden- tal or consequential regardless of the legal theory asserted.

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