4000 Series Pedestal and Pole- Mount Cabinets (Quick Connect)

Transcription

1 4000 Series Pedestal and Pole- Mount Cabinets (Quick Connect) Instructions September A

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3 Contents: Page I. GENERAL A. Introduction B. MS 2 Cross-Connect Pedestal and Pole-Mount Cabinets C. Cross-Connect Pedestal Cabinets Component Assembly MS (300-Pair) Pedestal Cabinet MS (600-Pair) Pedestal Cabinet MS (900-Pair) Pedestal Cabinet MS (1800-Pair) Pedestal Cabinet MS (2700-Pair) Pedestal Cabinet D. Cross-Connect Pole-Mount Cabinets Component Assembly MS (300-Pair) Pole-Mount Cabinet with 4098 Conversion Kit MS (1200-Pair) Pole-Mount Cabinet MS (1800-Pair) Pole-Mount Cabinet E. MS 2 Cross-Connect Module Description MS 2 Cross-Connect Module Chart MS 2 Cross-Connect Module Detail II. PEDESTAL CABINET INSTALLATION AND PREPARATION A. Cable Preparation Stub and Loop Cable Lengths B. Ground Mount Installation MS (300-Pair) Pedestal Cabinet Ground Mount Installation MS (600-Pair) and 4082 (1900-Pair) Pedestal Cabinets MS (1800-Pair) and 4086 (2700-Pair) Pedestal Cabinets C. Slab Mount Installation for 4084 and 4086 Cabinets Ground Preparation Slab Mounting the Cabinet D. Split Slab E. Cable Preparation F. Assembly of Module Frame Assembly III. PEDESTAL CABINET CABLE ROUTING A. MS (300-Pair) Cabinet B. MS (600-Pair) Cabinet MS (900-Pair) Cabinet MS (1800-Pair) Cabinet MS (2700-Pair) Cabinet C. Cable Terminated in Cabinet D. Cable Looped Through Cabinet IV. POLE-MOUNT CABINET INSTALLATION AND PREPARATION A. MS (300-Pair) with Pole-Mount Conversion Kit Cable Adapter-Top Bottom Plate and Cable Adapter Installation...17 B. MS (1200-Pair) and 4095 (1800-Pair) Pole Mount Installation Cable Installation C. Cable Preparation V. TERMINATING A. Location of Feeder and Distribution Modules MS 2 Pedestal Cabinets MS 2 Pole-Mount Cabinets B. Identification of Feeder and Distribution Modules C. Cables Entering From Top of Cabinet D. Cables Entering From Bottom of Cabinet E. Terminating Procedure Laying Pairs into Module Crimping Cable Separator Installation Module Cover Protectors a Protector Cover F. Tapping Tapping a Non-Working Feeder Cable Tapping into a Working Feeder Cable VI. JUMPERING A. Running Jumper Wires B. Routing Jumper Wires MS 2 Pedestal Cabinets MS 2 Pole-Mount Cabinets C. Half-Tap Jumpering D. MS 2 25-Pair Probes Pair Probe A Kit (25-Pair Probe with Connector) E. Pair Test Plug F. Priority Circuit Caps G. 4016E Bunch Block H. 4017E Bunch Block VII. GLOSSARY A. Splicing Head Detail B. MS Air/Hydraulic Crimping Unit C. MS Hand/Hydraulic Crimping Unit D. Supply Information E. MS 2 Cross-Connect System Ordering Guide... 35

4 I. General A. Introduction The 3M Brand/MS 2 Cross-Connect is designed to provide random cross-connecting between Feeder and Distribution PIC cables of diameter.7 mm -.32 mm (22-28 AWG). Frames within the cabinets hold banks of terminated 25-Pair Feeder and Distribution Modules. Cable pairs are terminated and excess cut off in a single mechanical operation. Modules can either be installed initially or added at a better date with no disruption of existing circuits. Cross-connecting is accomplished using.5 mm diameter (24 AWG) plastic-insulated wire which is run from Feeder to Distribution Modules. Jumper connections are made and excess wire is cut off by pressing wire in proper U contact channels with an MS Impact Insertion Tool. Wire race ways are provided for protection of all cable and jumper pairs as they are installed. B. MS 2 Cross-Connect Pedestal and Pole- Mount Cabinets Due to the terminal sizes and frequency of installation visits, the closures should be located as specified by the engineering plan. The closures should be located in unobtrusive locations acceptable to the property owners and where they are reasonably protected from damage by motor vehicles and other machinery. They should also be at least 1.5 m (5 feet) from utility poles and at least.3 m (1 foot) from buildings, fences or other objects considered to be potential lightning attractions. The terminals are constructed of galvanized steel with a gray/green baked enamel finish. The pedestal cabinets feature a ventilation system whereby the vents may be opened or closed depending on local condensation conditions. All MS 2 Cross-Connect Cabinets include: (1 ) 4047 Pair Test Plug (2) 4055 Impact Insertion Tool (3) Talk Block (4) Jumpering Instructions (5) Binding Post Log (6) Wire Run Guide (7) Spindle for mounting wire spool

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6 C. Cross-Connect Pedestal Cabinets Component Assembly 1. MS (300-Pair) Pedestal Cabinet The 4065 cabinet consists of hinged front doors equipped with one lock, a removable hinged panel and backboard assembly, bond bar, module mounting frame and base, spool for Jumper Wire and Adjustable Wire Run Guide. Figure 1 is an exploded view of the 4065 cabinet. 2. MS (600-Pair) Pedestal Cabinet MS (900-Pair) Pedestal Cabinet The 4080 and 4082 cabinets consist of hinged front doors equipped with one lock, impact tool, test probe and an internal bond bar, module mounting frame, a base and two anchor stakes. Figure 2 is an exploded view of the 4080 cabinet. The 4082 differs only in height. Figure MS (1800-Pair) Pedestal Cabinet MS (2700-Pair) Pedestal Cabinet The 4084 and 4086 cabinets consist of hinged front and back doors equipped with two locks, a wrap-around bonding bar, a removable skirt, a module mounting frame, two impact tools and two test probes. Figure 3 is an exploded view of the 4084 cabinet. The 4086 differs only in height. Figure Figure 3.

7 D. Cross-Connect Pole-Mount Cabinets Component Assembly 1. MS (300-Pair) Pole-Mount Cabinet with 4098 Conversion Kit The 4098 Conversion Kit adapts the 4065 pedestal cabinet to pole-mount applications. In addition to 4065 components, the 4098 Conversion Kit consists of top and bottom polemount brackets, plastic cable adapters, bottom plate, and necessary hardware. Figure 4 is an exploded view of the 4065 cabinet with 4098 pole-mount conversion kit. 2. MS (1200 pair) Pole-Mount Cabinet MS (1800 pair) Pole-Mount Cabinet The 4094 and 4095 cabinets consist of test probe, impact insertion tool, hinged front doors equipped with two locks, two internal bond bars, a center wire nun guide, module mounting frames, and a pre-drilled backboard for pole mounting. Figure 5 is an exploded view of the 4094 cabinet. The 4095 differs only in height. Cable port I.D. of these cabinets is 68.1 mm (2.68 ). Figure 4. Figure 5. 7

8 E. MS 2 Cross-Connect Module 1. Description Each cross connect application is based on the 25-Pair MS 2 Module, a two-part block which contains U contacts, wire channels, and cut-off blades. Molded of polycarbonate with phosphor bronze U-contacts and stainless steel cutoff blades, the module body-cover assembly and base are crimped together to terminate Feeder or Distribution pair with a 3M hand or air hydraulic crimping unit The U- contacts strip the insulation and mate with the conductors, and the cut-off blades trim excess wire, in the mechanical crimping operation. Binder groups may be identified on the module mounts, and pairs can be identified on tagging labels on the cover protector. 2. MS 2 Cross-Connect Module Chart: Item Plastic Color Contacts Cut-off Blades Wire Range Insulation Jumper Wire Description Polycarbonate Green (4010E:Feeder) Blue (4011 E: Distribution) U Contact phosphorbronze Stainless Steel mm (22-28 AWG) (sizes maybe mixed) PIC-Air Core or Filled 5 mm (24 AWG) 3. MS 2 Cross-Connect Module Detail (Figure 6) Figure 6.

9 II. Pedestal Cabinet Installation and Preparation A. Cable Preparation 1. Stub and Loop Cable Lengths (See Figure 7) TABLE I Stub Loop Cabinet Length Min. Length Min. m (ft.) m (ft.) 4065 (300-Pair) 1.5 (5) 2.7 (9) 4080 (600-Pair) 1.5 (5) 2.7 (9) 4082 (900-Pair) 1.5 (5) 2.7 (9) 4084(1800-Pair) 2.1 (7) 2.7 (9) 4086 (2700-Pair) 2.1 (7) 2.7 (9) Carefully remove earth from around cables as follows: TABLE II Length Width Depth Cabinet mm (in.) mm (in.) mm (in.) 4065 (300-Pair) 305 (12) 457 (18) 457 (18) 4080 (600-Pair) 457 (18) 457 (18) 457 (18) 4082 (900-Pair) 457 (18) 457 (18) 300 (12) 4084 (1800-Pair) 1000 (40) 500 (20) 300 (12) 4086 (2700-Pair) 100C (40) 500 (20) 300 (12) NOTE: Uncover cables sufficiently to definitely establish their location so that anchor stakes will not injure them. B. Ground Mount Installation 1. MS (300-Pair) Pedestal Cabinet Ground Mount Installation a. Carefully remove earth from around cables per Table II. b. Open doors on Cabinet Assembly. Cabinet has a removable Hinged Panel and Base Assembly for easy access. c. Fill excavation with coarse gravel to within 102 mm (4") of ground level. d. Place Cabinet over cables in a vertical position so that the Cabinet is centered in the excavation. e. Place Anchor Stake (optional) to rear of Cabinet. (Protect Stake top with wood block to prevent damage while driving.) See Figure 8. f. Using a sledge, drive until Stake top is 406 mm (16") above ground level as shown in Figure 9. NOTE: Do not hammer on Cabinet to drive the Stake into ground. g. Secure Anchor Stake to rear of Cabinet with the 3/8" x 1" bolts and nuts provided. See Figure 10. h. Fill cabinet base with pea gravel to within 102 mm (4") of top of skirt. Figure 7. Figure 8. Figure 9. Figure 10.

10 2. MS (600-Pair) and 4082 (900-Pair) Pedestal Cabinets a. Carefully remove earth from around cable per Table II. b. Fill excavation with coarse gravel to within 153 mm (6 in.) of ground level. c. Place Cabinet over cables in a vertical position so that the Cabinet is centered in the excavation. d. Place Anchor Stake next to Cabinet side. (Protect Stake top with wood block to prevent damage while driving.) e. Using a sledge, drive until Stake top is at ground level. (See Figure 11.) Repeat for opposite side. NOTE: Do not hammer on Cabinet to drive Stakes into ground. f. Align and secure Anchor Stakes to Cabinet with the 3/8" x 1" bolts and nuts provided. g. Fill cabinet base with pea gravel to within 102 mm (4 in.) of top of skirt. Figure MS (1800-Pair) and 4086 (2700-Pair) Pedestal Cabinets NOTE: The MS S Stakes are needed for this installation. a. Carefully remove earth from around cables per Table II. See Figure 12. Figure 12. b. Fill excavation with pea gravel to within 150 mm (6 ) of ground level. See Figure 13. Figure

11 c. Place Cabinet over cables and center on excavation. See Figure 14. Figure 14. d. Place an Anchor Stake next to Cabinet side. (Protect Stake top with a wood block to prevent damage while driving.) See Figure 15. Figure 15. e. Using a sledge, drive until Stake holes are aligned with appropriate holes in Support Column. Repeat for opposite side. f. Align and secure Anchor Stakes to the Cabinet with the 3/8" x 1" bolts provided. See Figure 16. Figure 16. g. Loosen the four door bolts, remove the four skirt bolts and remove the Cabinet Skirt. See Figure 17. h. Upon completion of bonding, preparation and termination of cables, replace the cabinet skirt making sure the skirt fits under the cabinet doors. i. Replace the four skirt bolts and tighten the four door bolts. Figure 17. j. Fill cabinet base with pea gravel to within 100 mm (4") of top of the skirt. See Figure 18. Figure

12 C. Poured Slab Mount Installation of 4084 and 4086 Cabinets NOTE: The MS Mounting Ring Kit is needed for this installation. See Figure Ground Preparation a. Excavate slab site to a depth of 300 mm (12 in.) below ground level allowing for slab dimensions of 1.8 m (6 ft.) x 1.8 m (6 ft.). See Figure 20. b. Set forms for a 1.8 m (6 ft.) x 1.8 m (6 ft.) x 100 mm (4 in.) slab. NOTE: Construct forms so that slope of slab from center is at the rate of 20 mm per running meter (1 /4 in. per running foot). c. Fill excavation with pea gravel to within 100 mm (4 in.) of ground level. See Figure 21. Figure 19. Figure 20. Figure 21. d. Attach Concrete Inserts and Support Legs to the Mounting Ring with the M12 x 25.4 mm (1 /2" x 1") bolts provided. See Figure 22. Figure 22. e. Nail wood stakes to Mounting Ring for ease in leveling. Center Mounting Ring in slab excavation and level. See Figure 23. (Nails must be cut off when wooden stakes are removed.) f. Place concrete reinforcing rods or wire mesh in slab area. g. Pour and finish slab. Figure

13 h. Wipe excess concrete from top surface of Mounting Ring. See Figure Slab Mounting the Cabinet a. After concrete has cured sufficiently, loosen bolts that secure Support Legs. See Figure 25. b. Position Cabinet over cables and onto Mounting Ring. Figure 24. c. Secure Support Legs to Side Column of Cabinet with the four 3/8" x 1" bolts provided. See Figure 26. d. Retighten bolts which secure Support Legs to the Mounting Ring. Figure 25. Figure 26. e. Loosen the four door bolts, remove the four skirt bolts and remove the Cabinet Skirt. See Figure 27. f. Upon completion of bonding, preparation and termination of cables, replace the Cabinet Skirt making sure the Skirt fits under the cabinet doors. g. Replace the four skirt bolts and retighten the four door bolts. h. Fill cabinet bas with pea gravel to within 100 mm (4") of top of the skirt. See Figure 28. Figure L Support Legs (Refer to Figure 19) 4056L Support Legs are available for surface mounting all 3M Brand Pedestal Cabinets in poured slab applications. Support Legs may be mounted to slab prior to Cabinet Installation and will provide firm support for 4065,4080, 4082, 4084 or 4086 Pedestals. (Instructions included with 4056L Kits.) Figure

14 D. Split Slab Mount Installation for 4084 and 4086 Cabinets Local Sources should be contacted to make the slabs per the diagrams in Figure 29. Figure 29. Dimensions for Split Slab. 14

15 1. Carefully remove earth from around cables per Table I. See Figure 30. Length Width Depth 1780mm (70") 1015mm (40") 150mm (6") Table I Figure 30. Remove earth around cables 2. Fill excavation with coarse gravel to within 75mm (3") of ground level. See Figure 31. Figure 31. Filling with gravel 3. Place cabinet over cables and center on excavation. 4. Attach a sib mount Angle Iron to each side of the cabinet using the six 3/8" x 1" bolts provided. Do not tighten. See Figure 32. Figure 32. Bolt on Angle Irons NOTE: Anchor Stakes must be used in conjunction with split slab. 5. Place an Anchor Stake next to cabinet side. (Protect stake top with wood block to prevent damage while driving.) Using a sledge, drive until stake top is 150mm (6") above ground level. Repeat for opposite side. See Figure 33. Figure 33. Drive in Stake 15

16 6. Secure Anchor Stakes to cabinet with the 3/8" x 1" bolts provided. See Figure 34. Figure Slide slab sections into place. Insert four slab mount bolts (not included) trough the Angle Irons and thread loosely into slab sections. 8. Drive Anchor Stakes so Angle Irons are flat on the slab. Tighten all mount bolts securely. See Figure Fill cabinet base with pea gravel to within 100 mm (4") of top of the skirt. Figure

17 E. Cable Preparation 1. Feeder cables terminated in the cabinet will be secured per standard procedure at the center of the Bond Bar. 2. If Feeder Cable is to loop through, secure Cables as close together as possible at the center of the bar. NOTE: On 4084 and 4086 Cabinets, the Bond Bar may be moved from outside bracket to center bracket location if center Bond Bar application is desired. See Figure Using the top of the Bond Bar as a guide, mark cables. NOTE: For easy cable preparation, Cabinet Skirt, Bond Bar and Frame Assembly may be removed. 4. Remove cable jacket(s), shield and core wrapper this mark. NOTE: If cables are to be sealed against moisture, a just sheath opening so that top of end seal is flush with top of Bond Bar. Bond Straps should be long enough to project from the top of the end seal one of the Bond Bar fastening bolts. 5. Bond cables to Bar per standard procedure. Repeat until all cables are bonded and secured. 6. If grounding of cabinet is required, do so per standard procedure. 7. Plug all ducts per standard procedure. 8. Fill cabinet base with pea gravel to within 102 mm (4 in.) of the top. Figure

18 III. Pedestal Cabinet Cable Routing A. MS (300-Pair) Cabinet 1. Pairs to be terminated must run through the grommeted holes in Hinged Panel. 2. Form a.6 m (2 ft.) gooseneck behind Panel to allow for slack. See Figure The loop through cable (express pairs) should be taped or wrapped and secured to rear of cabinet. 4. Cable Ties are provided to secure cable to Backboard. B. MS (600-Pair) Cabinet MS (900-Pair) Cabinet MS (1800-Pair) Cabinet MS (2700-Pair) Cabinet 1. Allow mm (3" - 4") of cable slack by forming a dog-leg and temporarily tie cable in place. This prevents stress damage to Modules during normal settling and shifting of ground. See Figure Remove tie after completion of terminating. Figure 37. C. Cable Terminated In Cabinet 1. If feeder or distribution pair count exceeds the capacity of the front side of the Frame, the balance should be terminated on the rear Frame. 2. Bond and secure cables to Bond Bar per standard procedure. 3. Repeat until all cables are bonded and secured. Figure 38. D. Cable Looped Through Cabinet 1. Identify binder groups that will terminate in this Cabinet. 2. Lay express binder groups in unused Frame (or behind Frame on MS , 4080 and 4082 Cabinets). 3. If future additions are to be made, store involved express binder groups in Frame where they will eventually be used. Wrap express binder groups if required. 4. Bond and secure cables to Bond Bar per standard procedure. See Figure Repeat until all cables are bonded and secured. Figure

19 IV. Pole-Mount Installation and Preparation A. MS (300-Pair) with 4098 Conversion Kit 1. Pole-Mount Conversion Kit a. Remove front Skirt and Hinged Panel for easy access. b. Locate Cabinet in desired position on pole per Figure 40. c. Assemble A1, A2, and A3 to Top Pole-Mount Bracket and tighten. d. Attach Top Pole-Mount Bracket assembly to pole with B-1. e. Assemble Bottom Pole-Mount Bracket to Cabinet with C1, C2, and C3. f. Hang Cabinet assembly on Bolt A1, and secure with D1 and D2. g. Screw E1 through Cabinet, bottom Pole-Mount Bracket and into pole. 2. Cable Adapter-Top a. Remove appropriate knockout. b. Remove foam around inside of knockout hole for Adapter Nut clearance. c. Install Cable Adapter per Figure 41. d. Insert Cable leaving 1.8 m (6 ft.) stub length. e. Tighten Adapter Nut securely. f. Secure Adapter on Cable with 3 half-lapped layers of Vinyl Plastic Tape. g. Secure Cable to Tab in rear of cabinet top using standard hose clamp. h. Install bond clamp per standard practice. i. Attach bonding strap to Bond Bar. NOTE: Do not clamp cable to pole any closer than 304.8mm (12") from top of cabinet. Figure 37. Figure Bottom Plate and Cable Adapter Installation a. Attach Bottom Plate with Nuts and Bolts provided as shown in Figure 42. b. Tighten securely. c. Install Cable Adapter per Figure 42. d. Insert cable leaving 1.8 m (6 ft.) stub length. e. Secure Adapter on Cable with 3 half-lapped layers of Vinyl Plastic Tape. f. Bond and secure cables to Bond Bar. g. Attach bonding strap directly to Bond Bar. Figure

20 B. MS (1200-Pair) and 4095 (1800-Pair) 1. Pole Mount Installation: Mount cabinet in desired position on pole using hardware included. Follow standard procedure. See Figure Cable Installation: a. Cables should enter cabinet through ports directly in line with appropriate module frame. If only a single cable is to be terminated, place cable in center port to provide the best protection for the cable. b. The preferred method is to mount the feeder cable in center Module frames and mount distribution cables in outer frames as shown in Figure 44. c. Loop through cables may be installed in the bottom of a cabinet by removing cabinet End Cap Plate. See Figure 36. d. The stub length should be a minimum of.6 m (2 ft.) longer than the farthest termination. C. Cable Preparation 1. Remove cable sheath and shield flush the top of tabs on the Bond Bar. 2. Install Bond Clamp per standard procedure and secure to holes in Bond Bar. 3. Place a standard hose clamp around the cable and Bond Bar Tab. Tighten securely. Repeat for all cables. 4. Identify binder groups. NOTE: The 4097 Split Gland Kit is available for sealing cable entrance in top or bottom of pole cabinets. Figure 43. V. Terminating A. Location of Feeder and Distribution Modules 1. MS 2 Pedestal Cabinets Figures 45, 46 and 47 illustrate the recommended location of Feeder (green Cover) and Distribution (blue Cover) Modules. Cable handling will be simplest with these layouts. However, alternate locations for feeder and Distribution Modules will in no way change the principle of cross connecting with MS 2. a. Feeder and Distribution Module Location in 4065 Pedestal Cabinet. See Figure 45. NOTE: Feeder Module Locations are Interchangeable from Top to Bottom by relocating the adjustable jumper wire run. Figure 44. Figure

21 Figure 46. Figure

22 b. Cabinet Venting To close vents and eliminate air circulation, turn blank side of plastic vent toward louver plate. To open vents for maximum air circulation, insert plastic vent with screened side toward louver plate. c. MS Terminal Block Bracket This Bracket will accommodate two 3-pair protected or unprotected terminal blocks in the MS Cross-Connect Cabinet. Service Wires may be bonded and secured directly to The front of the Bracket per system practice. 1. Loosen both Bond Bar Fastening Bolts using M12 (7/16") wrench. 2. Install Terminal Block Bracket as shown in Figure Retighten Bolts. Figure MS 2 Pole-Mount Cabinets a. Feeder and Distribution Module Location in 300 pr. Pole-Mount Cabinet. See Figure 49. NOTE: Feeder Module locations are interchangeable from top to bottom. Figure 49 shows Distribution Modules on top and Feeder Modules on bottom. Feeder and Distribution should be separated by the Wire Run Guide. Figure 49. b. Feeder and Distribution Module Location in 4094 and 4095 Pole Cabinets. See Figure 50. Figure

23 B. Identification of Feeder and Distribution Modules Feeder Modules (MS E) have green covers. Distribution Modules (MS E) have blue covers. C. Cables Entering From Top of Polemount Cabinet 1. Lay all binder groups to be terminated inside U Frame Channel. 2. Module Mounts are used in sets of left and right. They are marked with an R or an L on the tab. 3. Slide Mount onto Frame Ear until it is seated against vertical Frame Member. See Figure 51. NOTE: Install Mount Sets just before completed Modules are to be snapped in place for ease in handling. 4. Temporarily tie a piece of wire or cord across the top module mounts. This will allow the pairs to be firmly seated in the wire channels of the module. This tie may be removed after first module is mounted. See Figure The first binder groups will be fed under the tie and over the top of the Splicing Head. Figure 51. Figure 52. D. Cables Entering From Bottom of Cabinet The first binder group will go up the channel of the Frame and over the top of the Splicing Head. Figure 53. E. Terminating Procedure 1. Laying Pairs into Module: a. Attach MS Splicing Head Frame Adapter to Splicing Head. (See Figure 53.) b. Squeeze legs of Frame Adapter together and snap end tabs into top diamond-shaped cut-outs in frame. Splice must proceed from top down. See Figure 54. Figure

24 c. Check that Splicing Head wire retainer spring is set to proper gauge. To change, loosen wire retainer screw and turn spring assembly to proper size as stated on spring face plate. See Figure 55. Springs are color coded: RED-.5 mm (24 Ga.) Pulp/paper and all.4 mm (26 Ga.) BLACK-.5 mm (24 Ga.) PIC and all.6-.8 mm (22 Ga.) d. Select either 4010E Feeder Module (green cover) or 4011 E Distribution Module (blue cover). e. Place Module Base into leaf springs of Splicing Head so alignment holes are towards head wire guides and cut-off blades are towards craftsman. f. On cables entering from top, train first binder group under the temporary tie and over the head. On cables entering from bottom, bring first binder group up the channel of the frame through the Splice Head Adapter Legs and over top of Splicing Head. See Figure 56. Figure 55. Figure 56. g. Pairs go to the right of the color-coded wire guides. Use a thumb and forefinger of each hand to guide wire pairs over pair splitter. Place TIP wire to the left, RING wire to the right. Take up slack by pulling wires firmly into wire channels on Base and into the wire retainer spring. Follow color code. h. When Base is filled, check wiring order with the 4052 Check Comb. See Figure 57. Figure 57. i. Place Module Body/Cover assembly into leaf springs of Splicing Head, with 3M logo in lower left hand corner and black marks toward Head wire guides. See Figure 58. Figure

25 2. Crimping: a. Put crimping clamp on Splicing Head; hose can be either to left or right. Pins on inside edge nest in pin pockets on Splicing Head when clamp is placed at an angle on head. See Figure 59. b. Rotate clamp until detents lock clamp in upright position. If detents do not lock or prevent rotation, they can be adjusted with screwdriver. See Fig. 60. c. Clamp is designed to crimp Module to proper height. Air/hydraulic system has by-pass so that it idles when crimp is complete. Hand pump also has bypass but is not as noticeable as with air pump. Close release valve on side of hand pump. Work hand pump about 5 strokes after Module appears closed. Watch for wires being cut. Both pumps must be properly positioned during crimping. Keep output end of hand pump level or lower than rear. This will keep air out of hydraulic lines. Instruction labels are on pumps. If pump does not operate properly, see Bleeding Instructions. d. Leave clamp in closed position. If crimp is complete, wires will be cut and will come off easily. Do not grasp all wires at once or you will damage the retainer spring. Take only one-quarter to one-third of them, lift and move straight up, gently. Wires should be cut; if not, crimp is not complete and additional pressure is required to cut wires. See Figure 61. e. Release pressure on clamp and remove it. To release pressure on air/hydraulic pump, push back on foot pedal. To release pressure on hand/hydraulic pump, open valve on side of pump. f. Rotate clamp and remove from head. g. An adjustment on crimping clamp limits return of pressure plate. This can be set for Module height to reduce number of strokes required. h. Remove temporary tie K cable entry is from top. (Only top Module requires tie.) Second Module will be terminated in this same position. On cable entering from bottom, unsnap adapter and place Splicing Head in next lower position. This will make it easy to remove module. i. Module Mounts are used in sets of right and left, with R or L on tab. See Figure 62. Craftsman may identify cable and mark pair counts on mounts before putting them into place. For uniformality, it is suggested that cable and binder groups be identified on matte surface of left mounts and pair counts on right mounts. Slide mount onto frame ear until it is seated against vertical frame member. See Figure 62. Install Mount Sets just before completed Modules are to be snapped in place for ease in handling. j. Remove Module from Splicing Head and snap firmly onto the Mount Set. Support mounts with fingers as Module is snapped into place. Figure 59. Figure 60. Figure 61. Figure

26 3. Cable Separator Installation: a. General 1. MS Cable Separators are used between modules and where frames are open to close off Feeder or Distribution binder groups in the 3M MS 2 Cross-Connect Frames. 2. The Cable Separators are supplied in sheets of four. To remove a single Separator from the sheet, snip along the notched section as shown in Figure 63. b. Installation Between Modules 1. The Cable Separator is installed after a module has been terminated and put on its mounts and before the next binder group termination starts. 2. When Module is completed, remove Splicing Head Frame Adapter and train binder group wires toward center of frame and slightly downward. Attach Mount Set (4060) and snap terminated Module onto Mounts. 3. Turn Separator so that left edge is well inside frame, then insert tab in right hand diamondshaped hole directly below Module. See Figure 64. Pull Separator forward until left tab snaps into hole in frame. c. Installation in Frame Openings 1. For installation in frame openings the Separators need not be individually cut apart but may be placed into the frame up to four at a time. See Figure Insert tabs on right end of Separators into appropriate diamond-shaped holes in frame. Bow Separators outward by pushing on left end and snap tabs into holes on left side of frame. NOTE: In frames having only one or two modules at the top, it may be necessary to place an appropriate be across the center of the frame after the Separators have been installed to compensate for outward bowing of the frame. 4. Installing Module Protectors. a Module Protector 1. General Color-Translucent Material-General Purpose Polypropylene The MS Module protector is designed to be attached to the module mount assembly, providing a more reliable and versatile means of protecting the module from dust, moisture and other environmental elements. See Figure 66. Figure 63. Figure 64. Figure 65. Figure

27 2. Insert Attachment Tabs to module mount on underside. See Figure 67. Figure Mount module and snap Module Protector over face of module. See Figure 68. Figure Identify pairs by marking on the matte-finished cover with an indelible marking pen. See Figure 69. b. Continue the termination of the modules. See Figure 70. IMPORTANT: For Pair Cabinet: Install a mount set and the adjustable wire run guide to separate the feeder and distribution modules. When next to last Module has been terminated, remove head. Lift Module off head and snap into place. Put Splicing Head Frame Adapter back into the same (last) frame holes and splice last Module. Remove Head and Module and snap Module into place. (Push any excess wire slack up and behind Module.) c. Mark ends of Modules with binder post or pair count numbers. Install Module protectors. Figure 69. Figure

28 F. Tapping Cables that are looped through may be tapped by using two Bodies in the Cross-Connect Feeder Module termination. See Figure 71. Electrical connection is made as the bodies are crimped, before the wires are cut. 1. Tapping a Non-Working Feeder Cable: a. Cable twist can be eliminated by cutting the loop center. Figure 71. b. Place a Base in the Splicing Head and lay C.O. side of loop pairs into it. c. Place an MS G Body over the Base and lay opposite side of loop pairs into it. d. Place a Cross Connect Module Body/Cover Combination over the first Body and crimp. See Figure Tapping into a Working Feeder Cable: NOTE: Do not cut binder groups. Excess wires will be cut as connection is made. Figure 72. a. Lay C.O. side of loop into module base. b. Place MS2 4002G Body over the Base and lay pairs back over themselves as shown in Figure 73, leaving excess slack out front of Module. Figure 73. c. Place a Cross Connect Module Body/Cover Combination over the first Body and crimp. Connection will be made with no interruption of service and excess wire will be cut. See Figure 74. Figure

29 VI. Jumpering Jumper wires must be plastic-insulated.5 mm (24 AWG) g with a maximum O.D. of 1.1 mm (.042 inches) to insure reliable connections with multiple insertions. See Figure 75. Figure 75. A. Running Jumper Wires 1. Pull wire from spool to either Feeder (green cover) or Distribution (blue cover) Module. 2. Split pair over black rib with TIP left, RING right and SNAP into BOTH front and rear catch areas on cover. See Figures 76 and Impact both Tip and Ring of jumper wire using ONLY the 4055 Insertion Tool. Tool will impact only when held perpendicular to module. See Figure 78. Remove excess wire by pulling through front catch. (Tool may not impact if used on previously impacted jumper wire or on contact with no wire.) 4. Follow wire raceways formed by Module mounts. a. DO NOT run wire across face of Modules. b. Jumper wires in Cover slots 1-12 go behind left Mounts and those in slots go behind right Mounts. c. Run jumper wire along back of Module towards nearest edge. d. Slip jumper wire behind Mounts and run over wire run guide. e. Slip behind Mounts on proper module bank and on to other Module. f. Always allow 76 mm (3 inches) total SLACK in jumper wire. Figure 76. Figure 77. Figure

30 B. Routing Jumper Wires 1. MS 2 Pedestal Cabinets a (300-Pair) Cabinet See Figure 79. Figure 79. b (600-Pair) Cabinet 4082 (900-Pair) Cabinet See Figure 80. Figure

31 c (1800-Pair) Cabinet 4086 (2700-Pair) Cabinet See Figure MS 2 Pole-Mount Cabinets a (300-Pair) Cabinet with 4098 Pole Mount Conversion Kit See Figure 82. Figure 81. b. 4094(1200-Pair)Cabinet 4095 (1800-Pair) Cabinet See Figure 83. Figure 82. Figure

32 C. Half-Tap Jumpering The MS HT Half-Tap Jumpering Tool is used to make cuts or cable transfers within a cross-connect box. The 4055 HT Tool (orange to distinguish it from the 4055 Impact Insertion Tool) allows a jumper wire to be punched into the contact of a Cross-Connect Module (MS OE 4011 E) but does not cut off the end of the wire as is done with the 4055 Tool. See Figure 84. The 4055 HT Tool is useful in an area re-build where distribution counts are half-tapped to provide continuous service while counts are being changed. A typical cut is outlined below: 1. Remove existing jumper wire between feeder and old distribution module (A and F of Figure 85). Figure Re-route new jumper wire from feeder point F to new distribution point in new distribution module (point B) (impacting wire with 4055 HT Tool) and back to the old distribution point in module A. Use the 4055 Tool to impact wire at A and F. See Figure 86. Figure 85. Figure After testing the new line coming to module B impact wire at point B with 4055 Tool and remove wire between points B and A. See Figure 87. Figure

33 D. MS 2 25-Pair Probes Pair Probe a. The MS Pair Pocket Probe is designed to make an electrical contact to each wire in all types of 25-Pair MS 2 Modules. The 4048 Probe should be inserted into test entry ports ONLY. These are the holes at mid-level of Module. See Figure 88. b. Put the long pin on the right side of the Probe in first and swing Probe into Module. See Figure 89. c. To hold Probe in position, slide spring clips forward and hook on to ends of Module. d. All pins are numbered and open exposure strip permits ready access for probing. See Figure 88. Whenever the MS Probe is not in use, replace pin protector to prevent damage to pins A Kit (25-Pair Probe with Connector) a. The MS A (25-Pair Probe with Connector) allows an electrical connection to be made with each wire in all types of 25-Pair MS 2 Modules: Use of this Probe will establish an inter-connect between any MS 2 Modular Splice and various types of testing and tagging equipment. b. MS A Probe should be inserted into Test Entry ports ONLY. These are the holes at mid-level of Module. See Figure 90. c. When using the Probe in a Cross-Connect con figuration, lock the spring clips onto Module Mounts at ends of the Module. See Figure 91. d. When testing with Probe while splicing, mount the Probe Clamp Bracket on the Crimp Head as shown in Figure 92. e. Tape may be placed over open exposure strip when not in use. IMPORTANT: Spacer Plate must be used when ever testing in a Splice Head. Figure 88. Figure 89. Figure 90. Figure 91. Figure

34 E. Pair Test Plug MS Pair Test Plug makes electrical connection from terminal block to module contacts. 1. Insert pins of plug into test ports in mid-level of Module. See Figure Slide catch forward over module cover to hold plug in place. 3. Attach alligator clips from test set to terminal block. Figure 93. F. Priority Circuit Caps MS Priority Circuit Caps are used to flag special circuits. They cover contacts and prevent accidental insertion of test plug into test entry ports. Place Cap into slots of pair to be protected. See Figure 94. Figure 94. G. 4016E Bunch Block A 4016E Bunch Block is a factory wired Module with contacts commoned in groups of 5 pairs (5 groups to a Module). Each group provides a means of multiplying one feeder pair with up to four extensions. See Figure Run jumper wire from desired binder post in feeder Module to (F) on Bunch Block. Leave 76 mm (3") total slack. 2. Any of the four multiple positions in this group may be used for extensions by running jumpers to appropriate distribution (house) Module positions. Figure 95. H. 4017E Bunch Block A 4017E Bunch Block is a factory wired Module with contacts commoned in groups of 3 pairs (8 groups to a Module). Each group provides a means of multiplying one feeder pair with up to two extensions. See Figure Run jumper wire from desired binder post in feeder Module to (F) on Bunch Block. Leave 76 mm (3") total slack. 2. Either of the two multiple positions in this group may be used for extensions by running jumpers to appropriate distribution (house) Module positions. VII. Glossary Figure

35 A. Splicing Head Detail (See Figure 97). Wire guides, pair splitters, and retainer springs are coated with an electrical insulation. Tape plate is plastic. B. MS 2 Air/Hydraulic Crimping Unit (See Figure 98). 1. Description-Pump can be operated either by foot or hand. An air cylinder or compressor with an output pressure of Kg/cm2 ( Psi may be used as source. It is recommended that this pressure be held as close to the upper end as possible to provide a faster crimping action. The air/hydraulic pump is factory adjusted to a pressure cutoff of 309 Kg/cm 2 (4400 psi) (nominal). A by-pass valve opens when cut-off pressure is reached; crimping clamp will hold until released. The air supply fitting on pump is air valve Schrader Catalog No. 645-A6. It mates with: a. Chuck, Air Snap-On Schrader No b. Chuck, Clip Schrader No Bleeding Instructions (if crimping bar does not come down)-to bleed if air-bound, place clamp lower than pump and tilt output hose of pump up. Press pedal until clamp resumes normal operation. 3. Connecting Hose-1.8 m X 6.4 mm (6' X 1/4") rubber hydraulic hose (steel reinforced) Male 1 /4" - 18 NPT fitting on each end with spring guards. C. MS Hand/Hydraulic Crlmping Unit (See Figure 99) 1. Pressure cut-off is set at factory to 309 Kg/cm 2 (4400 psi) (nominal). By-pass valve opens when cutoff pressure is reached; crimping clamp will hold until released. 2. Bleeding Instructions (if crimping bar does not come down)-to bleed if air-bound, place clamp lower than pump and tilt output hose of pump down. Actuate handle until clamp resumes normal operation. 3. Connecting Hose-1.8 m X 6.4 mm (6' X 1/4") rubber hydraulic hose (steel reinforced) Male 1 /4" - 18 NPT fitting on each end with spring guards. Figure 97. Figure 98. Figure

36 D. Supply Information 36

37 37

38 E. MS 2 Cross-Connect System Ordering Guide The following ts the process to be used to order MS 2 Cross-Connect Products after feeder and distribution cable pair counts have been determined. 38

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40 3M is a trademark of 3M Company. Important Notice All statements, technical information, and recommendations related to 3M s products are based on information believed to be reliable, but the accuracy or completeness is not guaranteed. Before using this product, you must evaluate it and determine if it is suitable for your intended application. You assume all risks and liability associated with such use. Any statements related to the product which are not contained in 3M s current publications, or any contrary statements contained on your purchase order shall have no force or effect unless expressly agreed upon, in writing, by an authorized officer of 3M. Warranty; Limited Remedy; Limited Liability. This product will be free from defects in material and manufacture for a period of one (1) year from the time of purchase. 3M MAKES NO OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY 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 prohibited by law, 3M will not be liable for any indirect, special, incidental or consequential loss or damage arising from this 3M product, regardless of the legal theory asserted. 3 Communication Markets Division 3M Telecommunications 6801 River Place Blvd. Austin, TX Fax Please Recycle. Litho in USA 3M A