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7

3.3

Hand Tools - 4255 Hand Presser

Used for crimping covers or
bases on 4000-D Super-Mini
Modules or for plugging com-
binations of two modules
together.

•

Base, Body, Cover

•

Male to Female (precon)

•

Super-Mini to Super-Mate

•

Super-Mate to Super-Mate

822380

3.3.1 Hand Tools - 4270-A Series Hand Presser

Used for plugging a combinations of from two
through seven modules together.

893724

4270-A Hand Presser

4.0

Accessories

4.1

4075-S Super-Mini Sealant Boxes with
Insertion Tool

Designed for moisture protection and reentry
applications. The boxes can be applied to both
foldback and inline splices. The 4075-S is
designed to be used in all 2-wire 4000-D Super-
Mini splice applications.

4.2

4077 Series Sealant Boxes with Insertion Tool

The 4077 Series
Sealant Box is
designed for use
with the 4005-DPM
module.

•

4077-A - One Super-Mate Module

•

4077-B - One Super-Mate / One Super-

Mini Module

•

4077-C - Two Super-Mate Modules

•

4077-D - Three Super-Mate Modules

75516

873600

4.3

4051 Wire Insertion and Cut Off Tool

Individual conductors can be inserted into ele-
ments by using the 4051 Wire Insertion and Cut
Off Tool.

781181

781247

4.4

4078-C Half Tap Cover

Used to protect wire ends after the half-taps has
been cut out of the Super-Mini 4008 Half Tap
Module in pulp/paper and pressurized PIC cable
splices and vault splices.

832569

863423

4.7

4027 Pair Test Plug

The MS2 4047 Pair Test
Plug is a connector probe
which permits pair checking
through the test entry port
without damaging wire insulation.

4.5

4053-PM Separator Tool

a.

The 4053-PM is the only tool recommended
for unplugging Super-Mate Modules.

863422

b.

The enlarged pins of the tool distinguish
the 4053-PM from the 4053 Cover Removal
Tool. The 4053-PM tool cannot be used to
remove covers or bases.

4.6

4047 Super-Mini Reentry Maintenance Kit

This kit is designed for maintenance and repair
work on Super-Mini Modules.

781184

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Summary of Contents for MS2

Page 1: ...May 2001 78 8130 4094 2 A MS2 Modular Splicing System Instructions ...

Page 2: ...PM Super Mate 22 6 9 Bridge Splicing using 4005 DPM Super Mate 23 6 10 Bridged Foldback Splicing 24 6 11 Half Tapping using 4008 Half Tap Module 25 6 12 Half Tapping using 4000 D Super Mini and 4005 DPM Super Mate 27 6 13 Half Tapping using 4005 DPM Super Mate 28 6 14 Slack Removal 29 7 0 Maintenance 30 7 1 Module Reentry 30 7 2 Wire Insertion 30 7 3 Splice Conversion to 4005 DPM Modules 31 8 0 En...

Page 3: ... for reentry Note Encapsulated versions are also available 4000 G Straight splice 4008 G Half tap 4005 GBM Bridge module 4008 D Half Tapping 2 1 Super Mini 4000 D Straight Splicing Cut Corner Write on Surface Cover Yellow Body Yellow Gold Base Gold Yellow Yellow Green Green Note 4000 D CO is all gray in color Note 4008 D CO is all gray in color Module Types 2 2 Super Mate Pluggable 4005 DPM Note 4...

Page 4: ...3 1 3 The support tube and related components provide support for cables and tools while splicing is being done Support Tube 76683 832594 843047 791330 Crimping Clamp 4030 Air Crimping Unit 4031 Hand Hydraulic Crimping Unit 893736 3 1 2 Air hydraulic and hand hydraulic crimping units are used with the 4041 Splice Head to crimp modules A mechanical crimper is also available to crimp modules Leaf Sp...

Page 5: ...Assy w Long Bar Pedestal Allen Wrenches 4053 Cover Removal Tool 4051 Wire Insertion Cutoff Tool 4047 Pair Test Plug 4031 Hand Hydraulic Crimping Unit Head Clamp 4042 Support Tube Assembly 4041 Splicing Head Assembly 4020M 4021M 4021M 2 4022M 4025K 4045K 4046A 4046 AT 4046 B 4046 BT ...

Page 6: ...046BT 4052 T Check Comb Carrying Rig Case Collapsible Support Tube 4053 PM Removal Tool 4025 Modular Connecting Head with Support Assembly 4044 Quick Connect Splicing Head Frame Adapter 4045 Universal Splicing Head Support Assembly Head and Bar Clamp 4046 Adjustable Traverse Clamp ...

Page 7: ...7 B One Super Mate One Super Mini Module 4077 C Two Super Mate Modules 4077 D Three Super Mate Modules 75516 873600 4 3 4051 Wire Insertion and Cut Off Tool Individual conductors can be inserted into ele ments by using the 4051 Wire Insertion and Cut Off Tool 781181 781247 4 4 4078 C Half Tap Cover Used to protect wire ends after the half taps has been cut out of the Super Mini 4008 Half Tap Modul...

Page 8: ...en test equipment and modular spliced conductors Field fabrication of the probe body is possible but it should be done only in the configuration shown below Note Stranded conductors must not be used in MS2 modules 2 Super Mates Probe Body CJ Plug female 22 AWG 843060 4 12 4005 DPM BTP Bottom Test Plug Test plug assembly consisting of 4005 DPM module attached by a 24 jumper to a module designed to ...

Page 9: ...ds to facilitate splicing in the unilength configuration 74011 4 17 E9 BM Crimping Tool Crimps MS2 module bases and covers onto connector bodies 883640 4 20 4005 DPM PTJ Preterminated Jumper Assemblies The 4005 DPM PTJ consists of 24 AWG PIC unsheathed 25 pair binder group terminated on each end with a 4005 DPM Module Available in 36 91 4 cm or 72 182 9 cm lengths the jumpers enable fast restorati...

Page 10: ...roup being handled Note Splice head should be higher than group being spliced 5 1 9 In the 4041 Splice Head the gold splice adapter is used with the Super Mini Modules only 2 1 3 4 75469 75470 75471 75472 75430 832595 832593 5 1 2 Attach buckle 5 1 3 Tighten strap 5 1 4 Attach traverse clamp assembly 5 1 5 Slide head clamp on traverse bar 75420 75421 75419 832593 5 1 8 Set retainer spring to prope...

Page 11: ...how Slide comb right only RING wires should show 5 2 2 Using Super Mini Install base Using Super Mate Install body insulator 812117 5 2 3 Select a 25 pair group and place wires in module according to color code Draw wires snug into wire channels in mod ule Secure in retainer springs 832596 832597 Thumb placed too far from rear of head could cause twist in pair resulting in shiners 75436 832601 5 2...

Page 12: ...osed until the cut conductors are removed Operate the PRESS RELEASE control to the PRESS position and hold until the pressure bypass is heard to operate This signi fies a completed crimp Leave crimping clamp closed until the cut conductors are removed Note To avoid damaging the retainer spring do not attempt to remove all the conductors at once Note An adjustment screw on crimping clamp can be set...

Page 13: ... a three conductor con nection bridged by plugging a Super Mate Module to the body top of the Super Mini Module 5 4 3 Two Way Pluggable Connection This combination makes a two conductor con nection by plugging a Super Mate Module to either the body top or body bottom of another Super Mate Module 843050 843049 843051 Super Mate 4005 DPM Super Mini 4000 D Super Mini Adapter Body Cover Body Base Supe...

Page 14: ...xisting splices 5 5 1 Pretermination of one Super Mate Module 5 5 3 Preterminated Super Mate plugged into a new Super Mate splice 5 5 2 Preterminated Super Mate plugged to a new Super Mini splice 843052 843054 Cover Body Insulator Cover Body Base Body Adapter Super Mate 4005 DPM Super Mini 843053 Cover Body Super Mate 4005 DPM Body Insulator Super Mate 4005 DPM ...

Page 15: ...ator 843054 843054 Super Mini 4005 DPM without cover 4270 A Hand Presser 4255 Hand Presser 4270 A Hand Presser 4255 Hand Presser 5 5 7 Preterminated Super Mate Module Combination Plugged to Preterminated Super Mate or Super Mini Module Combination Any two module combination from two single modules to a total of seven modules may be plugged togeth er Only a combination of up to three modules may be...

Page 16: ... 1 10 Tie down splice bundle in center first working any slack toward both cable butts 75473 6 1 8 Check for correct placement of pairs 6 1 9 Place covers and crimp Repeat process for remaining 25 pair groups 832601 893745 893756 17 43 2 cm Free conductors length each cable 1 5 X splice opening 4 4 Note Splice heads set 4 10 2 cm from butt of group being spliced and slightly higher 893756 6 1 3 Wh...

Page 17: ...bank 26 66 cm 893756 Free conductors length each cable minimum splice opening plus 6 152 mm 6 3 4 Adjust splice head for next 100 pair 6 3 Inline Splicing 4 Bank 6 3 1 Splice opening must be that recommended for closure used with a minimum of 34 86 4 cm for a 4 bank splice Note This opening will require an extended sup port tube to attach to the cable butts or support tube can be attached to a low...

Page 18: ...3 Alternate tie points from side to side until all matching groups are tied Note Tie down core of splice with three ties or as per your company practice 75449 Mark cable 75450 6 4 4 Wrap core with polyethylene on PIC muslin on pulp or paper per your company practice 6 4 5 Set up splicing rig 75442 6 4 6 Three measurements must be repeated for each binder group to be spliced FIRST Align splicing he...

Page 19: ...4 7 Bundle modules as they are being spliced Plan first module location Splice first 100 pair group at proper location Mark each module with binder group number for identification Use indelible marker on matte finish of module cover Place tie around group near modules for eace of bundling and group identification 75459 Lay group against core and bundle 75460 Move head to other side Plan second gro...

Page 20: ...bly to vertical cable Mount long traverse bar in top holes of traverse clamp with 3 16 allen wrench supplied 75428 75427 Attach traverse clamp assembly head clamp and splicing head assembly onto support tube Measure an upper binder group so modules will fall below the lower 1 25 mm mark 75465 75465 Measure an lower binder group so modules will fall below the upper 1 25 mm line Each craftsperson wi...

Page 21: ...ower back groups tightly tie matching groups togeth er as close to cable butt as possible For easy group ID foldback odd number groups to left side and even number groups to the right 75449 6 7 5 Splice first group identify and bundle to the core 75463 6 7 8 Splice third group Note When making three bank foldback splices bundle while splicing Splice a 100 pair group in one position bundle to core ...

Page 22: ...the splice opening then fold back 2 51 mm and splice Note Unilength measurement is always used when stubs are added to a splice and for any distribution cables in a modified fold back splice Configuration Splice Openings Unilength 2 bank 17 43 2 cm 19 48 3 cm 19 48 3 cm 21 55 3 cm 3 bank 27 68 6 cm minimum 29 73 7 cm 4 bank 36 91 4 cm minimum 38 96 5 cm All modules preterminated at this location t...

Page 23: ...bels 6 9 2 3Begin pretermination stub by removing tagging label from module in splice and placing it on the tape plate of splicing head Immediately identify module from which tagging label was removed by marking the pair number on each end of the cover 893742 76586 781259 6 9 2 4Preterminate Super Mate Module then plug to corresponding groups according to label Pair numbers on each end of cover Mo...

Page 24: ... to corresponding groups 6 10 3 Bridging PIC Stup Pulp Splice 6 10 3 1 Tag modules that receive stub count using 4079 S Tagging Labels 6 10 3 3 Begin pretermination stub by removing tagging label from module in splice and placing it on the tape plate of splicing head Immediately identify module from which tagging label was removed by marking the pair number on each end of the cover 893742 76586 78...

Page 25: ...ral position It is preferred to last the tap cable on top of the cable to be removed Lay run or through conductors only in the module base with conductors to be removed out the front of module spring side Use one splicing head 6 11 1 Open cable sheath and expose conductors the length of the splice closure plus the amount of necessary slack 6 11 3 Identify binder groups Note Layered cable must be c...

Page 26: ...d do another 100 pair Bundle Repeat above alternating left and right Insulate all cable cut ends with 4078 C Half Tap Cover or a 4075 S Sealant Box depend ing on application requirements 6 11 12 To remove half tapped cable use a flush cut offset pair of pliers to allow one conductor to be cut at a time Care should be taken not to short against adjacent cut conductors 76588 893743 Cover 4008 Half T...

Page 27: ...e 4000 Super Mini Module and place a red insulator on the Super Mate Module New C O Old C O FIELD 6 12 2 Lay tap new conductors into base of a 4000 Super Mini Module in unilength configura tion Crimp 4000 Super Mini Module body using the back edge of the check comb as a temporary cover and remove cut conductors Lay field conductors into Super Mini body top but DO NOT CRIMP Place Super Mate body on...

Page 28: ...te into the splice head and crimp using the back edge of the check comb as a tempo rary cover and remove cut conductors Lay the field conductors into the second Super Mate Module but DO NOT CRIMP Place a third Super Mate Module into the splice head Lay corresponding pairs old into the matching wire channels of the third Super Mate Module Place cover crimp and remove conductors 903881 New C O Old C...

Page 29: ...4 6 14 4 Take conductors from other side of splice opening and place in body top 893744 Body Top Closure Body Splice Opening 893744 6 14 2 Place 4000 base in splice head and place a 25 pair group in base Let slack loop fall down in front and below retainer springs Base 6 14 1 Remove sufficient sheath so that once slack is removed the splice opening remaining will accommodate closure to be used Set...

Page 30: ...D FORTH 7 2 Wire Insertion The 4051 Wire Insertion and Cut Off Tool is used to insert wires into the U contact and to cut off excess wire in Super Mini Modules when conductor or Super Mate rearrangements are made inside the module 7 21 Pull wire across top of U contact and cut off blade 7 2 4 To cut off wire align slot with cut off blade and groove with wire Push straight down Remove excess wire f...

Page 31: ...7 3 1 Foldback Conversion Maintaining Foldback Configuration 7 3 1 1 Place the splice head into the approximate position of the original connectors when they were spliced Remove front wire retainer spring 7 3 1 2 Straighten the wires at the rear of the existing old connectors 7 3 1 3 Place DPM into splice head and secure exist ing connector to tape panel Wire Retainer Spring Rear Spring Holder Loo...

Page 32: ...Modules Alternate Super Mini and 4005 DPM Modules between right and left banks C O FIELD Rear Spring Place cover and crimp 883641 7 3 4 3 Fold wires up and over themselves across the second body and lay wires into the rear spring 7 3 4 2 Lay in second DPM body and lightly tap the body on each end set latches and reduce movement 883634 Body 1 Body 2 Tap Here Tap Here 7 3 5 2 Center double head set ...

Page 33: ...ng each successive pair in the 25 pair group moving over one pair each time until both module body tops are filled The last of the 25 pair group will be made at pair number seven r o of the right hand splice head 7 3 5 9 Add cover and crimp Tag and splice new DPMs here FIELD C O Existing Modules Connectors 883641 7 3 6 4 Remove all tie points 7 3 6 5 Mount single splicing head in a position 2 52 m...

Page 34: ... splices require 10 to 12 254 to 305 mm of slack for conversion Without required slack piecing out is necessary Piecing out requires additional modules in splice resulting in reduced splice capacity in splice closure Use proper symbols to fully identify all splice points Note If Rear Spring Holder is used a minimum of 6 152 mm of slack is required 8 5 Rebuild Coding Engineering by chart com putati...

Page 35: ... mm in mm in mm 400 26 4 17 432 2 6 66 24 5 2 9 74 22 6 3 2 81 600 26 4 3 1 79 24 5 3 5 89 22 6 4 6 117 900 26 4 3 8 94 24 5 4 2 107 22 6 17 432 5 6 142 1100 26 6 19 483 4 0 102 1200 26 4 17 432 4 2 107 24 5 17 432 4 7 117 1500 26 4 19 483 4 9 124 24 5 5 5 140 1800 26 4 5 4 137 24 5 6 0 152 2100 26 4 5 8 147 24 5 6 5 165 2400 26 4 6 2 157 2700 26 4 6 6 168 3000 26 4 19 483 7 0 178 3600 26 4 19 483...

Page 36: ...S IN INCHES NOTE For 22 AWG conductors increase values by 25 For 24 AWG conductors increase values by 12 If sealant boxes are used increase values approximately 25 Main Cable Pair Count Zero 100 200 300 400 600 900 1200 1500 1800 2100 2400 2700 3000 300 1 8 2 1 2 4 2 7 600 2 6 2 8 3 1 3 3 3 4 3 7 900 3 3 3 5 3 8 4 0 4 1 4 3 4 8 1200 3 9 4 1 4 3 4 5 4 7 5 0 5 5 5 7 1500 4 5 4 6 4 7 4 9 5 1 5 5 5 9 ...

Page 37: ...2 If sealant boxes are used increase values approximately 25 8 6 5 3 4 26 AWG Two Bank Super Mate Apparatus Splice Main Cable Pair Count Zero 50 100 200 300 400 600 900 1200 1500 1800 50 1 3 1 6 100 1 6 1 9 2 3 200 2 3 2 6 2 7 3 3 300 2 7 3 1 3 3 3 8 4 2 400 3 1 3 4 3 8 4 2 4 6 5 2 600 3 7 4 1 4 4 4 8 5 2 5 8 6 3 900 4 8 5 0 5 2 5 6 5 9 6 3 6 8 7 7 1200 5 4 5 7 5 9 6 2 6 5 6 8 7 4 8 0 8 4 1500 6 1...

Page 38: ...s increase values by 12 If sealant boxes are used increase values approximately 25 8 6 5 3 6 26 AWG Four Bank Super Mate Apparatus Splice Main Cable Pair Count Zero 100 200 300 400 600 900 1200 1500 1800 2100 400 2 3 2 7 3 1 3 7 3 9 600 2 7 3 1 3 5 4 0 4 2 5 1 900 3 3 3 6 4 0 4 5 4 7 5 6 6 3 1200 3 9 4 2 4 5 5 0 5 2 6 0 6 5 7 1 1500 4 5 4 8 5 1 5 5 5 8 6 5 7 0 7 6 7 8 1800 5 0 5 4 5 6 6 0 6 2 7 0 ...

Page 39: ...lor Coded Lay into Super Mate module in color code order 2 Quaded Pair Lay in and out pairs into corresponding position in appropriate Super Mate modules On feeder routes engineers should note the proper measurements on the work print where equipment could be added Construction can then build that splice with Super Mate Modules for simple plugging and unplugging as needed in the future Load coil s...

Page 40: ... placed in position where the C O and FIELD modules can be connected OUT FIELD C O Apparatus 843062 IN 8 9 Deloading By building the apparatus load coil splice with Super Mate modules loading deloading can be per formed without interruption of service 1 Crimp the corresponding loaded groups together C O to FIELD using the 4270 A Hand Presser 2 Using the 4053 PM Separator Tool remove load coil Supe...

Page 41: ...ture distribution additions transfers and rearrangements can be made without reentering main cable splices Main Feeder Stub Unilength Splicing Method Distribution Distribution Inline Splice Method Tagged Pairs 843058 Cover Body Super Mate 4005 DPM Body Insulator Super Mate 4005 DPM Unilength Splice Method 8 Cleared and Capped Cover Base Body Super Mini Spares for future ...

Page 42: ...ansfer 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 Lay pairs into Super Mate Modules Make sure that all existing C O and FIELD conductors are placed in corresponding wire channels in each Super Mate Module FIELD C O Cover Body Insulator Body 843060 ...

Page 43: ... exposed elements or conductors are protected with a red insulator or cover 4053 PM Separator Tool Existing C O FROM Count Existing FIELD Subscriber Existing FIELD Subscriber New C O TO Count 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 Existing C O ...

Page 44: ... circuits cannot be multiplied because of bridge tap excessive conductor and engineering restrictions Unilength Splice Method Spice Opening plus 2 50 mm FIELD C O FIELD 19 48 3 cm Body Super Mate 4005 DPM Unilength Splice Method 17 or 19 843056 Cover Body Base Super Mini ...

Page 45: ...tions where bridged tap is not a concern Note The Inline Splice Method is recommended because this splice should be treated only as a through connection for the main cable and an access point for multiplied cable Unilength Splice Method Spice Opening plus 2 50 mm Inline Splice Method Inline Splice Method FIELD BRIDGE C O Body Base Super Mini Body Super Mate 4005 DPM Cover 19 48 3 cm 2 Bank 4 Bank ...

Page 46: ...product will be free from defects in material and manufacture as of the date of pur chase 3M MAKES NO OTHER WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILI 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 p...

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