3M 2178 User manual

Instructions
2178 Fiber Optic Splice Case
Issue 3, March 1992

2
Contents:
1.0 General......................................................................................................................................................... 3
2.0 Specifications ............................................................................................................................................... 3
3.0 Kit Contents.................................................................................................................................................. 3
4.0 Cable/Splice/Kit Matrix ................................................................................................................................. 6
SECTION 1: 2178 SPLICE CASE INSTRUCTIONS............................................................................................. 9
5.0 Cable Preparation ........................................................................................................................................ 9
6.0 Mid-Span Splice (Balloon Splice) ................................................................................................................. 9
7.0 Bonding for Shielded Cable.......................................................................................................................... 11
8.0 Core Blocking ............................................................................................................................................... 12
9.0 Sealing Washer Installation.......................................................................................................................... 16
10.0 Grounding for Shielded Cable ...................................................................................................................... 17
11.0 Buffer Tube and Ribbon Cable Preparation ................................................................................................. 19
12.0 Universal Organizer Adapter ........................................................................................................................ 20
13.0 Splice Trays and Fiber Splicing.................................................................................................................... 21
14.0 Splice Preparation ........................................................................................................................................ 26
15.0 Splice Case Assembly.................................................................................................................................. 26
16.0 Racking in Building Entrances and Vaults.................................................................................................... 28
17.0 Splice Case Re-entry ................................................................................................................................... 29
SECTION 2: 2181 CABLE ADDITION KIT............................................................................................................ 30
18.0 Cable Addition Placement, Preparation and Installation (Butt Adapter)....................................................... 30
19.0 Butt Adapter 1 Installation ............................................................................................................................ 30
20.0 Splice Case Assembly with One Adapter..................................................................................................... 31
21.0 Cable Addition Placement, Preparation and Installation (Two Adapters)..................................................... 32
22.0 Butt Adapter 2 Installation ............................................................................................................................ 33
23.0 Splice Case Assembly with Two Adapters ................................................................................................... 33
24.0 Splice Case Re-entry with Butt Adapters ..................................................................................................... 34

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1.0 General
The 3M 2178 Fiber Optic Splice Case is used in underground, aerial, building entrance, and pedestal
applications. The splice case has two cable entrance ports on each end. Port plugs allow the case to be
used for butt or inline splices. The rigid nonfilled case provides moisture protection and can be pressurized.
The integral organizer and splicing trays accommodate single-mode and multi-mode fiber optic field splices.
Three series of trays are available: The 2116 Splice Tray for fusion splices, the 2118 Splice Tray for
mechanical splices, and the 2120 Splice Tray for rotary splices. Splice trays and bonding and grounding
hardware are not included in the kits.
The Universal Organizer Adapter allows the 2178 Splice Case to accommodate other splice trays when the
2116, 2118 and 2120 are not used. Splice trays which will work with the Universal Organizer Adapter include
3M 2524 FibrlokTM Tray and 2524F Fusion Tray, AT&T, UC Series, Siecor, Ditel, Preform and Northern
Telecom. One Universal Organizer Adapter is included with the splice case. For further information, see
manufacturer's tray size specifications on page 3.
The 2180 Cable Kit is used when the 2178 Fiber Optic Splice Case is reentered. All materials necessary for
cable addition and splice case reassembly are included.
The 2181 Cable Addition Kit increases the cable entrance capacity of the 2178 Fiber Optic Splice Case. One
butt adapter is included in each 2181 Kit. A single butt adapter allows the 2178 Splice Case to accommodate
four cables in a butt configuration or eight cables total. Double stacking the butt adapter increases the
capacity to six cables in a butt configuration or twelve cables total. The 2181B Double Butt Adapter Kit
contains the fasteners necessary to assemble the splice case when the butt adapters are double stacked.
The 2181 Kit can be installed at initial splicing or at reentry.
2.0 Specifications
- Maximum cable diameter: 1.0" (25 mm)
- Minimum cable diameter: 0.4" (10 mm)
- Maximum cable entry: 4 (2 per end)
with 2101 3 (4 per end)
with (2) 2181 & 2181B 12 (6 per end)
with (3) 2181 & 2181B 16 (8 per end)
3.0 Kit Contents
3.01 2178 Contents
Qty.
2178 Fiber Optic Splice Case/Cover & Base 1
Sealing Washer Tree 4
Sealing Plugs 2
Key, Hex (Allen Wrench) 1
Nut, Machine (10-32 3/8") 2
Green Cable TY 2
Blue Cable TY 2
Clamp (Hose, .439/1.00) 2
2178 Universal Organizer/Adapter 1
Sealing Cord 1
Sealing Tape 1

4
3.02 2180 Contents
Qty.
Sealing Washer Tree 2
Key, Hex (Allen Wrench) 1
Green Cable TY 1
Blue Cable TY 1
Clamp (Hose, .439/1.00) 1
Sealing Cord 1
Sealing Tape 1
3.03 2181 Contents
Qty.
Spacer Assembly 1
Spacer Clamp Assembly 1
Sealing Washer Tree 2
Sealing Plugs 3
Bolts, 3.5" 10
Green Cable TY 1
Blue Cable TY 1
Clamp (Hose, .439/1.00) 1
Key, Hex (Allen Wrench) 1
Fillister Head Screws 2
Sealing Cord 1
Sealing Tape 1
3.04 2181B Contents
Qty.
Fillister Head Screw, 4.95" (Screw Clamp Retention) 2
Bolts, 4.95" 10

5
3.05 2524-FT Splice Tray
Qty.
Tray Base 1
Buffer Tube Tubing 1 Rl.
Fusion Splice Holder 2
Dual Lock 3/4" x 3" 1
3.06 2185 Core Block Kit
Qty.
4445 Sealant (will core block 4 cables) 1 Bag
Gloves 1 Pr.
Foam Tape 2 Rls.
Tongue Depressor 1
3.07 Aerial Hanger Bracket
2182 2184
3.08 Additional Material Required:
3/4" (19 mm) Vinyl Tape
2" (51 mm) Rubber Tape
Cable Cleaner
Shield Bond Connectors
Sheath Scuff Material
3.09 Tools Required:
3/8" (9.5 mm) Socket Wrench Set
1/2" (12.7 mm) Socket Wrench Set
7/16" (11.1 mm) Socket Wrench Set
9" Lineman Pliers
Needle Nose Pliers
Cable Stripper
Sheath Knife
Tape Measure
3.10 Optional Specialized Material Required:
#6 AWG Ground Braid or equivalent for isolated cable shields.
AT&T unit splitter kit for unitube fiber optic cable.
Spiral wrap used to protect express fibers with mid-span splicing and unitube cable.
1" (25mm) vinyl tape and #69 Glass tape for sheath isolation for crossply and LXE cable only.
RC-100 splice support for racking in vaults.
1/2" x 2" bolts (2) with washers used with splice support system.
1/2" x 2" self-tapping screws (2) with washers for fire retardant backboards.
Threaded rod (1) 5 1/2" x 1/4" used with Siecor and Ditel trays with full volume and single butt adapter.
Threaded rod (2) 7" x 1/4" used with Siecor and Ditel trays with full volume and double butt adapter.
Split bolt for sheath isolation for crossply and LXE.

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4.0 Cable/Splice/Kit Matrix
4.01 The matrix below shows the number of cables that can be placed into a splice case and the components that
would be required to build a new splice.
2181B
DOUBLE BUTT
ADAPTER KIT
1
1
1
1
2181 BUTT
ADAPTER KIT
1
1
1
1
2
2
2
2
3
3
3
3
2180 CABLE
ADDITION KIT
1
2
2
3
4
5
5
6
7
8
8
9
10
11
2178
FIBER OPTIC
SPLICE
CASE
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
# OF
CABLES
2
3
4
5
6
7
8
9
10
11
12
13*
14*
15*
16*

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4.02 The following matrix describes the maximum number of splices that can be made to the maximum number of
cables that can be placed in a splice case:
MAJOR
COMPONENTS *
2178
2178
2178
2181 (1)
2178
2181 (1)
2178
2181 (1)
2178
2181 (1)
2178
2181 (2)
2181B (1)
2178
2181 (2)
2181B (1)
2178
2181 (2)
2181B (1)
2178
2181 (2)
2181B (1)
2178
2181 (2)
2181B (1)
2178
2181 (2)
2181B (1)
2178
2181 (2)
2181B (1)
BUTT
SPLICE
x
x
x
x
x
x
IN-LINE
SPLICE
x
x
x
x
x
x
x
# OF
CABLES *
2
2-4
2
3-4
3-4
5-8
2
3-4
5-6
2
3-4
5-8
9-12
# OF 24
FIBER TRAYS
8
8
12
8
12
8
15
12
8
15
15
12
8
# OF FIBERS
SPLICES
192
192
288
192
288
192
360
288
192
360
360
288
192
* See cable/splice/kit matrix in paragraph 4.01 for other components needed to complete the
splice.

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4.03 Tray Size Specifications:
Tray Size
Number of
Fibrloks
per Tray
3M/Brand Rex
2118
.375"
2524
.42"
2524F
.42"
ACT-200
.375"
AT&T-UCSSM1
.375"
Ditel
UST-1000
UST-4000
.32"
Ditel
UST-3000
.42"
Northern Telecom
NT6F3ICA
.430"
Preform
PN-8001041
.375"
Siecor
M67-031
M67-041
M67-045
.22"
Siecor
M67-070
.430"
12
24
24
12
18
12
12
12
12
12
12
Standard
3.46" Space
Available
9 trays
8 trays
8 trays
9 trays
9 trays
11 trays
8 trays
8 trays
9 trays
15 trays
8 trays
Maximum
Numberof
Fibrloks
108
192
192
108
162
132
96
96
108
180
96
2178 with a 2181
and No Cable
4.96" Space
Available
13 trays
12 trays
12 trays
13 trays
13 trays
16 trays
11 trays
11 trays
13 trays
22 trays
11 trays
Maximum
Number of
Fibrloks
156
288
288
156
234
192
132
132
156
264
132

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SECTION 1: 2178 SPLICE CASE INSTRUCTIONS
5.0 Cable Preparation
Caution: When removing cable sheathing, do not cut, kink, or
damage underlying layers. If damage occurs, cut back
sheath components to adequately inspect and repair.
5.01 Remove 96" (2.43 m) of outer cable sheath (and shield or armor if present). Remove successive sheath
layers and wrappings to expose primary tube(s) protecting fibers. Stagger layers as recommended by cable
manufacturer or per standard practice.
5.02 Remove all cable grease. Clean all primary tube(s) and dielectric strands with approved cable cleaner.
Cover all sharp edges with vinyl tape.
Note: Carefully follow health, safety and waste disposal instructions as given on Material Safety Data
Sheet or container label for cable cleaner solvent being used.
5.03 Trim any solid filler tubes and discard. Trim central strength members (if present) to 7" (178 mm) from sheath
openings.
5.04 Scuff and center 6" (152 mm) of each cable
as shown.
5.05 Size and place washers on cable.
5.06 Slide two sealing washers down each cable. Use sealing washers
with smallest ID which will slide on the cable.
Note: If necessary, sealing washers can be split on washer mark
and placed on the cable. Place the cuts off set 180
degrees.
6.0 Mid-Span Splice (Balloon Splice)
6.01 Mark the cable in the center of the stored slack.
6.02 Locate the approximate center of the mid-span opening and remove 18" (450 mm) of outer sheath, shield
(if present), inner sheath and Kevlar wraps. Locate the reverse point of the buffer tube(s) oscillations.

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6.03 Remove 48" (1.2 m) of cable sheath (and shield, if present) from either side of the reverse point (60" from
mid-point for LXE). Remove inner sheath to within 1/2" (13 mm) of the outer sheath ring cut.
Note: Removal of 48" (1.2 m) (60" for LXE) of outer cable sheath in both directions is required when the
spliced fibers are not dedicated. The fibers to be spliced will be cut in the middle. This will allow
96" (2.4 m) of stored slack available for re-splicing or bi-directional feed.
48" (1.2 m)
48" (1.2 m)
Buffer TubesSheath
96" (2.4 m)
6.04 Remove all cable grease. Clean all primary tube(s) and dielectric strands with approved cable cleaner.
Cover all sharp edges with vinyl tape.
Note: Carefully follow health, safety, and waste disposal instructions as given on the Material Safety Data
Sheet or container label for cable solvent being used.
6.05 Trim any solid filler tubes and discard. Trim central strength members (if present) to 7" (178 mm) from sheath
openings.
6.06 Scuff 6" (152 mm) of each cable.
6.07 The buffer tubes to be spliced will be opened 2" (51 mm) from the cable end at the field side.
6.08 If the cable is a ribbon, unitube, or slotted core, loose tubes from a
unit splitter kit will be placed over the fibers to be spliced for
protection.
6.09 Ribbon or non-buffer tube design cable will require 1/2" (13 mm)
spiral wrap to protect the stored expressed fiber.
6.10 Fibers expressed, or not spliced, will be stored in the base under
the central members.

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7.0 Bonding for Shielded Cable
Note: Use caution when installing shield bond connector so underlying layers of cable are not damaged.
7.01 When splicing any standard, terneplate type, shielded fiber optic cable, install the 4460-D Shield Bond
Connector.
7.02 Prepare cable/tab 180 degrees from shield bond connector location and insert base.
Note: When a non-core wrap fiber optic cable is being used, use caution to not damage buffer tubes
when inserting connector base.
7.03 Install the connector top over the stud and tighten firmly with one
of the securing nuts. Place the braid over the connector stud and
secure in place with the nut.
7.04 If double sheath, double shield fiber optic cable is being used,
both outer shield and inner shield need to be bonded.
Leave 3/4" inner sheath and 3/4" of core wrap exposed and install
two shield bond connectors 180 degrees apart per practice. Both
shield bond connectors need to be commoned with a bond strap.
7.05 When bonding LXE cable, the two LXE members must be placed in the two slots at the back of base unit
after it is installed. Twist LXE members together twice.

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7.06 When using steel reinforced crossply, and crossply with ribbon
cable, install the 4460-D per practice and twist all reinforcing
members together and bring to one side.
8.04 Lay a 4" (102 mm) long piece of E-Z wrap lengthwise on the
workstation and position between foam collars. Wrap E-Z wrap
edges around foam collars.
8.03 Separate buffer tube(s) and strength members. Build another foam collar by wrapping foam tape between
buffer tube(s) and strength members so the distance between collar outer edges is 4" (102 mm). Wrap two
more layers of foam tape around outside of buffer tube(s).
4" (102 mm)
8.02 Cut two 3/4" (19 mm) wide by 15" (381 mm) long strips of foam
collar tape. Build a foam collar by wrapping at least two layers of
foam collar tape around cable sheath 1" (25 mm) from the end of
sheath.
1" (25 mm)
3/4" (19 mm)
8.0 Core Blocking
Note #1: This core blocking method is used on fiber cable design as of this practice issue date, except
slotted core fiber cable.
Note #2: Core blocking of OFNR cable is not necessary.
Note #3: If sheath has not been scuffed, do before proceeding.
8.01 Non-Armored Application

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8.05 Cut corner of 4445 Sealant bag. Starting at opposite end, force
sealant out and fill area between foam collars.
Note: Carefully follow health, safety and disposal instructions as
given on Material Safety Data Sheet or product label for
4445 Sealant.
Note: Protective gloves should be worn during sealant
dispensing and overwrapping steps.
8.06 Overwrap with at least two additional half-lapped layers of E-Z
wrap.
8.07 Secure E-Z wrap by compressing foam collar ends with three half-
lapped layers of highly stretched 3/4" (19 mm) vinyl tape.
8.08 Evenly work the 4445 Sealant between buffer tube(s) and strength
members.
8.09 Overwrap entire block with one half-lapped layer of highly
stretched 3/4" (19 mm) vinyl tape.
8.10 Apply a compression wrap with two half-lapped layers of highly
stretched 3/4" (19 mm) DR tape.

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8.14 Armored Application
Note: This procedure is the same for LXE, steel re-enforced crossply, crossply ribbon cable, loose buffer
tube and steel central member make up fiber optic cable.
Crossply LXE Loose Buffer Tube
8.15 Prepare cable for bonding the armor and strength members.
8.16 Cut stud of the shield bond connector flush with top nut and file
sharp edges.
8.17 Cut two 3/4" (19 mm) wide by 15" (381 mm) long strips of foam
collar tape. Starting 1" (25 mm) behind shield bond connector
build foam collar with the foam collar tape, build collar high
enough to accommodate the shield bond connector, bonding
straps and nuts.
1"
(25 mm)
3/4"
(19 mm)
8.11 Overwrap with one additional half-lapped layer of vinyl tape.
8.12 Repeat steps 8.02 thru 8.11 until all cables are blocked.
8.13 Secure the cables to the splice case per splice case practice.

15
8.18 Separate buffer tube(s), strength member and bond members. Build another collar between buffer tube(s),
strength members and bonding strap so distance between collar outer edges is 5" (127 mm). Wrap two more
layers of foam tape around outside of tubes.
5" (127 mm)
8.19 Lay a 5" (127 mm) long piece of E-Z wrap lengthwise on the
workstation and position between foam collars. Wrap E-Z wrap
edges around foam collars.
8.20 Cut corner of 4445 Sealant bag. Starting at opposite end, force
sealant out and fill area between foam collars.
Note: Carefully follow health, safety and disposal instructions as
given on Material Safety Data Sheet or product label for
4445 Sealant.
Note: Protective gloves should be worn during sealant
dispensing and overwrapping steps.
8.21 Overwrap with at least two additional half-lapped layers of E-Z
wrap.
8.22 Secure E-Z wrap by compressing foam collar ends with three half-
lapped highly stretched 3/4" (19 mm) vinyl tape.
8.23 Evenly work sealant between buffer tubes and strength members.

16
8.24 Overwrap entire block with one half-lapped layer of highly
stretched 3/4" (19 mm) vinyl tape.
8.25 Apply a compression wrap with two half-lapped layers of highly
stretched 3/4" (19 mm) DR tape.
8.26 Overwrap with one additional half-lapped layer of vinyl tape.
8.27 Follow steps 8.15 thru 8.26 until all cables are blocked.
8.28 Secure the cables to the splice case per the splice case practice.
9.0 Sealing Washer Installation
9.01 Wrap each cable with two wraps of 2" wide DR Tape. Place wraps
behind foam tape collar from core block.
9.02 Place the first sealing washer against the DR Tape. Build cable
entrance seals by wrapping 1 1/2" (38 mm) sealing tape between
washers. Wrap each cable until sealing tape O.D. is flush with the
washer O.D. Slide second washer against sealing tape.

17
9.03 Press cable seals onto cable entrance port(s).
9.04 Attach each cable to splice case by installing and tightening hose
clamps over previously wrapped DR Tape on the down brackets.
Double sheath cable will have hose clamp tightened over metallic
tape previously placed on the cable instead of DR Tape.
9.05 Place cable ties outside of splice case. Install one large green
cable tie on the "C.O. Cable" and trim. Install one large blue
cable tie on the "Field Cable" and trim.
10.02 Place ground stud protector cap on ground studs.
10.03 If separate external grounding is not required, bond across splice
to either ground stud.
10.0 Grounding for Shielded Cable
10.01 Remove ground stud protectors. If bonding to central clamp is
not required, remove strap from external ground stud. If
separate external grounding is required, bond "C.O. Cable" and
"Field Cable" directly to the closest ground stud.

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10.04 Ground isolation from the central block using AT&T crossply or LXE cable. This method will provide ground
isolation plus strain relief protection.
a. The cables must enter the case in a butt configuration at the external ground stud end.
Note: When terminating OFNR cable, ground isolation is not necessary.
b. The crossply members must be twisted or spirally wound. The two LXE members are twisted together
twice.
Note: The double tape method is required to assure ground isolation from the central clamp.
c. The final crossply and LXE member length should extend 3" (76 mm) beyond the central clamp.
d. Starting 3" (76 mm) from the final cut end, wrap two strips 2" (51 mm) long of 1" (25mm) wide vinyl tape
lengthwise around the crossply members. Make sure the tape is overlapped and no metal is exposed.
Each LXE member requires only one piece of vinyl tape.
e. Wrap a 2" (51 mm) length of #69 glass cloth backed tape over the vinyl tape. Two pieces of tape are
required for crossply cable and one piece for each LXE member.
Note: The double tape method is required to assure ground isolation from the central clamp.

19
f. The crossply members go under both central retention screws along the outer edge. The LXE members
go under both sides of the two screws. Make sure the taped area is under the screws.
g. A split bolt clamp is required to join the crossply members to a number six or equivalent bond strap.
Wrap vinyl tape over the bolt connection to protect against sharp edges or pinch points. Attach external
ground stud.
11.0 Buffer Tube and Ribbon Cable Preparation
11.01 Unit splitter kits are required on all ribbon, unitube, or slotted core cable. Follow instructions supplied with
the unit splitter kits.
11.02 Gather all buffer tubes from "C.O. Cable" and install one small green cable tie approximately 36" (914 mm)
from sheath end. Install one small blue cable tie on the "Field Cable" buffer tubes or ribbon cable.
Note: Spiral wrap or equivalent must be applied to unitube cable before applying cable tie.
11.03 Coil buffer tube, ribbon, unitube, or fibers bundles inside splice
case base. If using a splice tray that allows fiber entry at all four
corners or two corners in the same end, the last 3/4 loop will
allow tray movement for splicing away from splice case. Coils
should be full splice case base length and width and should be
under the cable and central member.
11.04 When using the 2524-FT Fibrlok splice trays, or other trays that
allow fiber entry from the same corner, the buffer tubes, ribbon,
unitube or slotted core fiber will need to route in the same
direction together. This is accomplished by having the fiber from
one cable pass in front of the central clamp and follow the route
of the other fiber. The 3M Fibrlok splice tray requires a
counterclockwise direction. Follow supplied instructions with
other splice trays to determine fiber route direction.

20
11.05 Cut and position central member under central clamp retention
screws. If necessary, remove insulation from central member.
Using the supplied 7/32" hex key, firmly tighten each retention
screw. If Kevlar is used for cable strain relief, wrap the Kevlar
fibers twice around one central clamp retention screw and
tighten the screw. Cut Kevlar fibers 1/2" (13 mm) from screw.
11.06 The crossply members go under both central clamp retention screws along the outer edge. The LXE
members go under both sides of the two screws. Make sure the taped area is under the screws.
12.0 Universal Organizer Adapter
12.01 The universal organizer adapter is secured onto the studs located on the central clamp. Trays that will fit on
the organizer adapter are the 3M Fibrlok Tray, AT&T, UC Series, Ditel, Preform, and Siecor. The bottom tray
is secured to the adapter by the adhesive-backed dual-lok pads. Additional trays are added by attaching to
the tray below or by using the supplied rod and wing nut.
AT&T Ribbon Cassette (for tray)
PNUC-RR Splice Organizer
AT&T par #103921961
11.07 A split bolt clamp is required to join the crossply members to a
number six or equivalent bond strap. Wrap vinyl tape over the
split bolt connection to protect against sharp edges or pinch
points. Attach to external ground stud.