3M MS2 User manual

May 2001
78-8130-4094-2-A
MS2™Modular Splicing System
Instructions

2
Contents:
1.0 General ......................................................................................................................................3
2.0 Module Description ..................................................................................................................3
2.1 Super-Mini........................................................................................................................3
2.2 Super-Mate Pluggable ......................................................................................................3
3.0 Tool Description ........................................................................................................................4
3.1 Main Splicing Rig Components ......................................................................................4
3.2 Rig/Kit Components ........................................................................................................5
3.3 Hand Tools........................................................................................................................7
4.0 Accessories ................................................................................................................................7
5.0 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
5.5 Preterminated Module Connections ................................................................................14
6.0 Applications ..............................................................................................................................16
6.1 Inline Splicing (2 Bank) ..................................................................................................16
6.2 Inline Splicing (3 Bank) ..................................................................................................17
6.3 Inline Splicing (4 Bank) ..................................................................................................17
6.4 Foldback Splicing (2 Bank) ............................................................................................18
6.5 Foldback Splicing (2 Person) ..........................................................................................20
6.6 Foldback Vertical Splicing (2 Bank)................................................................................20
6.7 Foldback Splicing (3 Bank) ............................................................................................21
6.8 Unilength Splicing using 4005-DPM 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 Engineering................................................................................................................................34
8.1 Job Planning ....................................................................................................................34
8.2 Moisture Protection ..........................................................................................................34
8.3 Fire Retardancy ................................................................................................................34
8.4 Rebuilding Existing Splices ............................................................................................34
8.5 Rebuild Coding ................................................................................................................34
8.6 Splice Planning ................................................................................................................35
8.7 Load Coil Splice “L”........................................................................................................39
8.8 Loading ............................................................................................................................40
8.9 Deloading..........................................................................................................................40
8.10 Transfer - Access Splice/Facility Splice “F” (Modified Foldback) ................................41
8.11 Cable Transfer - Conductor Termination ........................................................................42
8.12 Cable Transfer - Using the Module..................................................................................43
8.13 Taper Feeder Splice/Junction Splice “J”..........................................................................44
8.14 Bridged Feeder Splice/Multiple Straight Splice “S” ......................................................45

3
1.0 General
1.1 These instructions describe MS2™ Modular System Splicing, including modules, tools and applications.
2.0 Module Description
2.01 3M MS2modules 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. of .065" (1.7 mm).
• Accept a variety of wire gauges and insulation types in one module.
2.02 3M MS2 modules have:
• Individual elements
• Cutoff blades
• Test entry ports
• Removable covers and bases 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: 4005-DPM/FR is gray/blue in color.
Cover (Yellow)
Insulator (Red)
Body
843004
843006
843004
Yellow
Top Conductor
Placement
Blue Bottom
Pluggable
Cover
Body
Body
Base
Body
Cover
Body
Body
Insulator
Super Mate
4005-DPM
to
Super-Mini
4000-D or
4008-D
Super Mate
4005-DPM
to
Super Mate
to
Super Mate
843064
Two Way Pluggability
843064
One Way Pluggability

4
3.0 Tool Description
3.1 Main Splicing Rig Components
The 4041 Splicing Head is used with a support
rig for:
• Initial termination of conductors in the
modules.
• Making connections with preterminated
modules.
3.1.1 The splice head allows you to arrange and hold
conductors in their proper locations during the
splicing procedure. The splice head will hold
the following module combinations:
• 1 Super-Mini and 1 Super Mate
• 2 Super Mates
• 3 Super Mates
4041 Splicing Head Double Head Set Up
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 Spring (2)
Wire
Retainer Screw
Pedestal
Detent
Pin Pocket
(Crimping Clamp)
Pair Separators
Color Coded
Wire Guides
Wire Retainer Spring (2)
Wire Retainer Size Plate
Connector Plate
Tape Plate
Allen Head Screws
Allen Head Screws
75495
Traverse Clamp
Buckle
Strap
Latch
Traverse Bar
Head Clamp

5
3.2 Rig / Kit Components
Type of Rig or Kit
Short Traverse Clamp ••••
Traverse Clamp 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

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 ••••••••••
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 ••••

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 MS24047 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

8
4.8 4079-S Super-Mini Tagging Labels
Permits easy and accurate recording of pair
counts during tagging operations.
76607
4.9 4048-S 25-Pair Pocket Probe
Designed to interface with Super-Mini and
Super-Mate Modules, the probe provides access
for identification of cable pairs.
4.10 4048-SA1 Kit Super-Mini 25-Pair Probe
Assembly
Provided with Cinch
Jones male plugs, the
probe assembly is spe-
cially designed for
accurate conti-
nuity testing
and tagging of
all Super-Mini
and Super-Mate
Modules.
781276
832640
4.11 4048-DPM CJ Super-Mate Module Probe
Used to transition between 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
MS2modules.
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 plug into the bottom of a Super-
Mate Module.
873540
4.13 4026 Module Maintenance Kit
Contains the tools necessary for reentry of
Super-Mini and Super-Mate Modules.
Kit Contents:
• 4270-A Hand Presser
• 4051 Wire Insertion and Cut Off Tool
• 4053-PM Separator Tool
• 4053 Cover Removal Tool
• 4047 Pair Test Plug
• DPM/DPM Jumper Assembly (2)
• 4005-DPM/BTP Bottom Test Plug
• Jumper Assembly (2)

9
4.14 4041 Rear Spring Holder
Allows the addition of a second set of wire
retaining springs to the back of the 4041 MS2
Splice Head. Used in the conversion of Super-
Mini splices to pluggable Super-Mate splices
and for cutting in Super-Mate Modules on
through cables.
4.18 4019 Check Comb
Used to detect splicing errors prior to module
crimping. Also used as a temporary module
cover in certain splicing applications.
903882
4.16 4053 Cover Removal Tool
Recommended tool for the removal of MS2
module covers and bases.
81203
4.15 4041-2......2" Unilength Hook
4041-4......4" Unilength Hook
Attaches to all MS2splicing heads to facilitate
splicing in the unilength configuration.
74011
4.17 E9-BM Crimping Tool
Crimps MS2module 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 restoration of cut or dam-
aged cables. Also used in maintenance of
Super-Mate Module splices where uninterrupted
service is required.
883640
903882
4.19 4000-D/PTJ Preterminated Jumper Assemblies
Consists of 24 AWG, PIC, unsheathed binder
group terminated on each end with a 4000-D
body/cover combination. Available in 36" (91.4
cm) or 72" (182.9 cm) lengths, the jumpers
enable fast restoration of cut or damaged cables.
903882

10
5.0 Use of Tools and Modules
5.1 Rig set-up as follows:
5.1.1 Attach support tube to cable.
5.1.6 Insert pedestal in head clamp.
75426
5.1.7 Splice back, bottom group first.
For inline splicing, adjust head(s) to group
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
34
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 proper wire gauge.

11
5.2 Wire Placement in Module
Note: Follow Color Code.
5.2.1 Wire pair to right side of
corresponding color coded wire guide.
Separate pair over pair separator, TIP left and
RING right.
Wire Guides
RING colors
TIP Colors
Pair
Separators
843436 843046
5.2.4 Make sure all wires are
lying flat in module
channel.
Check for empty channels,
2 wires in one channel or
reversed pairs.
Slide comb left, only TIP
wires should show. 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
5.2.7 Install module cover.
Module Cut Corner Upper Left
893745
893745
5.2.6 Check for correct
wire placement using
the orange check comb.
5.2.5 Install next module
component.
Place pairs from corre-
sponding group.
832600

12
5.3 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.
75444
Adjust for proper height Detents can be adjusted
for tightness
Hand / Hydraulic Pump
Note: Always position output end level or
lower than rear.
Air / Hydraulic Pump
Note: Always position output end level or
lower than rear.
75444
Close the pressure release valve and operate the pump handle
until the audible bypass is heard, then pump three additional
times. Leave the crimping clamp closed 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 to limit return on crimping bar.
This screw can be adjusted to reduce the
number of strokes required for crimping a
two-wire splice when using the hand
pump, but must be completely backed off
for crimping 3-wire bridge splices..
5.3.1.3 Remove one fourth to one third of the cut con-
ductors at a time by lifting them straight up
from the retainer spring.
5.3.1.4 Remove crimping clamps.
781167
75447
75446
781170
Adjusting Screw

13
5.4 Basic Module Connections
5.4.1 One Way Pluggable Connection
This combination connects two conductor
groups by plugging the Super-Mate Module to
the body top of the Super-Mini Module.
Conductors can be terminated either in the body
bottom or body top of the Super-Mini Module.
5.4.2 Pluggable Bridge Connection
This combination makes 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
Super-Mate
4005-DPM
Super-Mini
4000-D
Cover
Body
Body
Base
Super-Mini
Adapter
Super-Mate
4005-DPM
Cover
Body
Body
Insulator
Super-Mate
4005-DPM

14
5.5 Preterminated Module Connections
Preterminated Super-Mate Modules can be used
as pluggable units with:
• Other modules during splice construction
• Modules in existing 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

15
5.5.4 Preterminated Super-Mate Plugged to
Preterminated Super-Mini
Note: A stripped splice head may be used.
5.5.5 Preterminated Super-Mate Plugged to
Preterminated Super-Mate
Note: A stripped splice head may be used.
Note: If a Super-Mini Module is used, it must always be on the bottom of the final configuration.
Note: It is recommended that only one module combination should be plugged together at a time.
Cover
Body
Super-Mate
4005-DPM
(without insulator)
Body
Base
Super-Mini
4000-D
(without cover)
Cover
Body
Super-Mate
4005-DPM
(without insulator)
Body
Base
Insulator
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 done in a stripped splice head.
*
*Can be either a Super-Mini Module or a Super-Mate Module with Insulator
842795
5.5.6 Three Super-Mate Modules
(3 Conductor Splice)
Note: A stripped splice head may be used.
Cover
Body
Super-Mate
4005-DPM
(wlithout insulator)
843055
Body
Insulator
Super-Mini
4005-DPM
(without cover)
Body Super-Mate
4005-DPM
(body only)
4270-A Hand Presser

16
6.1.5 Place the check comb
over the base and slide
it to the left, only TIP
conductors should
show. Slide the check
comb to the right, only
RING conductors should
show. Also check for two
conductors in one channel,
for vacant channels and for
reversed pairs.
6.1.7 Select matching 25-pair groups from field
cable. Lay pairs into module bodies.
6.0 Application
Note: Splice modules so that equal number of
modules will fall in each bank.
6.1 Inline Splicing (2 Bank)
6.1.1 Splice opening must be that recommended for
closure used, with a minimum of 17" (43.2 cm)
for a 2 bank splice.
893745
6.1.6 Place body into
leaf spring
tracks of both
splice heads
with cut corner
to left of rear
splice heads.
832600
6.1.10 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 When splicing with Super-Mini Module, splice
head adapter must be used.
Select back bottom 25-pair group from C.O.
cable.
Lay pairs into module base on C.O. side of
splice opening.
For easy group ID, place odd groups to left
side, even groups to right side.
6.1.2 Attach rig using double heads.
Center heads in opening.
6.1.4 Select next back bottom 25-pair group from
C.O. cable.
Lay pairs into module base on field side of
splice opening.
75469
FieldC.O.
893756
893756
FieldC.O.
75469
Field
893756 75469
C.O.

17
6.2 Inline Splicing (3 Bank)
6.2.1 Splice opening must be that recommended for
closure used, with a minimum of 26" (66 cm)
for a 3 bank splice.
6.2.4 Adjust splice head for third connector.
6.2.5 Complete splicing and bundling.
6.2.3 Adjust splice head for second connector. Splice
per standard procedure (6.1).
6.2.2 Attach rig using single head. Splice first con-
nector following wire handling procedure Inline
Splicing (2 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
lower adjacent cable.
Free conductors length (each cable) = minimum splice opening plus 6" (152 mm)
6.3.2 Attach rig using double heads. Splice 100-pair
in both heads in this position.
6.3.3 Adjust splice head for next 100-pair.

18
6.4 Foldback Splicing (Two Bank)
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)
X
6.4.2 Identify all binder groups. Starting with lower
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
6.4.3 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 head with marks to prevent mod-
ules from overlapping at center of splice or lay-
ing over tie points.
75451
75452
SECOND
Rotate splicing head to assure that modules will
lay parallel with core.
75453
75454
1/2"
1/2"

19
THIRD
Adjust height of splicing head to prevent con-
ductors from lifting out of wire channels before
module is crimped, and to assure easy removal
of module from head after crimping.
Position head slightly higher than origin of
group to be spliced so that wires are running at
a slight angle up into splicing head.
75455
75456
WRONG
6.4.7 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 group
location.
Splice second group, identify and bundle to
core. Repeat above, alternating left and right
until splice is completed.
75461
RIGHT

20
6.5 Foldback Splicing (Two Person)
Set up two splicing heads using LONG traverse
bar.
Put long traverse bars on two traverse clamps.
A 3/16" allen wrench is supplied.
Note: For two person foldback splicing you will
need two long traverse bars. (There may
only be one to a rig.)
75424
75458
Long
Standard
75423
6.6 Foldback Vertical Splicing (Two Bank)
Mount support tube assembly 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 will splice from one side,
making the three basic measurements, described
in Section 6.4.6. The modules spliced on the
left will swing to the right of center and vice
versa.