2178-L/S Series Fiber Optic Splice Case with Gasket

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1 2178-L/S Series Fiber Optic Splice Case with Gasket Instructions for: 2178-S Splice Case 2178-LS Splice Case 2178-LL Splice Case 2181-LS Cable Addition Kit May A 1

2 Table of Contents 1.0 General Specifications Kit Contents Cable Preparation Strength Member Termination Gasket Installation Cable Installation Primary Tube Preparation Splice Case Assembly Splice Case Reentry LS Cable Addition Adapter Installation

3 3M 2178-L/S Series Fiber Optic Splice Case Description 1.0 General 1.1 The 3M 2178-L/S Series Fiber Optic Splice Cases are closures that can be used in buried, underground, aerial, and pedestal applications. These closures are suitable for short term pressurization during flash testing. Please refer to your company's approved applications. Each splice case has two cable entrance ports on each end. Port plugs allow the cases to be used for butt or inline splices. The rigid non-encapsulated case provides moisture protection. A gasket is used to seal the closure and provide easy reentry. 1.2 The 3M 2181-LS Cable Addition Kit expands the case to provide more cable entries. It can be used on the 3M 2178-S, 3M 2178-LS or 3M 2178-LL Splice Cases. The cable addition kit can also be added to increase splice capacity. 2.0 Specifications Maximum cable diameter:...1.0" (25 mm) Minimum cable diameter:...0.4" (10 mm) Closure length: " (55.7 cm) Closure width:...8.5" (21.5 cm) 2178-S closure height:...4.7" (11.9 cm) 2178-LS closure height:...8.0" (20.3 cm) 2178-LL closure height: " (28.7 cm) Available splice chamber space: length: " (41.6 cm) width:...5.5" (14 cm) 2178-S height:...1.2" (3 cm) 2178-LS and 2178-LL height:...3.7" (9.4 cm) 2181-LS (1) height:...1.5" (3.8 cm) 2181-LS (2) height:...3.0" (7.6 cm) 2181-LS (3) height:...4.5" (11.4 cm) 2.1 Splice Tray Capacity: Capacity of 2524 Splice Tray M Fibrlok Splices Fusion Splices Capacity of 2523 Splice Tray Fibrlok Splices M Fibrlok Multi-Fiber Splices* (12 fibers each) Discrete Fusion Splices Fusion Splices (12 fibers each) Capacity of 2522 Splice Tray Fibrlok Splices M Fibrlok Multi-Fiber Splices* (12 fibers each) Discrete Fusion Splices Fusion Splices (12 fibers each) *Varies with ribbon size 3

4 2.2 Splice Case Capacities 2178-S 2178-LS 2178-LL 2178-S* 2178-LS* 2178-LL* 2178-S 2178-LS 2178-LL Number of 2181 Cable Addition Kits ADDED Number of Cables INSTALLED CAPACITY (Max Number of 2524 Splice Trays) CAPACITY (Max Number of 2523 Splice Trays) CAPACITY (Max Number of 2522 Splice Trays) Number of 2181 Cable Addition Kits ADDED Number of Cables INSTALLED CAPACITY (Max Number of 2524 Splice Trays) CAPACITY (Max Number of 2523 Splice Trays) CAPACITY (Max Number of 2522 Splice Trays) Number of 2181 Cable Addition Kits ADDED Number of Cables INSTALLED CAPACITY (Max Number of 2524 Splice Trays) CAPACITY (Max Number of 2523 Splice Trays) CAPACITY (Max Number of 2522 Splice Trays) * The 3M 2181-LS Cable Addition is added for additional tray capacity. The 3M 2178-S Splice Case will accommodate up to four 1.0" (25 mm) diameter cables inline when using 3M 2522 trays. When using 3M 2523 or 3M 2524 trays it is limited to four.5" (12.5 mm) diameter cables inline. Butt applications will accommodate up to 1.0" (25 mm) diameter cables. 4

5 3.0 Kit Contents 3.1 3M 2178-S Splice Case Kit Contents: a) Case assembly includes tray support, gasket, air valve, bolts, and cable strain relief b) sealing washer trees... 6 ea c) plugs... 2 ea d) cable ties, blue and green... 4 ea e) sheath scuff... 1 f) 3M 2172 strength member clamps w/ rubber boot and hose clamp... 3 ea g) 3M 130C tape... 1 roll h) silicone grease (5 cc tube)... 2 ea i) small allen wrench... 1 a b c d g h e f i 3.2 3M 2178-LS Splice Case Kit Contents: a a) Case assembly includes tray support, gasket, air valve, bolts, and cable strain relief b) sealing washer trees... 6 ea c) plugs... 2 ea d) cable ties, blue and green... 4 ea e) sheath scuff... 1 f) 2172 strength member clamps w/ rubber boot and hose clamp... 4 ea g) 130C tape... 1 roll h) silicone grease (5 cc tube)... 2 ea i) small allen wrench... 1 c g f b d e h i 3.3 3M 2178-LL Splice Case Kit Contents: a a) Case assembly includes tray support, gasket, air valve, bolts, and cable strain relief b) sealing washer trees... 6 ea c) plugs... 2 ea d) cable ties, blue and green... 4 ea e) sheath scuff... 1 f) 2172 strength member clamps w/ rubber boot and hose clamp... 4 ea g) 130C tape... 1 roll h) silicone grease (5 cc tube)... 2 ea i) small allen wrench... 1 c g h f b d e i 5

6 3.4 3M 2181-LS Cable Addition Kit Contents: a) adapter with gasket... 1 b) sealing washer trees... 8 ea c) plugs... 4 ea d) cable ties, blue and green... 4 ea e) sheath scuff... 1 f) 3M 2172 strength member clamps w/ rubber boot and hose clamp... 4 ea g) 3M 130C tape... 1 roll h) silicone grease (5 cc tube)... 2 ea i) small allen wrench... 1 j) bolts ea b c e d a h i j f g 3.5 3M 2178-LS Gasket Kit Contents: a) gasket... 1 b) 130C tape... 1 roll c) silicone grease (5 cc tube)... 2 ea a 3.6 Additional Materials Required: Cable Cleaner #6 AWG Ground Wire or equivalent Splice Tray / Organizer 3M Scotchlok 4460 D/FO Shield Bond Connector, if using shielded cables 3.7 Tools Required: c b 3/8" (10 mm) Hex Driver 1/2" (13 mm) Hex Driver 7/16" (12 mm) Hex Driver Side Cutting Pliers Needle Nose Pliers Cable Stripper Cable Splicer Knife Tape Measure Wire Cutter for Steel Strength Members Electrician's Scissors Screwdriver 3M 2178-S, 2178-LS, 2178-LL Fiber Optic Splice Case Instructions If wall mount bracket is required for the 2178-S Splice Case or the 2178-LS Splice Case, use the 3M 2198 Mounting Bracket Kit. Attach brackets to base (as shown) prior to cable preparation. Torque bolts to 25 in-lbs ± 5 in-lbs (2.8 N m ± 0.6 N m). 6

7 If wall mount bracket is required for the 3M 2178-LL Splice Case, use the 3M 2199 Mounting Bracket Kit. Attach brackets to base (as shown) prior to cable preparation. Torque bolts to 25 in-lbs ± 5 in-lbs (2.8 N m ± 0.6 N m). Proper sealing of the 3M 2178-L/S Series Fiber Optic Splice Case depends on strict adherence to these instructions and the use of specified materials. Deviations can cause leakage or case damage. Maintain clean sealing surfaces to ensure proper sealing. DO NOT USE any release agents or other unspecified materials. These types of materials may lead to loss of sealing effectiveness. Installation procedures are the same for all combinations of the 2178-S, 2178-LS, and 2178-LL Splice Cases. 4.0 Cable Preparation When removing cable sheathing, do not cut, kink, or damage underlying layers. If damage occurs, cut back sheath to adequately inspect and repair. 4.1 Remove 96" (244 cm) of outer cable sheath (and shield or armor, if present). Remove successive sheath layers and wrapping to expose primary tubes protecting fibers. Stagger layers as recommended by cable manufacturer or per standard practice. 4.2 Remove all cable grease. Clean all primary tubes and dielectric strands with approved cleaner. Cover all sharp edges with vinyl tape. Carefully follow health, safety and environmental instructions as given on Material Safety Data Sheet or container label for cable cleaner solvent being used. 4.3 Trim any solid filler tubes and discard. Do not trim strength members at this time. 4.4 Scuff 5" (127 mm) of each cable end using supplied sheath scuff. Do not use a carding brush to scuff sheaths. 7

8 5.0 Strength Member Termination 5.1 Slide two sealing washers down each cable. Use sealing washers with smallest inside diameter which will slide on cable. If necessary, sealing washers can be split and placed on the cable. 5.2 Locate cables in appropriate entrance ports, as shown. Feeder Distribution Feeder Distribution Feeder Distribution Distribution 5.3 Strength Member Termination for Non-Shielded Cable a. Cut strength member 1.75" (44.5 mm) from cable sheath end. 1.75" (44.5 mm) b. Install strength members into 3M 2172 Strength Member Clamp by loosening screw and placing strength member under screw assembly. Insure strength member is flush with end of clamp prior to tightening the screw. Install rubber boot onto clamp. To insure proper fit, remove coating on strength member. 8

9 5.4 Bonding and grounding for shielded cable. Use care when installing shield bond connectors so underlying layers of cable are not damaged. a. Install 3M Scotchlok 4460-D/FO Shield Bond Connector following instructions provided with connector. To insure proper fit, remove coating on central strength member. b. If separate external grounding is required, bond "Feeder Cable" and "Distribution Cable" directly to separate ground studs. Torque ground stud nut to 35 in-lbs ± 5 in-lbs (4 N m ± 0.6 N m). c. If separate external grounding is not required, bond across splice to either ground stud. 6.0 Gasket Installation Gasket cannot be used as a replacement for the original mastic sealant in a reentry. 6.1 Inspect closure base and ensure the surface is clean and free from any debris. 6.2 The gasket is factory installed in the 3M 2178-L/S Series Fiber Optic Splice Case. For replacement of the gasket, place the gasket into the sealing channel with the gasket ports opening from the top. Match "AIR VALVE END" note on gasket with air valve end on closure. In this position, the stabilizing pads should be facing down. stabilizing pad 9

10 6.3 Use the 1.5" (38 mm) rubber tape included with the gasket to build the cable seals. Check the placement of the tape by positioning the strength member clamp where it will be anchored to the cable tie down bracket. Wrap the supplied rubber tape between sealing washers 2" (51 mm) from cable sheath end. The tape should be wrapped to 1" (25 mm) outside diameter. Use the Tape Collar Gauge to determine tape wrap. Tape wrap should not be smaller than the left side of the gauge, and not larger than the right side of the gauge. Stretch tape slightly to ensure better fit between washers. If using 1" (25 mm) cables, the supplied 1.5" (38 mm) rubber tape is not required. 6.4 If using sealing plug(s), apply the supplied 1.5" (38 mm) rubber tape to the plug(s). Wrap tape to 1" (25 mm) outside diameter, approximately 2 1/2 wraps. Tape collar gauge can be used to determine tape wrap. 6.5 Apply the supplied silicone grease to the inside and outside of the port area on the gasket. Apply the grease to the gasket area between the ports, and to the top of the gasket along the sides of the closure. Carefully follow health, safety and environmental instructions as given on Material Safety Data Sheet for the silicone grease. 10

11 6.6 Apply the grease to the gasket in the split or cut edge that allows for cable placement. grease 6.7 Apply the supplied grease onto the cable area between the washers and to the outside of the wrapped sealing plugs, if any. Plugs should be placed inside gasket at the unused entry ports. The grease allows the cables and gasket to slide into place and helps seal the cable port area. 6.8 Place cables inside the port area on the gasket. Ensure that the rubber tape seals are inside the gasket ports. The two washers should be placed in the port grooves on the closure with one washer on each side of the gasket. 7.0 Cable Installation 7.1 The set screws which hold the cable tie down brackets are factory installed. One or both of the set screws can be removed. If removal is necessary, use the allen wrench included in the kit. It is recommended to tape the allen wrench to the inside of the closure for later use. set screw SET SCREW MUST NOT EXTEND ABOVE PLASTIC "U" CHANNEL. INSTALL ONLY TILL FLUSH WITH "U" CHANNEL. cable tie down bracket 11

12 7.2 Attach cables to closure base, using one of the two methods below: 3M 2172 Strength Member Clamp: Attach each cable to the closure base by installing a hose clamp through the slot on the strength member clamp, then around the cable tie down bracket, and tighten the clamp. 3M Scotchlok 4460-D/FO Shield Bond Connector: Attach each cable to closure base by installing a hose clamp around the cable and under the cable tie down bracket and tighten clamp. cable tie down bracket 7.3 Install one green cable tie on the "Feeder Cable" and trim. Install one blue cable tie on each "Distribution Cable" and trim. Cable ties may also be placed inside case per company standard practice. 12

13 8.0 Primary Tube Preparation 8.1 Gather all primary tubes from "Feeder Cable" and install one green cable tie approximately 36" (914 mm) from sheath end. Install one blue cable tie on the "Distribution Cable" primary tubes. Install two blue cable ties on "Branch Cable" primary tubes. 8.2 Remove tray support by lifting straight up from closure base. 8.3 Coil primary tube bundles inside closure base per company standard or organizer installation instructions. 8.4 Install tray support into slots on closure base and tighten screws until snug. 8.5 Install organizers and splices per company standard or organizer installation instructions. 9.0 Splice Case Assembly If 3M 2183 Universal Aerial Hanger Bracket is to be used, follow its practice prior to splice case assembly. 9.1 Before placing the closure cover on the closure base or the 3M 2181-LS Cable Addition Kit (top adapter), ensure that the air valve matches up with "AIR VALVE END" note on the base or top adapter. 9.2 Screw all bolts until they have been threaded several complete turns into nut inserts. 9.3 Tighten ten bolts half way down in the sequence shown. Then tighten ten bolts in sequence shown until there is metal to metal contact. See label and numbers on cover of splice case. Final tightening should be done with a hand wrench to 20 ft-lbs (27.12 N m) torque. Case leakage may occur if procedure is not followed To check for leaks, flash test the splice case by applying air to 10 psi (0.67 bar) MAXIMUM, THEN RELEASE PRESSURE Splice Case Reentry 10.1 Remove the ten bolts holding the splice case halves together. The cover can easily be removed by hand. 13

14 11.0 3M 2181-LS Cable Addition KitAdapter Installation 11.1 Installation procedures for the 2181-LS Adapters are the same as the 3M 2178-L/S Series Splice Cases (Sections ) with the following exceptions: For SINGLE Adapter Installation, replace all ten bolts inserted in the closure cover with the ten bolts supplied with the 2181-LS Cable Addition Kit. For DOUBLE Adapter Installation, replace all ten bolts inserted in the closure cover with the ten longer bolts supplied with the 3M 2181-B Cable Addition Kit. For TRIPLE Adapter Installation, replace all ten bolts inserted in the closure cover with the ten longer bolts supplied with the 3M 2181-C Cable Addition Kit. The 2181-B and the 2181-C Cable Addition Kits contain only the longer bolts. The 2181-LS Cable Addition Kit is needed to add an adapter The tray support can be installed in the closure base or any of the adapters. Install the tray support onto the desired level by placing it into the slots on the closure base or adapter, and tightening the screws until snug If needed, two tray supports can be used. Tray supports may be ordered separately as the 3M 2178-STS (for the 3M 2178-S Splice Case), and 3M 2178-LTS (for the 3M 2178-LS Splice Case and the 3M 2178-LL Splice Case). Install the lower level tray support first. Install organizers and splices per company standard or organizer installation instructions. Then install the next level tray support with the next level of organizers and splices The following steps are for all adapters installed: a. To prevent cables from being damaged or pinched between adapters and the closure, the adapters can be pulled down into place before the closure cover is installed. If using more than one adapter, remove all corner inserts on the lower level adapter(s). A screwdriver can be used to take out the corner inserts. b. The threaded inserts should be in the four corners on the top portion of the top adapter only. The raised threads should be facing down so that the insert surface is flush with the adapter. c. Prior to placing an adapter on the closure base, ensure that the note "AIR VALVE END" on the adapter is aligned with the "AIR VALVE END" note on the gaskets and the closure base. 14

15 d. If placing one adapter on another adapter, make certain the note "AIR VALVE END" lines up for all adapters, gaskets, and the closure base. e. Set adapter, with the word "BOTTOM" facing down, on top of the closure. It is important to orient the gaskets correctly on each level of the assembly (see Section 6.2 and 6.3). f. Continue assembly for each level, following the instructions from Section 4.0 to 8.0. g. After cables have been installed on the lower levels and top adapter is in place, insert the bolts from underneath into the four corner inserts. Screw the four bolts until they have been threaded several complete turns into the corner inserts. Slowly bring adapters down by working from corner to corner (as shown) until snug. Ensure no cables have been pinched between the adapters and the closure base After assembly is complete, follow the instructions in 9.0 except only tighten bolts 1 to 6 in the sequence shown. After cover has been installed with six bolts, remove the four corner bolts. Use these four bolts for the remaining cover bolts, using the sequence shown. Final tightening should be done with a hand wrench to 20 ft-lbs (27.12 N. m) torque. Case leakage may occur if procedure is not followed To check for leaks, flash test splice case by applying air to 10 psi (0.67 bar) MAXIMUM, THEN RELEASE PRESSURE

16 Important Notice All statements, technical information and recommendations related to the Seller's products are based on information believed to be reliable, but the accuracy or completeness thereof is not guaranteed. Before utilizing the product, the user should determine the suitability of the product for its intended use. The user assumes all risks and liability whatsoever in connection with such use. Any statements or recommendations of the Seller which are not contained in the Seller's current publications shall have no force or effect unless contained in an agreement signed by an authorized officer of the Seller. The statements contained herein are made in lieu of all warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose which warranties are hereby expressly disclaimed. SELLER SHALL NOT BE LIABLE TO THE USER OR ANY OTHER PERSON UNDER ANY LEGAL THEORY, INCLUDING BUT NOT LIMITED TO NEGLIGENCE OR STRICT LIABILITY, FOR ANY INJURY OR FOR ANY DIRECT OR CONSEQUENTIAL DAMAGES SUSTAINED OR INCURRED BY REASON OF THE USE OF ANY OF THE SELLER'S PRODUCTS THAT WERE DEFECTIVE. Telecom Systems Division 6801 River Place Blvd. Austin, TX / Printed on 50% recycled paper with 10% post-consumer 16 Printed in USA 3M A

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