2178-L/S Family Fiber Optic Splice Case with Gasket...• Cable Splicer Knife • Tape Measure •...

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November 199834-7046-4859-0-A

2178-L/S Family Fiber Optic SpliceCase with Gasket

Instructions for:

2178-L/S Series Splice Cases and 2178-L/S-FR Flame Retardant Splice Cases

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Table of Contents

1.0 General ...............................................................................................................................................3

2.0 Specifications .....................................................................................................................................3

3.0 Kit Contents........................................................................................................................................5

4.0 Cable Preparation ...............................................................................................................................8

5.0 Strength Member Termination ...........................................................................................................8

6.0 Cable/Port Seal Assembly ..................................................................................................................9

7.0 Cable Installation................................................................................................................................11

8.0 Primary Tube Preparation ..................................................................................................................13

9.0 Splice Case Assembly ........................................................................................................................13

10.0 Splice Case Reentry ...........................................................................................................................14

11.0 2181-LS and 2181-LS/FR Cable Addition Kit Adapter Installation .................................................14

12.0 Splice Case Reentry with Adapters....................................................................................................16

13.0 Accessories.........................................................................................................................................16

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1.0 General1.1 This instruction bulletin details the installation of the 2178-L/S family of fiber optic splice closures.

1.2 The L/S family of cases consists of two series: the 2178-L/S series for outside applications and the2178-LS-FR Series for inside building applications. (see below for application details)

2178-L/S Series:2178-S Small fiber optic case2178-LS Large fiber optic splice case2178-LL Extra large fiber optic splice case2181-LS Cable addition kit

2178-L/S-FR Series:2178-S/FR Small flame retardant fiber optic case2178-LS/FR Large flame retardant fiber optic splice case2178-LL/FR Extra large flame retardant fiber optic splice case2181-LS/FR Flame Retardant cable addition kit

Black cases for outdoorapplications: underground,buried, aerial and pedestal.

Gray cases for indoor flameretardant applications:vault and building ONLY.

2.0 Specifications for 2178-L/S Family

Maximum cable diameter:.......................................1.0" (25 mm)Minimum cable diameter: .......................................0.4" (10 mm)Case length: .............................................................21.9" (55.7 cm)2178-S case height: .................................................4.7" (11.9 cm)2178-LS case height: ...............................................8.0" (20.3 cm)2178-LL case height:...............................................11.3" (28.7 cm)

Available splice chamber space:length:........................................................16.4" (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 height (1): ...................................1.5" (3.8 cm)2181-LS height (2): ...................................3.0" (7.6 cm)2181-LS height (3): ...................................4.5" (11.4 cm)

2.1 Splice Tray Capacity:

Capacity of 2524 Splice Tray ........................... 24 3M™ Fibrlok™ Splices.......................................................................... 24 Fusion Splices

Capacity of 2523 Splice Tray ........................... 24 Fibrlok Splices.......................................................................... 12 3M™ Fibrlok™ Multi-Fiber Splices* (12 fibers each).......................................................................... 48 Discrete Fusion Splices.......................................................................... 12 Fusion Splices (12 fibers each)

Capacity of 2522 Splice Tray ........................... 12 Fibrlok Splices.......................................................................... 8 3M Fibrlok Multi-Fiber Splices* (12 fibers each).......................................................................... 24 Discrete Fusion Splices.......................................................................... 10 Fusion Splices (12 fibers each)

*Varies with ribbon size

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Number of 2181 Cable Addition Kits ADDED 0 0 0 1 1 1 1 1 1

Number of Cables INSTALLED 2-4 2-4 2-4 2-4 2-4 2-4 5-8 5-8 5-8

CAPACITY (Max Number of 2524 Splice Trays) 3 9 9 7 12 12 3 9 9










CAPACITY (Max Number of 2524 Splice Trays) - 20 20 11 16 16 7 12 12



2.2 Splice Case Capacities

*Note: The 3M™ 2181-LS Cable Addition is added for additional tray capacity.

Note: The 3M™ 2178-S and 2178-S/FR Splice Cases will accommodate up to four 1.0" (25 mm) diametercables 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) diametercables.

Note: The 2178 L/S and 2178-L/S-FR families of fiber optic splice cases come with a reusable rubber gasketfor easy closing and reentry. Do not use release agents or chemicals.

Note: 2181-LS cable addition kits expand the 2178-L/S and 2178-L/S-FR families to provide for either morecable entries or added internal capacity.

Chart applies to both 2178-L/S Series and 2178-L/S-FR Series.

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3.0 Kit Contents

3.1 3M™ 2178-S and 2178-S/FRSplice Case Kit Contents:

3.2 3M™ 2178-LS and 2178-LS/FRSplice Case Kit Contents:

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a) Case assembly includes tray support,gasket, air valve, bolts, and cable strain relief

b) sealing washer trees.......................6 eac) plugs ..............................................2 ead) cable ties, blue and green ..............4 eae) sheath scuff....................................1f) 2172 strength member clamps

w/ rubber boot and hose clamp .....3 eag) 130C rubber tape ...........................1 rollh) silicone grease (5 cc tube) .............2 eai) small allen wrench.........................1j) dual lock (for tray support)............4k) brass nut and washer .....................2 eal) tape collar gauge............................1m) tray strap........................................1


b) sealing washer trees.......................6 eac) plugs ..............................................2 ead) cable ties, blue and green ..............4 eae) sheath scuff....................................1f) 3M™ 2172 strength member clamps

w/ rubber boot and hose clamp .....3 eag) 3M™ 130C rubber tape ..................1 rollh) silicone grease (5 cc tube) .............2 eai) small allen wrench.........................1j) dual lock (for tray support)............4k) brass nut and washer .....................2 eal) tape collar gauge............................1

3.3 3M™ 2178-LL and 2178-LL/FRSplice Case Kit Contents:

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b) sealing washer trees.......................6 eac) plugs ..............................................2 ead) cable ties, blue and green ..............4 eae) sheath scuff....................................1f) 3M™ 2172 strength member clamps

w/ rubber boot and hose clamp .....3 eag) 3M™ 130C rubber tape ..................1 rollh) silicone grease (5 cc tube) .............2 eai) small allen wrench.........................1j) dual lock (for tray support)............4k) brass nut and washer .....................2 eal) tape collar gauge............................1m) tray strap........................................1

Note: L/S-FR Series is gray in color.



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3.4 3M™ 2181-LS Cable Addition Kitand 2181-LS/FR Contents:

a) adapter with gasket........................1b) sealing washer trees.......................6 eac) plugs ..............................................4 ead) cable ties, blue and green ..............4 eae) sheath scuff....................................1f) 2172 strength member clamps

w/ rubber boot and hose clamp .....2 eag) 130C rubber tape ...........................1 rollh) silicone grease (5 cc tube) .............2 eai) small allen wrench.........................1j) bolts ...............................................10 eak) tape collar gauge............................1

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a) gasket.............................................1b) 130C rubber tape ...........................1 rollc) silicone grease (5 cc tube) .............2 ea

3.5 3M™ 2178-LS/GSKT Gasket Kit Contents:

3.7 Tools Required:

• 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

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 shieldedcables


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Note: If wall mount bracket is required for the 3M™

2178-LL or the 3M™ 2178-LL/FR Splice Case,use the 3M™ 2199 Mounting Bracket Kit. Attachbrackets to base (as shown) prior to cablepreparation.

Tighten bracket bolts securely.

Note: Proper sealing of the 3M™ 2178-L/S Series and the 2178-L/S-FR Series Fiber Optic Splice Casedepends on strict adherence to these instructions and the use of specified materials. Deviations cancause leakage or case damage. Maintain clean sealing surfaces to ensure proper sealing.

3M™ 2178-L/S Family Fiber Optic Splice Case Notes

Note: If wall mount bracket is required for the 2178-S,2178-S/FR Splice Case or the 2178-LS, 2178-LS/FRSplice Case, use the 3M™ 2198 Mounting Bracket Kit.Attach brackets to base (as shown) prior to cablepreparation.

Tighten bracket bolts securely.

Note: Information on accessories available for the 2178-L/S and FR Series can be found in the back of thisinstruction document.

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4.0 Cable PreparationNote: For clarity, the 2178-S Splice Case has been shown. Installation procedures are the same for all

combinations of the 2178-L/S Family of Splice Cases.

Note: 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 sheathlayers and wrapping to expose buffer tubes protecting fibers. Stagger layers as recommended by cablemanufacturer or per standard practice.

4.2 Remove all cable grease. Clean all buffer tubes and dielectric strands with approved cleaner.

Note: Carefully follow health, safety and environmental instructions as given on Material Safety DataSheet or container label for cable cleaner solvent being used.

4.3 Trim any solid filler tubes and discard.

Note: Do not trim strength members at this time.

4.4 Scuff 5" (127 mm) of each cable sheath end using supplied sheath scuff.

Note: Do not use a carding brush to scuff sheaths.

1.75" (44.5 mm)

5.3 Strength Member Termination for Non-Shielded Cable

a. Cut strength member 1.75" (44.5 mm) from cablesheath end.

DistributionFeederDistribution

FeederDistribution Distribution

Feeder

5.0 Strength Member Termination

5.1 Slide two sealing washers down each cable. USE THE SMALLEST INSIDE DIAMETER SEALINGWASHERS WITH THAT WILL SLIDE ONTO THE CABLE.

Note: If necessary, sealing washers can be split and placed on the cable.

5.2 Locate cables in appropriate entrance ports, as shown.

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b. Install strength members into 3M™ 2172 Strength Member Clamp by loosening screw andplacing strength member under screw assembly. Insure strength member is flush with end ofclamp prior to tightening the screw. Install protective boot onto clamp.

Note: To insure proper fit, remove coating on strength member.

5.4 Bonding and grounding for shielded and LXE type cable.

Note: 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 withconnector.

Note: To insure proper fit, remove coating on central strength member.

b. If separate external grounding is required, bond "Feeder Cable" and "Distribution Cable" directly toseparate ground studs.

Note: 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 Cable/Port Seal Assembly

6.1 The rubber gasket is factory installed in all 3M™

2178-L/S Family Fiber Optic Splice Cases.

To replace the gasket, use the 2178-LS/GSKT Kit.

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6.3 Use the 1.5" (38 mm) rubber tape included with the caseto build the cable seals. Check the placement of the tapeby positioning the strength member clamp where it will beanchored to the cable tie down bracket.

Wrap the rubber tape between sealing washers2" (51 mm) from cable sheath end.

Note: Stretch tape slightly to ensure better fit between washers.

Note: If using 1" (25 mm) cables, the supplied 1.5" (38 mm)rubber tape is not required.

6.5 Apply silicone grease to the outside of the port area onthe gasket. Apply the grease to the gasket area betweenthe ports, and to the top of the gasket along the sides ofthe case.

Note: Carefully follow health, safety and environmentalinstructions as given on Material Safety Data Sheetfor the silicone grease.

6.4 Apply a thin layer of the supplied silicone grease to thebottom side of the gasket in the port area.

The tape should be wrapped to 1" (25 mm) outsidediameter. Use the Tape Collar Gauge to determine tapewrap. Tape wrap should not be smaller than the leftside of the gauge, and not larger than the right side ofthe gauge.

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grease

6.7 Apply the silicone grease to the tape collar between thewashers and to the outside of the sealing plugs, if any.

Plugs should be placed inside gasket at the unused entryports.

Note: The grease allows the cables and gasket to slide intoplace and helps seal the cable port area.

6.8 Place cables inside the port area on the gasket. Ensurethat the rubber tape seals are inside the gasket ports.

The two washers should be placed in the port grooves onthe case with one washer on each side of the gasket.

Note: Be sure that both washers are perpendicular (90°) tocable.

7.0 Cable Installation

7.1 The set screws which hold the cable tie down bracketsare factory installed. One or both set screws can beremoved. If removal is necessary, use the allen wrenchincluded in the kit. It is recommended to tape the allenwrench to the inside of the case for later use.

Note: SET SCREW MUST NOT EXTEND ABOVEPLASTIC "U" CHANNEL.

INSTALL ONLY TILL FLUSH WITH "U"CHANNEL.

6.9 Apply a thin coat of the grease to the top of the gasketaround the closure perimeter.

6.6 Apply silicone grease to the split or cut edge of thegasket.

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For Non-Shielded Cables:

3M™ 2172 Strength Member Clamp:

Install a hose clamp (included with case) through the sloton the strength member clamp.

7.3 Install one green cable tie on the "Feeder Cable" andtrim. Install one blue cable tie on each "DistributionCable" and trim.

Note: Cable ties may also be placed inside case percompany standard practice.

For Shielded Cables:

3M™ Scotchlok™ 4460-D/FO Shield Bond Connector:

Attach each cable to case base by installing a hoseclamp around the cable and under the cable tie downbracket and tighten clamp.

Then slide the cable tie down bracket inbetween the hose clamp and strengthmember clamp as shown. Tighten theclamp until it is secure.

7.2 Attach cables to case base, using one of the methodsbelow:

An alternative method is to attach each cable to thecase base by installing a hose clamp through the sloton the strength member clamp, then around the cabletie down bracket, and tighten the hose clamp.

(bottomview)

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8.0 Primary Tube Preparation

8.1 Gather all buffer 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" buffer tubes. Install two bluecable ties on "Branch Cable" buffer tubes.

8.2 Remove tray support by loosening the captive screws andlifting straight up from case base.

8.3 Coil buffer tube bundles inside case base percompany standard or organizer installation instructions.

8.4 Install tray support into slots on case base and tightenscrews until snug.

8.5 Install organizers and splices per company standard ororganizer installation instructions.

9.3 Tighten ten bolts half way down in the sequence shown.Then tighten ten bolts in sequence shown until there ismetal to metal contact.

Note: See label and numbers on cover of splice case.

Final tightening should be done with a hand wrench to240 in-lbs (27.12 N•m) torque. Case leakage may occurif procedure is not followed.

9.4 To check for leaks, flash test the splice case by applying airto 10 psi (0.67 bar) MAXIMUM, THEN RELEASEPRESSURE.

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9.0 Splice Case Assembly

Note: If 3M™ 2183 Universal Aerial Hanger Bracket is to be used, follow its practice prior to splice case assembly.

9.1 Before placing the case cover on either the case base or the3M™ 2181-LS or 2181-LS/FR 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 severalcomplete turns into nut inserts.

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10.0 Splice Case Reentry

10.1 Remove the ten bolts holding the splice case halves together. The cover can easily be removed by hand.

11.4 The following steps are for all adapters installed:

a. To prevent buffer tubes and fibers from beingdamaged or pinched between adapters and thecase , the adapters can be pulled down into placebefore the case cover is installed. If using morethan one adapter, remove all corner inserts on thelower level adapter(s). A screwdriver can be used totake out the corner inserts.

11.3 If needed, two tray supports can be used. Tray supports may be ordered separately as the 3M™ 2178-STS(for the 3M™ 2178-S or 2178-S/FR Splice Case), and 3M™ 2178-LTS (for the 3M™ 2178-LS or 2178-LS/FR Splice Case and the 3M™ 2178-LL or 2178-LL/FR Splice Case). Install the lower level tray supportfirst. Install organizers and splices per company standard or organizer installation instructions. Theninstall the next level tray support with the next level of organizers and splices.

11.0 3M™ 2181-LS and 2181-LS/FR Cable Addition Kit Adapter Installation

11.1 Installation procedures for the 2181-LS Adapters are the same as the 3M™ 2178-L/S Series Splice Cases(Sections 4.0 - 9.0) with the following exceptions:

For SINGLE Adapter Installation, replace all ten bolts inserted in the case cover with the ten boltssupplied with the 2181-LS or 2181-LS/FR Cable Addition Kit.

For DOUBLE Adapter Installation, replace all ten bolts inserted in the case cover with the ten longer boltssupplied with the 3M™ 2181-B Cable Addition Kit.

For TRIPLE Adapter Installation, replace all ten bolts inserted in the case cover with the ten longer boltssupplied with the 3M™ 2181-C Cable Addition Kit.

Note: The 2181-B and the 2181-C Cable Addition Kits contain only the longer bolts. A 2181-LS or2181-LS/FR Cable Addition Kit is needed to add an adapter.

11.2 The tray support can be installed in the case base or any of the cable addition kits. Install the tray supportonto the desired level by placing it into the slots on the case base or adapter, and tightening the screws untilsnug.

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b. The threaded inserts should be in the four cornerson the top portion of the top adapter only.

c. Prior to placing an adapter on the case base,ensure that the note "AIR VALVE END" on theadapter is aligned with the "AIR VALVE END"note on the gaskets and the case base.

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d. If placing one adapter on another adapter, makecertain the note "AIR VALVE END" lines up forall adapters, gaskets, and the case base.

e. Set adapter, with the word "BOTTOM" facingdown, on top of the case.

Note: It is important to orient the gaskets correctly oneach level of the assembly (see Section 6.2 and 6.3).

f. Continue assembly for each level, following theinstructions from Section 4.0 to 8.0.

g. After cables have been installed on the lower levelsand top adapter is in place, insert the bolts fromunderneath into the four corner inserts. Screw thefour bolts until they have been threaded severalcomplete turns into the corner inserts.

h. Slowly bring adapters down by working fromcorner to corner (as shown) until snug. Ensure nobuffer tubes have been pinched between the adaptersand the case base.

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11.5 After assembly is complete, follow the instructions in9.0 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 theremaining cover bolts, using the sequence shown. Finaltightening should be done with a hand wrench to 240 in-lbs(27.12 N.m) torque. Case leakage may occur if procedureis not followed.

To check for leaks, flash test splice case by applying air to 10psi (0.67 bar) MAXIMUM, THEN RELEASE PRESSURE.

Note: Use only E-pressure testing solution or diluted dish washing soap for flash testing.

12.0 Splice Case Reentry with Adapters

12.1 Remove bolts 7, 8, 9 and 10. Install these four bolts from underneath into the four corner inserts. Tightenuntil snug. Remove remaining bolts. The cover can then be easily removed by hand. This procedure willkeep the adapters in place while the cover is removed.

13.0 Closure Accessories

2178-EGI-External Ground Isolation Kit

2178-L/S 4 Lug(Base contains four external ground lugs)

2199 Wall Mount Bracket2178-LL Mounting Bracket Kit and 2178-LL/FR cases

2178-LS Rod Threaded Rod Assembly

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2519 and 2519-X Cable Fanout Kit

2183 Aerial Hanger Kit

2198 Mounting Bracket Kit

2178-ASB Adjustable Support Bracketfor table top mounting 2178-L/S family cases

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Important Notice

All statements, technical information and recommendations related to the Seller's products are based on information believed to bereliable, but the accuracy or completeness thereof is not guaranteed. Before utilizing the product, the user should determine the suitabilityof 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 effectunless contained in an agreement signed by an authorized officer of the Seller. The statements contained herein are made in lieu of allwarranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purposewhich warranties are hereby expressly disclaimed.

SELLER SHALL NOT BE LIABLE TO THE USER OR ANY OTHER PERSON UNDER ANY LEGAL THEORY, INCLUDING BUT NOTLIMITED TO NEGLIGENCE OR STRICT LIABILITY, FOR ANY INJURY OR FOR ANY DIRECT, INDIRECT, INCIDENTAL ORCONSEQUENTIAL DAMAGES SUSTAINED OR INCURRED BY REASON OF THE USE OF ANY OF THE SELLER'S PRODUCTS.

Telecom Systems Division6801 River Place Blvd.Austin, TX 78726-9000800/426-8688http://www.3m.com/telecom

Printed on 50% recycled paperwith 10% post-consumer

Printed in USA© 3M 1998 34-7046-4859-0-A

2178-L/S Family Fiber Optic Splice Case with Gasket...• Cable Splicer Knife • Tape Measure •...

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Transcript of 2178-L/S Family Fiber Optic Splice Case with Gasket...• Cable Splicer Knife • Tape Measure •...