3M™ Cabinets 4300 Series for 3M Modular Hardwire Blocks, 3M™ Self-Strip Blocks or 3M™ Quick Connect Systems

Instructions

June 2011 78-0013-1943-9-A

3

Table of Contents 1.0 General...........................................................................................................................................................3 2.0 Description.....................................................................................................................................................4 3.0 3M™ Modular Hardwire Interface 4365 Installation Instructions................................................................5 4.0 3M™ Modular Hardwire Interface 4382 Installation Instructions................................................................9 5.0 3M™ Modular Hardwire Interface 4384 and 4386 Installation Instructions..............................................10 6.0 3M™ Modular Hardwire Interface 4395 Installation Instructions..............................................................15 7.0 3M™ Modular Hardwire Block 4310-25 Splicing Instructions...................................................................18 8.0 Jumpering....................................................................................................................................................23 9.0 Accessories..................................................................................................................................................25 10.0 3M™ Self-Strip Terminating Block 4320 SS-25..........................................................................................29 11.0 Jumper Wire Installation and Routing of the 3M™ Quick Connect System QCS Blocks 2810................34 12.0 Accessories Installation of the 3M™ Quick Connect System QCS Blocks 2810......................................35



2 78-0013-1943-9-A

1.0 General A. Introduction

B. Pedestal and Pole-Mount Cabinets

1.1

The 3M™ Modular Hardwire Cabinets 4300 1.3 Series provide a point for cross connections between feeder and distribution cables of diameter 0.7 mm–0.32 mm (22–28 AWG). Frames within the cabinets hold banks of preconnectorized 25-pair feeder and distribution blocks. Blocks can either be installed initially or added at a later date with no disruption of existing circuits.

1.2

Jumpering is accomplished using 0.7 mm (22 AWG) plastic insulated wire which is run from 1.4 feeder binding posts to distribution binding posts. Wire raceways are provided for protection of all 1.5 jumper pairs as they are installed.

Product Illustration

Product Number

Type

Maximum Capacity

Opening Style

Block Banks

Due to the terminal sizes and frequency of installation visits, the cabinets should be located as specified by the engineering plan. The cabinets should be located in unobtrusive locations acceptable to the property owners and where they are reasonably protected from damage by motor vehicles and other machinery. They should be 1.5 m (5 feet) from utility poles and at least 0.3 m (1 foot) from buildings, fences, or other objects considered to be potential lightning attractions. The cabinets are constructed of galvanized steel with a gray/green baked enamel finish. The pedestal cabinets feature a ventilation system whereby the vents may be open or closed depending on local condensation conditions. Overall Dimensions

Final Packaging Above Ground Weight Height If Units Per Per Buried Carton Carton

Width

Depth

Height

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

4365

Pedestal*

200 pair

Hinged Doors Front

1 Front

267 (10 1/2)

191 (7 1/2)

1086 (42 3/4)

984 (38 3/4)

1

20.5 (45 1/2)

4382

Pedestal

600 Pair

Hinged Doors Front

1 Left 1 Right

264 (10 3/8)

318 (12 1/2)

1391 (54 3/4)

1238 (48 3/4)

1

45 (100)

4384

Pedestal

1200 Pair

Hinged Doors Front and Rear

3 Front 3 Rear

711 (28)

267 (10 1/2)

1168 (46)

1016 (40)

1

77 (168)

4386

Pedestal

1800 Pair

Hinged Doors Front and Rear

3 Front 3 Rear

711 (28)

267 (10 1/2)

1416 (55 3/4)

1264 (49 3/4)

1

83.7 (183)

4395

Pole

1200 Pair

Hinged Doors Front

6 Front

660 (26)

267 (10 1/2)

1648 (64 7/8)

–

1

58.5 (130)

* Pole Mount with 3M™ MS2™ Pole Mount Conversion Kit 4098

78-0013-1943-9-A 3

2.0 Description A. Modular Hardwire Interfaces (See Modular Hardwire Interface Description Chart) 2.1

3M™ Modular Hardwire Interface 4365 The 3M™ Modular Hardwire Interface 4365 is a 200-pair cabinet that can either be ground mounted or pole mounted (with 3M™ MS2™ Pole Mount Conversion Kit 4098). The cabinet includes a talk block, jumper wire spool mounting bracket, bond bar and space for 3-pair drop wire blocks, using the 3M™ Terminal Block Bracket 4064.

2.2

3M™ Modular Hardwire Interface 4382 The 3M™ Modular Hardwire Interface 4382 is a stake mounted pedestal cabinet holding 600-pair. The cabinet includes a talk block, jumper wire spool mounting bracket, external bond plate and space for 3-pair terminal blocks.

2.3

3M™ Modular Hardwire Interfaces 4384 & 4386 The 1200-pair 4384 and 1800-pair 4386 Modular Hardwire Interfaces can be either stake or slab mounted. The double sided cabinets have fold down frames for cable routing access and include a talk block, jumper wire spool mounting bracket, external bond pair and space for 3-pair drop wire blocks.

2.4

3M™ Modular Hardwire Interface 4395 The pole-mounted 3M™ Modular Hardwire Interface 4395 holds 1200 pair. Cable entry can be either through the top or bottom. The cabinet includes mounting brackets, talk block, jumper wire spool mounting bracket, external bond plate and space for 3-pair terminal blocks.

B. 3M™ Modular Hardwire Block 4310-25 (See Figure 1) 2.5

3M™ Modular Hardwire Interface 4365 The 3M™ Modular Hardwire Block 4310-25 contains 50 binding posts to accommodate 25 cable pairs. The blocks are preconnectorized to a 3M™ MS2™ Super Mini Module Body/Cover 4000 D. The right-ring-binding post is colored red on the otherwise white modular hardwire block. factory sealed rear connections are potted in resin for protection against moisture and other environmental hazards. The 3M Modular Hardwire Block 4310-25 NC is a white modular hardwire block with no connectors and color coded leads.



(SIDE VIEW)

NOTCH

TIP (WHITE–LEFT) RING (RED–RIGHT)

CUT CORNER

IDENTIFICATION TABS PAIR ONE

PAIR FIVE

PAIR 21

PAIR 25 (FRONT VIEW)

Figure 1: 3M™ Modular Hardwire Block 4310-25

4 78-0013-1943-9-A

3.0 3M™ Modular Hardwire Interface 4365 Installation Instructions A. Pole Mount Set-up

POLE 3M TOP POLE MOUNT BRACKET ™

3M™ MS2™ Pole Mount Conversion Kit 4098 (See Figure 2) 3.1

Remove front skirt and hinged panel for easy access.

3.2

Locate cabinet in desired position on pole.

3.3

Assemble A1, A2, and A3 to top pole mount bracket and tighten.

3.4

Attach top pole mount bracket assembly to pole with B1.

3.5

Assemble bottom pole mount bracket to cabinet with C1, C2, and C3.

3.6

Hang cabinet assembly on bolt A1, and secure with D1 and D2.

3.7

Screw E1 through cabinet, bottom pole mount bracket, and into pole.

3M™ CABINET 300-PAIR

B1

A1

A2 A3

D1 D2

C1 E1 3M BOTTOM POLE MOUNT BRACKET ™

C2 C3

Figure 2: Installation of 3M™ MS2™ Pole Mount Conversion Kit 4098

Cable Adapter – Top (See Figure 3) 3.8

Remove appropriate knockout.

3.9

Remove foam around inside of knockout hole for adapter nut clearance.

CABINET TOP

CABLE ADAPTER

3.10 Install cable adapter.

ADAPTER NUT

Figure 3: Cable Adapter Installation

Bottom Plate and Cable Adapter 3.11 Attach bottom plate with nuts and bolts provided. 3.12 Tighten securely.

ADAPTER NUT

3.13 Install cable adapter.

ROUND HEAD SLOTTED SCREW

BOTTOM PLATE

CABLE ADAPTER

Figure 4: Bottom Plate and Cable Adapter Installation 78-0013-1943-9-A 5

B. Pedestal Set-up 3.14 Carefully remove earth from around cables according to the table at right.

Note: Uncover cables sufficiently to definitely establish their location so anchor stakes will not injure them.

3M™ Cabinet

Length mm (in.)

Width mm (in.)

Depth mm (in.)

4365 (200-Pair)

305 (12)

457 (18)

457 (18)

3.15 Open doors on cabinet assembly. Cabinet has a removable hinged panel and base assembly for easy access. 3.16 Fill excavation with coarse gravel to within 102 mm (4 in.) of ground level. 3.17 Place cabinet over cables in a vertical position with cabinet centered in excavation. 3.18 Place anchor stake (optional) to rear of cabinet. (Protect stake top with wood block to prevent damage while driving.) (See Figure 5.)

REAR OF CABINET

STAKE Figure 5: Anchor Stake Installation 3.19 Using a sledge, drive until stake top is 406 mm (16 in.) above ground level. (See Figure 6.)

Note: Do not hammer on cabinet to drive stake into ground.

406 mm (16 in.)

508 mm (20 in.) GROUND LINE

Figure 6: Anchor Stake in Place 3.20 Secure anchor stake to rear of cabinet with 3/8" × 1" bolts and nuts provided. (See Figure 7.) 3.21 Fill cabinet base with pea gravel to within 102 mm (4 in.) of top of skirt. Figure 7: Secured Anchor Stake

6 78-0013-1943-9-A

C. Cable Preparations Top Entry (See Figure 8)

VINYL TAPE

3.22 Insert cable leaving 1.8 m (6 feet) stub length. 3.23 Tighten adapter nut securely. 3.24 Secure adapter on cable with three half-lapped layers of vinyl plastic tape. 3.25 Secure cable to tab in rear of cabinet top using standard hose clamp.

HOSE CLAMP

3.26 Install bond clamp per standard procedure. 3.27 Attach bonding strap to bond bar.

Note: Do not clamp cable to pole any closer than 305 mm (12 in.) from top of cabinet.

1.8 m (6 in.) FREE CONDUCTOR

Figure 8: Cable Preparation – Top Entry

Bottom Entry

1.8 m (6 in.) FREE CONDUCTOR

(See Figure 9) 3.28 Insert cable leaving 1.8 m (6 feet) stub length. 3.29 Secure adapter on cable with three half-lapped layers of vinyl plastic tape. 3.30 Bond and secure cables to bond bar. 3.31 Attach bonding strap directly to bond bar.

VINYL TAPE

Figure 9: Cable Preparation – Bottom Entry

78-0013-1943-9-A 7

D. Cable Routing Top Entry Cable Routing

Figure 10: Cable Routing – Top Entry

Bottom Entry Cable Routing

Figure 11: Cable Routing – Bottom Entry

E. Splicing 3.32 See Section 7.0 for 3M™ Modular Hardwire Block 4310-25 splicing instructions and Section 8.0 for Jumpering instructions.



8 78-0013-1943-9-A

4.0 3M™ Modular Hardwire Interface 4382 Installation Instructions A. Initial Set-up (See Figure 12)

Ground Mount

4.1

Open cabinet doors.

4.2

Remove the two frame bolts and lift frames up and out of hinges.

4.3

Carefully remove earth from around cable as follows:

Side View of 3M™ Modular Hardwire Interface 4382 Ground Mount Installation

Pea Gravel Cabinet

Length mm (in.)

Width mm (in.)

Depth mm (in.)

4380 (400-Pair)

457 (18)

457 (18)

457 (18)

4382 (600-Pair)

457 (18)

457 (18)

457 (18)

4.4

Fill excavation with coarse gravel to within 153 mm (6 in.) of ground level.

4.5

Place cabinet over cables in a vertical position with cabinet centered in excavation.

102 mm (4 in.)

Figure 12: Side View of 3M™ Modular Hardwire Interface 4382 Ground Mount Installation 4.6

Place another stake next to cabinet side. (Protect stake tip with wood block to prevent damage while driving.) See Figure 13.

4.7

Using a sledge, drive until stake top is at ground level. Repeat on opposite side.

REAR OF CABINET

STAKE Figure 13: Anchor Stake Installation

Note: Do not hammer on cabinet to drive stake into ground. 4.8

Align and secure anchor stakes to cabinet with 3/8" × 1" bolts and nuts provided. See Figure 14.

Figure 14: Secured Anchor Stake

B. Cable Preparations (See Figure 15) 4.9

Remove sheath leaving 1.8 m (6 feet) of free conductor measuring from top of tie bar.

4.10 Place moisture block and bond according to standard procedure. 4.11 Secure cable to vertical tie bar. 4.12 Attach bond strap to bonding plate.

MODULE RETAINER

VERTICAL TIE BARS

FRAME

4.13 Plug ducts per standard procedure. 4.14 Fill cabinet base with pea gravel to within 101.6 mm (4 in.) of top of skirt.

Note: Attach 50-pair groups securely with tie wraps to the bottom of the module retainer

BOND STRAP BONDING PLATE

TIE BAR

Figure 15: Cable Preparations and Cable Routing 78-0013-1943-9-A 9

C. Cable Routing 4.15 Replace frames. 4.16 To maintain adequate slack, attach 50-pair groups to module retainer bars with frame in FULLY OPENED position. 4.17 Close frame and secure at top and bottom.

D. Splicing 4.18 See Section 7.0 for 3M™ Modular Hardwire Block 4310-25 splicing instructions and Section 8.0 for Jumpering instructions.

5.0 3M™ Modular Hardwire Interfaces 4384 & 4386 Installation Instructions A. Initial Set-up (See Figure 16) 5.1

Open side of cabinet opposite bond bar.

5.2

Remove doors. Remove the four skirt bolts, and remove cabinet skirt assembly.

5.3

Remove frame screws to lower frame and detach chains.

FRAME

SKIRT ASSEMBLY

BOND BAR

Figure 16: 3M™ Modular Hardwire Interfaces 4384 & 4386 5.4

Remove frame as shown in Figure 17.

3 1

2

4

Figure 17: Frame Removal

B. Cabinet Mounting 5.5

Attach cabinet either to the 3M™ Stake Mount 4056 S (see Part 1) or the 3M™ Mounting Ring Kit 4056 (see Part 2).

1. 3M™ Stake Mount 4056 S 5.6

Carefully remove earth from around cables per the table at right.

Length mm (in.)

Width mm (in.)

Depth mm (in.)

1016 (40)

508 (20)

305 (12)

10 78-0013-1943-9-A

5.7

Fill excavation with pea gravel to within 150 mm (6. in.) of ground level. See Figure 18.

150 mm (6 in.)

Figure 18: Cabinet Excavation

5.8

Place cabinet over cables and center on excavation. See Figure 19.

Figure 19: Center Cabinet in Excavation

Place an anchor stake next to cabinet side. (Protect stake top with a wood block to prevent damage while driving.) See Figure 20. SIDE OF CABINET

5.9

WOOD BLOCK STAKE

Figure 20: Anchor Stake in Position

5.10 Using a sledge, drive until stake holes are aligned with appropriate holes in support column. (Protect stake top with a wood block to prevent damage while driving. See Figure 21.) Repeat for opposite side. 5.11 Align and secure anchor stakes to cabinet with 3/8" × 1" bolts provided.

Figure 21: Anchor Stakes Secured to Cabinet 78-0013-1943-9-A 11

5.12 Remove the doors and the cabinet skirt. See Figure 22.

Figure 22: Cabinet Skirt Removed

2. 3M™ Mounting Ring Kit 4056 5.13 Excavate slab site to a depth of 300 mm (12 in.) below ground level allowing for slab dimensions of 1.8 m (6 feet) × 1.8 m (6 feet). See Figure 23.

GROUND 1.8 m (6 ft.)

300 mm (12 in.)

5.14 Set forms for a 1.8 m (6 feet) × 1.8 m (6 feet) × 102 mm (4 inch) slab.

Figure 23: Excavation

Note: Construct forms so that slope of slab from center is at the rate of 6 mm per running meter (1/4-inch per running foot). 5.15 Fill excavation with pea gravel to within 100 mm (4 in.) of ground level. See Figure 24.

PEA GRAVEL 100 mm (4 in.)

Figure 24: Excavation Filled

5.16 Attach concrete inserts and support legs to the mounting ring with 1/2" × 1" bolts provided. See Figure 25.

MOUNTING RING

4056 SUPPORT LEGS WASHERS

CONCRETE INSERTS M12 × 25.4 mm (1/2" × 1") BOLTS

Figure 25: 3M™ Mounting Ring with Support Legs and Concrete Inserts

12 78-0013-1943-9-A

5.17 Nail wood stakes to mounting ring for ease in leveling. Center mounting ring in slab excavation and level. Nails must be cut off after wooden stakes are removed. See Figure 26.

WOOD STAKES

5.18 Place concrete reinforcing rods or wire mesh in slab area. 5.19 Pour and finish slab.

Figure 26: Leveling Mounting Ring

5.20 Wipe excess concrete from top surface of mounting ring. See Figure 27.

6 mm SLOPE PER RUNNING METER (1/4 in. PER RUNNING FOOT) SUPPORT LEGS MOUNTING RING

Figure 27: 3M™ Mounting Ring Poured

5.21 To position cable ducts in mounting ring, rest ducts up against side of ring and hold in position by placing a cable tie around duct and through positioning holes. Ducts should be positioned so TOP of duct is level with TOP surface of mounting ring. See Figure 28.

CABLE DUCTS MUST BE PLUGGED

DUCT POSITIONING HOLES

Figure 28: Cable Ducts in Place

3. Cable Preparations 5.22 FILLED CABLE. Remove sheath leaving 2.1 m (7 feet) of free conductor beyond top of bond bar. 5.23 AIR CORE CABLE. Place moisture block and bond according to standard procedure. Leave 2.1 m (7 feet) of free conductor above moisture block. Attach bond to bonding plate. See Figure 29.

Caution: Leave enough slack in bond straps to allow passage through opening in skirt plate.

78-0013-1943-9-A 13

Figure 29: Bond Straps Installation

Note: Moisture block should not extend beyond top of bond bar. See Figure 30. Caution: Sheath opening or moisture block should not extend beyond top of bond bar.

BONDING PLATE

BOND BAR

Figure 30: Moisture Block 5.24 Plug ducts per standard procedure. 5.25 Replace cabinet skirt making sure skirt fits UNDER cabinet doors. Replace four skirt bolts and replace doors. 5.26 Fill cabinet base with pea gravel to within 100 mm (4 in.) of top of skirt.

4. Cable Routing 5.27 Reinstall frame and chains. See Figure 31.

Note: Attach binder group securely to bottom of horizontal tie braces. Figure 31: Cable Routing 5.28 Route 50-pair binder groups as shown.

Note: When routing to adjacent frame, ALWAYS go up and over to splice location (use tie wraps at 90º turn and at splice location). See Figure 32.

TIE WRAPS

Figure 32: Frame Routing 14 78-0013-1943-9-A

5.29 Close frame and secure with screws at top. 5.30 Replace cover plate.

5. Splicing 5.31 See Section 7.0 for 3M™ Modular Hardwire Block 4310-25 splicing instructions and Section 8.0 for Jumpering instructions.

6.0 3M™ Modular Hardwire Interface 4395 Installation Instructions A. Initial Set-up 6.1

Remove top or bottom cover plate depending on cable entry. See Figure 33. TOP COVER PLATE

CENTER FRAME MOUNT PLATE

BOTTOM COVER PLATE

Figure 33: Remove Cover Plate

6.2

Mount top pole mount bracket according to standard procedure. Use cable suspension bolt. See Figure 34.

6.3

Hang cabinet.

Figure 34: Top Pole Mount Bracket

78-0013-1943-9-A 15

6.4

Attach 3M™ Bottom Pole Mount Brackets. See Figure 35.

BOTTOM POLE MOUNT BRACKETS

Figure 35: Attach Bottom Pole Mount Brackets

B. Cable Preparations 6.5

Cables should enter cabinet through ports directly in line with appropriate frame. If only a single cable is to be terminated, place cable in center port to provide the best protection for cable.

Note: The 3M™ Split Gland Kit 4097 is available for sealing cable entrance in top or bottom of pole mount cabinets. 6.6

The preferred method is to mount the feeder cable in center frames and mount distribution cables in outer frames.

6.7

Remove sheath and shield flush with cable tie bar. Leave minimum of 2.1 m (7 feet) of free conductor. See Figure 36.

6.8

Install shield connecter per standard procedure.

6.9

Secure cable to tie bar using hose clamp.

2.1 m (7 ft.) FREE CONDUCTOR CABLE TIE BAR

COVER PLATE

6.10 Identify binder groups. 6.11 Remount cover plate.

Note: Pull bonding strap through grommets in cover plate. Figure 36: Cable Preparations

16 78-0013-1943-9-A

6.12 Attach bonding strap to bond plate and enter cable bond position on binding post log. See Figure 37.

COVER PLATE

BOND PLATE

Figure 37: Attach Bonding Strap to Bonding Plate

C. Cable Routing (See Figure 38) 6.13 Route binder groups to desired frame location. Groups should be placed UNDER the center frame mount plate. 6.14 Secure all conductors appearing at each tie wrap location. Use standard cable ties. 6.15 At each tie wrap location drop off the conductors to be spliced (Two 25-pair standard Modular Hardwire Blocks are spliced at each tie point).

CENTER FRAME MOUNT PLATE

Figure 38: Cable Routing

D. Splicing 6.16 See Section 7.0 for 3M™ Modular Hardwire Block 4310-25 splicing instructions and Section 8.0 for Jumpering instructions.

78-0013-1943-9-A 17

7.0 3M™ Modular Hardwire Block 4310-25 Splicing Instructions 7.1

Loosen screws under 3M™ Splicing Head and slide head onto adapter. Tighten screws. See Figure 39.

Note: Set 3M Retainer Spring to proper wire gauge.

3M™ MS2™ SUPER MINI ADAPTER PLATE

3M™ SPLICING HEAD 3M™ RETAINER SPRING 3M™ MODULAR HARDWARE SPLICE HEAD ADAPTER (4344)

Figure 39: 3M™ Splice Head Adapter Assembly

7.2

Attach splice head assembly to second position of frame as shown. Top tabs of adapter are positioned inside frame and bottom prongs are inserted into the mounting holes. Two blocks are spliced at the 2nd, 4th, 6th, 8th, etc. position. See Figure 40.

Figure 40: 3M™ Splice Head Adapter Assembly in Frame

7.3

Position 3M™ MS2™ Super-Mini adapter plate in splice head. See Figure 41.

Figure 41: Place 3M™ Adapter Plate in 3M™ Splice Head

18 78-0013-1943-9-A

7.4

Place the gold base into adapter with cut corner to LEFT and AWAY from craftsman. See Figure 42.

7.5

Holding group behind head with guide hand, use thumb and forefinger to place each pair in the wire guide to the right of its matching color and split the pair over the pair separator, tip – left, ring – right.

GOLD BASE

Figure 42: Place Base in 3M™ Splice Head 7.6

Once pair is spearated tip – left, ring – right, release pair with guide hand, draw pair up snug to back of head and place the conductors into the wire channels of base and into wire retainer spring. See Figure 43. Posts in center of module base are marked BLACK. Pairs must separate over these black marks (tip – left, ring – right).

7.7

After 25-pair are in place, check to see that all wires are completely in each channel.

Figure 43: Laying Wires into Base Channels 7.8

Check the conductors for wire order with the 3M Check Comb. Place the comb over the base and slide it to the left: only the TIP conductors should show. Slide the comb to the right: only the RING conductors should show. Also check for two conductors in one channel and for vacant channels. See Figure 44.

Figure 44: Checking TIP and RING Conductor Order with 3M™ Check Comb 7.9

Position 3M™ Modular Hardwire Block and attached 3M™ MS2™ Super-Mini Body/Cover as follows: a)

Fold and position wires to Super-Mini Body/ Cover as shown to avoid interference with crimping bar. See Figure 45.

b)

Rest Modular Hardwire Block on support tray.

SUPPORT TRAY

Figure 45: 3M Modular Hardwire Block Positioned in 3M™ Splice Head ™

78-0013-1943-9-A 19

7.10 Place 3M™ Crimping Unit on 3M Splicing Head; hose can be either left or right. Pins on inside edge of clamp nest in pin pockets on splicing head as clamp is placed at an angle on head with legs of clamp pointing out towards front of head. See Figure 46.

Figure 46: Positioning 3M™ Crimping Unit on 3M™ Slicing Head

7.11 Rotate the crimping unit until it is locked by the detents in an upright position. See Figure 47. If the detents are either too tight or too loose they may be adjusted from the side with a screwdriver.

ADJUSTABLE DETENTS

Figure 47: Rotating 3M™ Crimping Unit to Upright Position

7.12 If the Air/Hydraulic crimping unit is used, operate the PRESS/RELEASE control to the PRESS position and hold until the pressure bypass is heard to operate. See Figure 48. This signifies a completed crimp. Leave crimping clamp closed until the cut conductors are removed.

PRESS TO RELEASE PRESS TO CRIMP

Figure 48: Operating 3M™ Air/Hydraulic Crimping Unit

7.13 If the 3M Hand/Hydraulic Crimping Unit is used, close the pressure release valve and operate pump until pump bypasses and module appears to be closed, then pump five more times. See Figure 49. Watch for the conductors being cut. Leave the crimping clamp closed until the cut conductors are removed.

PUMP TO CRIMP

TURN TO RELEASE

Figure 49: Operating 3M™ Hand/Hydraulic Crimping Unit

20 78-0013-1943-9-A

7.14 Remove the cut conductor ends by grasping approximately one-third to one-fourth of the ends and gently lifting them straight up from the retainer spring. See Figure 50. TO AVOID DAMAGING THE RETAINER SPRING, DO NOT ATTEMPT TO REMOVE ALL THE CONDUCTORS AT ONCE. If a gentle pull does not remove the ends, the crimp may not be complete or a conductor may not be in its wire channel.

Figure 50: Removing Cut Wires

7.15 Remove clamp from head by rotating legs of clamp toward front of head and lifting off. See Figure 51.

Figure 51: Removing Crimping Clamp

7.16 Insert module into 3M™ MS2™ Sealant Box and press into sealant as far as possible. See Figure 52.

Figure 52: Inserting Module into 3M™ MS2™ Sealant Box

7.17 Install Insertion Tool. Lift insertion tool wings to press module completely into 3M MS2 Sealant Box. See Figure 53.

Figure 53: Lift Wings

78-0013-1943-9-A 21

7.18 Snap latches on ends of 3M™ MS2™ Sealant Box to lock module into place. See Figure 54. Remove tool.

Figure 54: Snap Latches 7.19 Remove 3M Splcing Head Adapter Assembly and screw 3M Modular Hardwire Block to frame using Allen Wrench included with blocks. See Figure 55. ™

PROTECTIVE TAPE

Figure 55: Mount 3M™ Modular Hardwire Block in Frame

7.20 Always place cut corner and notch in upper left. See Figure 56.

CUT CORNER

NOTCH

IDENTIFICATION LABEL PADS

Figure 56: Cut Corner & Notch in Upper Left

7.21 When placing modules in frame, fold and position module behind block as shown in Figure 57.

1

2

7.22 Splice the first two blocks in the second frame position. Move the splice head adapter assembly down to the fourth frame position and splice two more blocks, repeating above splicing procedure. Repeat procedure at sixth, eighth, etc. frame position until frame is full.

3

4

5

6

7.23 After ALL blocks are mounted, remove protective tape from identification pads on the blocks. Figure 57: Module Position Behind Blocks

22 78-0013-1943-9-A

7.24 Select proper sequence of labels (blue – distribution, green – feeder) and detach strip of 20 labels from sheet. These 3M™ Identification Labels 4379 are provided within envelope on cabinet door.

Note: 1-6-11 etc. are attached to left side of block and 5-10-15 etc. are attached to the right side of block. a)

Carefully remove protective backing from strip as shown in Figure 58. Figure 58: Remove Backing

b)

Align strip of numbers with 3M Modular Hardwire Block Identification Pads and press in place. Carefully remove top premask leaving labels on pads. See Figure 59.

Figure 59: Positioning Labels

3M™ Modular Hardwire Block Number 4310-25 NC (white) 7.25 Splice per standard procedure taking care that positioning of connectors and excess wire will permit closing of frame.

8.0 Jumpering A. Running Jumper Wires 8.1

Pull wire from 3M™ Jumper Wire Spool 4368 to Feeder Block (green labels on tabs).

8.2

Split pair TIP – left, RING – right at the assigned binding post. Strip wire ends. See Figure 60.

TIP LEFT

RING RIGHT PAIR 1

PAIR 5

PAIR 21

PAIR 25

51 mm (2 in.) SLACK LOOP

51 mm (2 in.) SLACK LOOP

Figure 60: Split Pairs TIP–Left, RING–Right 8.3

Wrap wires between washers in a CLOCKWISE direction. Single wrap each jumper and trim excess wire. See Figure 61.

Caution: Excessive tightening of screw breaks wire.

78-0013-1943-9-A 23

WRAP CLOCKWISE SINGLE WRAP

Figure 61: Wrap Wire

8.4

Lay jumpers into runway between binding posts. See Figure 62. Leave a 51 mm (2 in.) slack loop in each jumper. See Figure 63.

3M™ Priority Circuit Caps 4314

Note: Push on 3M™ Priority Circuit Caps 4314 available to designate and insulate priority circuits. RUNWAYS

Figure 62: Lay Jumpers in Runway

51 mm (2 in.) SLACK LOOP

Figure 63: 51 mm (2 in.) Slack Loop in Jumpers 8.5

Route jumpers to assigned distribution block (blue label on tabs). Attach jumpers to assigned binding post leaving a 51 mm (2 in.) slack loop.

A. Routing Jumper Wires 8.6

JUMPER ROUTING FOR ALL CABINETS: Route jumper wires in horizontal channels between binding posts of 3M Feeder Block to the jumper runway. Slip wires behind identification pads and route along appropriate runways to binding posts of distribution block. LEAVE 51 mm (2 in.) OF SLACK AT EACH END OF JUMPER.

8.7

3M™ Modular Hardwire Interface 4365 – Route jumpers as above.

8.8

3M™ Modular Hardwire Interface 4382 – To route jumpers from left side to right side, see Figure 64.

LEFT SIDE

RIGHT SIDE

Figure 64: 3M™ Modular Hardwire Interface 4382 Jumper Wire Routing

24 78-0013-1943-9-A

8.9

3M™ Modular Hardwire Interface 4384 & 4386 – To route jumpers from one side to the other, cross through jumpering tunnel as shown in Figure 65.

FRAME DOWN

JUMPERS

JUMPERING TUNNEL

Figure 65: 3M™ Modular Hardwire Interface 4384 and 4386 Jumper Wire Routing 8.10 3M™ Modular Hardwire Interface 4395 – To route jumpers from one bank to another, see Figure 66.

Figure 66: 3M™ Modular Hardwire Interface 4395 Jumper Wire Routing

9.0 Accessories A. 3M™ Controlled Feeder Block 4311 (Green) 1. Controlled Feeder Block Description 9.1

The 25-pair binding post Controlled Feeder Block contains 50 binding post tereminal switches. The terminal post pulled OUT to the locked position express the feed cable through the cabinet with no local termination. See Figure 67

Figure 67: Terminal Post OUT, Feed Thru

78-0013-1943-9-A 25

9.2

When the terminal post is pushed IN to the locked position, the feed is then terminated. See Figure 68.

9.3

The feeder cable is spliced to the black preterminated conductors (3M™ MS2™ Super Mini Body/Cover 4000 D) and the field cable is spliced to the white preterminated conductors (3M™ MS2™ Super Mini Body/Cover 4000 D). The right-ringbinding post is colored red on the otherwise green 3M Controlled Feeder Modular Hardwire Block. Factory sealed rear connections are potted for protection against moisture and other environmental hazards. The Controlled Feeder Binding Post Blocks are identical in size to the standard 25-pair hardwire block and can be used in any of the standard pedestal and pole mount cabinets.

Figure 68: Terminal Post IN, Feed Terminated

2. Cable Routing 9.4

Cable routing modification for controlled feeder block: The 50-pair feed in cable and the 50-pair feed out cable are tied at the same point on module retainer tie bar of cabinet.

3. Controlled Feeder Block Splicing Instructions 9.5

Splicing controlled feeder blocks is the same as splicing modular hardwire blocks EXCEPT feed in and feed out cable must be spliced for each controlled feeder block.

9.6

Begin splicing procedure by following Section 7.0 paragraphs 1 through 4.

9.7

Splice FEED IN (Black) TAIL first. Holding groups behind head with guide hand, use thumb and forefinger to place each pair in the wire guide to the right of its matching color and splite the pair over the pair separator, TIP – left, RING – right. See Figure 69.

9.8

Splice and crimp conductors according to Section 7.0, paragraphs 6 through 15.

9.9

After FEED IN (Black) TAIL is spliced to 'feed in' module, splice FEED OUT CABLE to 'feed out' module, following the procedure outlined in Section 7.0 paragraphs 5 through 15.

9.10 Insert modules into 3M™ MS2™ Sealant Boxes according to Section 7.0 paragraphs 16 through 18.

Figure 69: 3M™ Controlled Feeder Block 4311 Positioned in Splice Head

26 78-0013-1943-9-A

9.11 Remove 3M™ Splicing Head Adapter Assembly and attach 3M Controlled Feeder Block to frame. See Figure 70.

Figure 70: Mount 3M™ Controlled Feeder Block 4311 in Frame

9.12 Always place cut corner and notch in the upper left. See Figure 71.

CUT CORNER

NOTCH

IDENTIFICATION LABEL PADS

Figure 71: Cut Corner and Notch in Upper Left

9.13 When placing modules in frame, fold and position module behind block as shown in Figure 72.

Note: Controlled feeder blocks are to be mounted ONLY in labeled location in each hardwire cabinet. 9.14 Finish Splicing Procedure according to Section 7.0 paragraphs 22 through 24.

1

2

3

4

5

6

Figure 72: Module Position Behind Block

78-0013-1943-9-A 27

B. 3M™ Four Party Bunch Block 4312 (Yellow) (See Figure 73)

Figure 73: 3M™ Four Party Bunch Block 4312

1. 3M™ Four Party Bunch Block 4312 Description 9.15 The 3M™ Four Party Bunch Block 4312 consists of five horizontal pairs tied together (one in and four out). (See Figure 74.) Identical in size to the standard 25-pair Modular Hardwire Block, the Four Party Bunch Block can be used in any of the standard pedestal and pole mount cabinets. The right-ring-binding post is colored red on the otherwise yellow Modular Hardwire Block. Each block has factory sealed rear connections that are potted in resin for protection against moisture and other environmental hazards.

Figure 74: Wiring Diagram, 3M™ Four Party Bunch Block 4312 (Label furnished with block)

2. 3M Four Party Bunch Block Installation Instructions 9.16 Mount four party bunch block at desired location in modular hardwire cabinet.

3M™ Specialty Block 4313 (Yellow) (See Figure 75)

Figure 75: 3M™ Specialty Block 4313

1. Specialty Block Description 9.17 The 3M Specialty Block 4313 is identical to the standard modular hardwire block except for the color coded 915 mm (36 inch) leads. The block can be used as a bridge lifter (see Figure 76), for load coils, capacitors, etc. The right-ring-binding post is colored red on the otherwise yellow modular hardwire block. Each block has factory sealed rear connections that are potted in resin for protection against moisture and other environmental hazards.

Figure 76: Wiring Diagram, Bridge Lifter (Label furnished with block)

28 78-0013-1943-9-A

2. 3M™ Specialty Block Installation Instructions 9.18 Splice pairs per standard procedure taking care that positioning of connectors and excess wire will permit closing of frame. 9.19 Mount block at desired location in cabinet.

10.0 3M™ Self-Strip Terminating Block 4320 SS-25 A. General 10.1 The 3M™ Self-Strip Terminating Block 4320 SS-25 is a factory stubbed, self stripping connecting block designed for 22 (0.6 mm) and 24 (0.5 mm) gauge jumper wire. The self strip caps automatically connect and trim the jumper wire with a 90º turn of the cap. The 4320 Blocks are dimensionally compatible with all pedestal and pole mount cabinets used in the 3M™ Modular Hardwire System 4310. 3M™ Self-Strip Terminating Block 4320 SS-25

3M™ Self-Strip Terminating Block 4320 SS-25 Pair Test Connector

B. Accessories

3M™ Self-Strip Pair Probe 4327

C. Running Jumper Wires 10.2 Pull Jumper wire from spool 24 AWG (0.5 mm) or 22 AWG (.6 mm) to feeder block. (Green labels on tabs.) 10.3 Split pair (TIP – left, RING – right) at the assigned cap position. Wire ends SHOULD NOT be stripped.

78-0013-1943-9-A 29

3M™ Self-Strip Priority Cap 4324

10.4 Form 90º hook on end of jumper wire as shown. Make sure wires have clean cut ends.

13 — 19 mm (1/2 in.—3/4 in.)

10.5 Make sure assigned caps are in the preinsertion position with the screwdriver slot oriented vertically.

SCREWDRIVER SLOT ENTRY PORT

ENTRY PORT

Preinsertion Cap Position

10.6 Insert wire into entry port and through the cap until the wire is visible from the exit port.

10.7 Insert screwdriver in cap slot and rotate 90º clockwise until you FEEL the cap come to rest against the stop. As the cap rotates, the wire is simultaneously connected and trimmed off.

90º

Note: Make sure the screwdriver blade is fully inserted into cap slot before rotating. Unconnected Position

Connected Cap Position

30 78-0013-1943-9-A

10.8 Always route jumper wires BELOW the connected cap.

Right—Ring (orange)

Tip—Left (tan)

Pair 1

Pair 21 50 mm (2 in.) Slack Loop Pair 5

Pair 25 50 mm (2 in.) Slack Loop

10.9 Lay jumper wires into runway between self strip caps. Push the jumpers down into the runway below the connection ports.

Connection Ports

10.10 Route jumper wires to assigned distribution block and pair. Cut wires to a length allowing 50 mm (2 in.) of slack. Form jumper wires and insert per Sections 10.4 through 10.7. 10.11 Again route jumper wires into channel BELOW the connected caps and form slack loop in jumper channel.

3M™ Self-Strip Priority Cap 4324

90º

10.12 Removing Jumper wire: Rotate cap 90º counter clockwise until you FEEL the cap come to rest against the stop. Remove jumper wire from port. The cap is now ready to accept a new jumper wire.

Note: If reinserting the same jumper wire, cut the wire end before insertion to avoid the original point of connection.

(Cut here if reinserting)

Connected Position

Removed Jumper Wire

Disconnected and Preinsertion Cap Position

78-0013-1943-9-A 31

D. Accessory Usage 3M™ Self-Strip Priority Circuit Caps 4324 10.13 4324 SS Caps are available to designate and isolate priority circuits. The holes in the cap permit partial insertion but NO electrical contact, when using either the 3M™ Self-Strip Test Connector 4328 or the 3M™ Self-Strip Pair Probe 4327. a) Insert extended legs between tip and ring caps until they snap under the cap head. One priority cap covers a full pair.

3M™ Priority Circuit Cap 4324 Legs

3M™ Priority Circuit Cap 4324

3M™ Self-Strip Pair Probe 4327 10.14 The 3M™ Self-Strip Pair Probe 4327 provides electrical access to a pair of 3M™ Self-Strip 4320 contacts.

Tip Cap

Ring Cap (Orange)

Cap Test Ports

a) Align pair probe as shown.

Tip

Ring

b) Insert pins in test ports. Depress spring loaded clamps sufficiently to allow clearance over cap heads.

32 78-0013-1943-9-A

c) Release and position fingers behind clamps. Push pair probe forward until the clamps snap behind the cap’s head.

Note: 3M™ Self-Strip Priority Caps 4324 prevent unauthorized (test probe) access.

c) Remove probe by depressing clamps clear of the cap head and pulling pair probe clear of the caps.

3M™ Self-Strip Pair Test Connector 4328 10.15 The 3M™ Self-Strip 25 Pair Test Connector 4328 provides access for test equipment to the 3M™ SelfStrip Terminating Block 4320. The test connector connects to test equipment with a female Cinchtype connector.

Attaching the Test Connector a) Remove the plastic protector cover. b) Holding the test connector around the rear cord strain relief, swing the handles out and push clamps to forward position.

c) Align the test connector in front of the block to be tested. Make sure the test connector is right side up (label up). Push in the test connector to compress the test pins against the elements in the caps. Slide the extended clamps under and against the inside of the block tabs.

Note: 3M™ Self-Strip Priority Caps 4324 allow self strip block to be tested with the test connector, making connections to all circuits except those with priority caps in place. The holes in the cap permit partial insertion (no electrical contact) into special circuit ports. d) Swing in the handles to lock the test connector in contact with the block.

78-0013-1943-9-A 33

Snap Catch Behind Head

e) Attach the test connector to test equipment and test block per standard procedure.

Removing the Test Connector a) Swing handles out and apply pressure at the sides of the base of each clamp. This will detach the clamps from the block tabs.

11.0 J umper Wire Installation and Routing of the 3M™ Quick Connect System QCS Blocks 2810 11.1 Open feeder pair jumper cap by pushing up on latch and rotating up. Insert jumper wire ends A (tip) left and B (ring) right into wire openings in cap, making sure they are inserted all the way to the back of the cap.

11.2 While holding the jumper wires in place, close the cap and press to snap latch firmly into place.

11.3 Route jumper wires to distribution pair through wire loops on block ends and through vertical and horizontal wireways. Cut jumper wires to appropriate length, leaving at least 5 cm (2 inches) of slack. 11.4 Terminate the jumper wires to the distribution pair by repeating the procedure. 11.5 Terminate additional jumper wires by repeating the above procedure.

34 78-0013-1943-9-A

11.6 To remove jumper wires, open the cap and pull wires straight out from block.

12.0 A  ccessories Installation of the 3M™ Quick Connect System QCS Blocks 2810 12.1 Plug the 3M™ Pair Test Probe 2827 into the cap of the pair being tested, with the black lead to the left and the red lead to the right.

12.2 To install 3M Priority Circuit Markers, place over the jumper cap of the pair to be marked and push it into place. Latching is indicated by an audible snap.

78-0013-1943-9-A 35

3M and MS2 are trademarks of 3M Company. Important Notice All statements, technical information, and recommendations related to 3M’s products are based on information believed to be reliable, but the accuracy or completeness is not guaranteed. Before using this product, you must evaluate it and determine if it is suitable for your intended application. You assume all risks and liability associated with such use. Any statements related to the product which are not contained in 3M’s current publications, or any contrary statements contained on your purchase order shall have no force or effect unless expressly agreed upon, in writing, by an authorized officer of 3M. Warranty; Limited Remedy; Limited Liability. This product will be free from defects in material and manufacture for a period of one (1) year from the time of purchase. 3M MAKES NO OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. If this product is defective within the warranty period stated above, your exclusive remedy shall be, at 3M’s option, to replace or repair the 3M product or refund the purchase price of the 3M product. Except where prohibited by law, 3M will not be liable for any indirect, special, incidental or consequential loss or damage arising from this 3M product, regardless of the legal theory asserted.

3 Communication Markets Division 6801 River Place Blvd. Austin, TX 78726-9000 1-800-426-8688 www.3MTelecommunications.com

Please Recycle. Printed in USA. © 3M 2011. All Rights Reserved. 78-0013-1943-9-A