Condux Deluxe Blower User Manual
USER'S GUIDE & SAFETY MANUAL
Deluxe Blower
Patent # 6264171
Important Safety Notice
Read and understand all procedures and safety instructions before using the Deluxe Blower. Observe all
safety information on this page and note specific safety requirements as explained by procedures in this
manual. Failure to follow these instructions could result in serious personal injury or death.
ADVERTENCIA:
Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si
Ud. no comprende las instrucciones favor de consultarle a su jefe.
READ MANUAL
FIRST
Save this user’s guide for future reference.
COMMUNICATIONS WITH THE MANUFACTURER
For any information related to the machine (use, maintenance, spare parts) always state Model, Serial
Number, Manufacturing Year and Order. This data can be found in the machine identification table.
Manufacturer:
Condux International Inc.
145 Kingswood Drive
Mankato, MN 56002-0247
1-507-387-6576
Fax 1-507-387-1442
Internet: http://www.condux.com
E-mail: cndxinfo@condux.com
If you have questions on:
SAFETY - OPERATIONS - APPLICATIONS
CALL 1-800-533-2077
2
Table of Contents
General Information ..........................................................................4
1
Technical Specifications ......................................................................6
2
A. Hydraulic ..........................................................................6
B. Condition of Use ....................................................................6
C. Air Compression Requirements ........................................................6
D. Operational Capacities ...............................................................8
E. Electronic Control Box ...............................................................8
F. Physical Specifications ...............................................................8
G. Acoustic Emission ..................................................................8
H. Caterpillar Drive Specifications .........................................................8
I. Conduit Coupling Requirements ........................................................8
Safe Operating Procedures ....................................................................9
3
A. Work Area Safety ...................................................................9
B. Hydraulic Devices ...................................................................9
C. Pneumatic Devices ..................................................................9
D. Electric Devices ....................................................................10
Unpacking the Deluxe Blower .................................................................10
4
A. Blower Components ................................................................10
B. Tools and Materials .................................................................10
Set Up the Blower ..........................................................................11
5
A. Attach Blower to Job Box ............................................................11
6
Cable Crash Test ...........................................................................12
Pressure Test Conduit .......................................................................17
7
Prepare Conduit for Cable ....................................................................22
8
Prepare Cable .............................................................................25
9
Final Set-Up ..............................................................................27
10
11
12
13
14
15
16
A. Final Inspection ....................................................................28
Blower Operating Instructions .................................................................28
A. Observer at Exit Pit .................................................................28
B. Connect Hydraulic Systems ..........................................................28
C. Set up the Electronic Control Box ......................................................29
D. Panel Layout ......................................................................30
E. Traction Control .................................................................... 32
F. Operation .........................................................................32
Tear Down Procedures ......................................................................34
A. Remove Power from Unit ............................................................34
B. Remove Cable from Blower ..........................................................35
C. Separate Unit from Conduit ..........................................................35
Maintenance ..............................................................................36
A. Track Cleaning & Tightening ..........................................................36
B. Replacement of Drive Belt ...........................................................36
Troubleshooting Guide .......................................................................38
Appendices ...............................................................................39
A. Blower with Job Box ................................................................39
B. Upper Drive Shaft Replacement Kit ....................................................40
C. Lower Drive Shaft Replacement Kit ....................................................41
D. Hydraulic Motor Replacement Kit ......................................................42
E. Idler Bracket Bushing & Idler Bracket Screw Replacement Kits ...............................43
F. Air Block Assembly Replacement Kits ...................................................44
G. Counter Clamp Roller & Cable Guide Replacement Kits ....................................46
H. Timing & Takeup Roller & Idler Roller Replacement Kits ....................................47
I. Hydraulic Coupler (Male) Replacement Kit ...............................................48
J. Hydraulic Coupler (Female) Replacement Kit .............................................49
K. Clamp Adjustment Replacement Kit ....................................................50
L. Lower Counter Roller Replacement Kit ..................................................51
M. RH Cable Guide Roller Replacement Kit ................................................52
N. LH Cable Guide Roller Replacement Kit ................................................53
O. Counter Spring Replacement Kit ......................................................54
P. Base Mount ......................................................................55
Q. Pneumatic & Electrical Circuits .......................................................56
R. Hydraulic Circuit ...................................................................57
S. Hydraulic Flow Control Valve .........................................................58
T. Possible Wear & Replacement Parts & Accessories ........................................59
Warranty Information ........................................................................67
3
1.
General Information
The operating instructions contain a full description of the Deluxe Blower, which has
been designed for the purpose of feeding fiber optic cable through round conduits of
uniform cross section. The conduit must previously have been installed underground
or overhead to receive the fiber optic cable and must be of sufficient length on exit to
be received by the machine. The conduit must be made of material with sufficient
compression strength for it to be adequately sealed in the exit of a machine. The
conduit must be airtight up to a pressure of 175 psi (12 bar). For this purpose,
connectors of screw, compression or fusion type must be used. Conduits from
(10 mm) to 1.97" (50.00 mm) and fiber optic cables from 1/4" (6 mm) to 1.13"
(28.7 mm) diameter can be accepted by the machine.
Fiber optic cable is fed into the conduit by combining pulling and pushing forces,
which draw the fiber optic cable through the conduit. The pulling force is achieved
by connecting the leading end of the fiber optic cable to a piston or carrier, which
fits exactly into the conduit to make an airtight seal. Air under pressure is fed in
behind the carrier causing it to be forced through the conduit. As the carrier moves
through the conduit, it pulls the fiber optic cable behind it. The fiber optic cable is
continuously pushed into the conduit by a tractor drive. This consists of two
caterpillar tracks, which grip the top and bottom of the fiber optic cable moving it into
the conduit. This ensures the fiber optic cable is always free as it moves into the
conduit and reduces the magnitude of the pulling forces needed to carry the leading
end through. Special lubricants are used to make it easier for the carrier to pass
through the conduit.
The exit of the machine consists of an air box that is made in two halves that clamp
together. The air box contains special removable seals on entry and exit, which
clamp around either the end of the conduit or the fiber optic cable to be fed into the
conduit. The seals can be changed to accommodate different conduit and fiber optic
cable sizes. The conduit is clamped between a pair of seals at the entrance to the
air block. A clamp located in front of the entrance to the air block holds the conduit
mechanically to prevent it from moving axially. The fiber optic cable enters through
two seals located in an aluminum nozzle that splits in half. The aluminum nozzle is
located in the entrance to the air box and is shaped to ensure an airtight seal around
the fiber optic cable. When the two halves of the air box are closed, air pressure is
admitted into the space between the seals on entry and exit.
The use of the Deluxe Blower for operations different from those discussed in this
manual are considered extremely dangerous and thus forbidden. The non-respect for
the
prescribed restraints of the machine causes a situation of improper use and relieves
the manufacturer from any responsibility, civil or penal. The manufacturer’s
responsibility declines even when one of the following happens:
a. The consequences caused by tampering and/or modifications carried out
without the manufacturer’s written acceptance.
b. The use of imitative spare parts.
c. Bad maintenance.
d. Use with disconnected safety devices.
e. The connection to machine and/or parts not produced and not directly
authorized by the manufacturer in a written acceptance.
The Deluxe Blower is a unique device for inserting fiber optic cable directly into
conduit. The Deluxe Blower is comprised of an air block and a tractor drive that,
4
when combined with an air compressor and a hydraulic power unit, will propel fiber
optic cable measuring from 1⁄4" to 1.13" (6 mm to 28.7 mm) into an unobstructed,
unoccupied, airtight conduit run at speeds of 0 to 300 feet per minute (0-91 m/min).
A cable carrier must be placed at the front end of the cable.
The Deluxe Blower greatly reduces pulling stress on the cable. When equipped with
the electronic counter box, the tractor drive will automatically shut down if the cable
hits an obstruction or if it begins to slip on the tractor drive.
The blower comes standard with job box, hydraulic hoses with couplings, digital
LCD electronic counter box, and an adjustable control valve to the tractor drive for
speed adjustment.
GENERAL MACHINE USE
a. Only qualified operators should use the machine. The operator should only be
the person who received qualified training from the product owning company or
trained by the manufacturer.
b. Machine must only be used for the work it was designed for.
c. Machine is not to be used with unauthorized personnel on the job site.
d. Should there be any doubt concerning use, functioning, maintenance or
anything else, please contact the factory or factory representative.
OPERATOR QUALIFICATIONS
a. Operator must know the required safety directives to run the machine that are
pertinent to the country where it is being used.
b. Operator in charge of the machine and installation project must be appropriately
dressed, avoiding large clothes, hanging jewelry or whatever might become
entangled in the moving parts.
c. Operator must also wear the necessary protective equipment such as gloves,
boots, helmet, etc.
d. Operator must carefully follow all advisements contained in the instruction
manual or on the machine.
e. Operator must have work area kept clean of obstacles that might inhibit a safe
working area.
MAINTENANCE QUALIFICATION
a. All of the machine maintenance must be carried out with the machine on a level
surface and not attached to any form of power source: electrical, pneumatic, nor
hydraulic.
b. Authorized and trained personnel must do all maintenance operations. Trained
personnel are defined as people who have received qualified training from the
using company or from the manufacturer.
5
2.
Technical Information
A. HYDRAULIC SYSTEM REQUIREMENTS
•HydraulicOperatingPressure:1500psi(103bar)maximum
•HydraulicFlow:6.8gpm(20.8l/m)maximum
•HydraulicCircuitType:OpenCenter
•5micronfiltration
•FittedwithBHTMAstandard1/2"flatfacedquickreleasecouplings
•Propersizedpowerunitshouldbeusedtoruntheblowermachineto
prevent overheating
IMPORTANT: Operators must take any precautions that may have been
recommended by the suppliers of lubricants or hydraulic fluids. This applies to
the use and disposal of lubricants and hydraulic fluids including the
lubricant used to ease the passage of fiber optic cables through conduits.
B. CONDITION OF USE
Temperature from 21° F ( -6° C) to 110° F (+43° C)
Humidity from 30% to 90% +/- 5%
Weather conditions relevant to working conditions
Natural and/or artificial lighting of the work site, minimum 200 lux
C. AIR COMPRESSOR REQUIREMENTS
•PneumaticPressure:175psi(12bar)Maximum
•RequiredFlowCapacity:375SCFM(11m3/min)Maximum
•ConduitSize:10mm-1.97"(50mm)OD
•Aircoolersarerecommendedforblowingfiber
•Compressorflowmayneedtobedoubledifblowingdistanceisgreaterthan
3,500 feet (1,067 meters)
•AirhosefittingsneedtobecompatiblewithDixon“AirKing”universal
couplings.
The following charts help to determine the compressor size requirement based on
testing the conduit system (Figures 1-3).
1. Pressurize the conduit up to the maximum compressor pressure. That is the
Pstart - value.
2. Time for 10 seconds and record the ending pressure, Pend.
3. Subtract Pstart-Pend and divide by 10.
4. Find the appropriate x value and approximate length of conduit run then correlate
that information with the size of the conduit on the graph. The resulting zone is the
approximate compressor requirement.
6
Figure 1. Compressor Sizing for 3,280 ft (1,000 m) of Conduit Run
OUT OF RANGE
Figure 2. Compressor Sizing for 4,921 ft (1,500 m) of Conduit Run
OUT OF RANGE
Figure 3. Compressor Sizing for 8,202 ft (2,500 m) of Conduit Run
7
D. OPERATIONAL CAPACITIES
•PushingForce:175lbs(778N)maximum
•PushingSpeed:300ft/min(91m/min)maximum
•CableSizes:.25"to1.13"(6mmto28.7mm)
•ConduitSizes:1/2",3/4",1",1-1/4"TRUE,1-1/4",1-1/2"SDR11&13.5,
2" and metric O.D. conduit; 10 & 12 mm, 12.7 mm, 14 mm, 16 mm,
18 mm, 25 mm, 32 mm, 36 mm, 37 mm, 40 mm, 42 mm, 44 mm, 46 mm
and 50 mm
E. ELECTRONIC CONTROL BOX
•PowerRequirements:12voltsDC
•Powerconsumptionis24Watts
•Powerconnectionmustbetoautomotivepowerpointorpowerpoint
connection on Condux hydraulic power unit
•Fusedwitha2.5ampfuse,250volt-5x20mm-GMAtype
•Displays:TotalMachineDistance,DistanceofRun,OperationalSpeed,
Errors Descriptions
•AutomaticShutdownSpeeds:300ft/min(91m/min)maximum
F. P H YSICAL SPECIFICATIONS (DOES NOT INCLUDE LEGS OR JOB BOX)
•Height 16.5"(419mm)
•Length 30"(761mm)
•Width 14.8"(375mm)
•Weight 82lbs(37kg)
G. ACOUSTIC EMISSION
•Levelofmax.soundpressuretotheoperatorseat(ISO11202)Lep=85dB(A)
H. CATERPILLAR DRIVE SPECIFICATIONS
•Maximumpushingforce:175lbs(778N),dependingoncablediameter
•Maximumpushingspeed:300ft/min(91.5m/min)
•Maximumclampingforce:<114lbf/in(20N/mm)
•Independentpushingdrivebeltswithpolyurethanepadsprofiledforcable
0.23" (5.8 mm) to 1.13" (28.7 mm)
•Mechanicalgaschargedshockabsorberclamptopreventcablecrush.
•Side
guards.
I. CONDUIT COUPLING REQUIREMENTS
•Mustwithstandmaximumairpressureof175psi(12bar).
•Mustwithstandaxialloadingandvibration.
•Mustbescrewtype,compressiontype,orfusiontype.
•SightHolesmustbesealed.
•Mustfitsnugly.
•Conduitendsmustbecutoffsquarelyanddeburred.
•Conduitmustbefullyseatedintothecoupler.
•Couplersshouldbeinstalledinastraightsectionofconduit.
•Mustbesamesizeconduit.
8
Safe Operating Practices
Read and understand all procedures and safety instructions before using the Deluxe
Blower. Observe all safety information on this page and note specific safety
requirements as explained by procedures called out in this manual. Failure to follow
these instructions could result in serious personal injury, property damage or death.
A. WORK AREA SAFETY
1. Wear personal protective equipment: hard hat, safety glasses, safety shoes, and
leather work gloves.
2. The safe operation of this equipment requires that the operators be on
stable footing.
3. Stay clear of cables or lines under tension.
4. Stay clear of pressurized line and conduit.
5. Stay out of manhole while blower is in use.
6. Use the blower only for its intended purpose. Do not use the tractor drive
without the air block to push or pull cable.
7. Do not place cable reel too close to unit. Place the reel far enough away from
the unit to ensure proper control.
8. Do not tamper with relief valves or pressure reducing valves.
9. Place cable grip on end of conduit to catch cable carrier and cable.
10. Keep hands away from tractor drive while blower is in operation.
B. HYDRAULIC DEVICES
Escaping fluids under pressure can penetrate the skin and cause serious personal
injury. Observe the following precautions to avoid hydraulic hazards:
1. Tighten all connections before applying pressure. Relieve pressure when
connecting or disconnecting hoses when servicing the unit.
3.
2. Check for leaks with a piece of cardboard. Do not use your hands!
3. Do not exceed working pressure of hydraulic hoses.
4. Visually inspect hoses regularly and replace if damaged.
C. PNEUMATIC DEVICES
The Deluxe Blower is a pneumatic device, using pressurized air to project cable at
high velocities. Please observe the following precautions when operating the blower:
1. Forced air creates flying debris. Always wear personal protective equipment.
Severe personal injury could result.
2. Ensure no personnel are in the destination access vault during the blowing
operation. Severe personal injury could result.
9
4.
D. ELECTRIC DEVICES
The electronic counter box and power supply are electrical devices. Electric shock
hazards exist that could result in severe personal injury or death. Observe the
following precautions to avoid electrical hazards:
1. Do not operate in or near water. This includes setting the electronic counter box
or battery pack on a wet surface or exposing them to rain.
2. Do not remove cover of electronic counter box. There are no user-serviceable
parts inside. Refer servicing to qualified service personnel.
3. The electronic counter box power switch should be in the off position before
connecting or disconnecting any cords.
Unpacking the Blower
A. BLOWER COMPONENTS
Each Deluxe Blower Package contains the following items.
•Hydraulichosefromhydrauliccontrolassemblytohydraulicpowerunit
•Owner’sManual
•ShippingCrate
•Metric&StandardAllenWrenchSet
•
•
•VenturiAirPlug
•PlasticDividedCasew/PartsLabel
•PartsandUserManual
•1Qt.BlowingLubricant
•CapscrewSet(10)(M04-0.7’s)
•O-RingSealKit
3
⁄8" Drive Ratchet & 9⁄16" Deep Well Socket
5
⁄8" x 600 lb. Swivel
10
NOTE: If any parts are missing: please contact your Condux representative or call
Condux International at 1-800-533-2077 (USA or CANADA), or 1-507-387-6576.
B. TOOLS AND MATERIALS REQUIRED
The tools and materials are necessary to connect the Deluxe Blower to a hydraulic
power source, and to change the inserts:
1. Allen Wrench (
2. Allen Wrench (2.5 mm)
3. Allen Wrench (5 mm)
4. Screwdriver, Flat
5. Screwdriver, Phillips
6. 3⁄8" Drive Ratchet
7.
9
⁄16" Deep Well Socket
3
⁄32")
Set Up the Blower
This manual contains setup and operating instructions for the Deluxe Blower with
job box.
IMPORTANT: The Deluxe Blower must not be located below overhead gantries,
power lines or walkways where there might be a risk of falling objects. The operator
must be wearing recommended protective gear before operating the blower.
Operating light levels should be at least 200 lux of light intensity.
A. ATTACH BLOWER TO JOB BOX
CAUTION: The machine should be removed with two people or lifted
mechanically by the lift rings located on the top of the machine (Figure 4).
IMPORTANT: The Deluxe Blower should not be parked on a slope in excess of 13°.
It should not be parked on a side hill of more that 15°.
Remove the ball detent pin from the bottom of the blower. Attach the Deluxe Blower
to the job box by aligning the guide tracks on the bottom of the blower with the
channel on the top of the box. Holes in the box channel need to align with holes on
the blower guide track. Once aligned, replace ball detent pin so it locks the blower in
place (Figure 5).
5.
Lift
Rings
Figure 4. Lift out Blower with
Lift Rings
Figure 5. Replace Ball Detent Pin
11
6.
Cable Crash Test
Cable Crash Testing is a very quick and easy step to be completed before attempting
the installation of cable with the Deluxe Blower. This test is necessary to set the
hydraulic motor pressure of the blower below the point that it may cause cable
damage as a result of over pushing or encountering an obstruction in the
sub-duct system.
Every cable has different pushing values and these values vary depending on
duct I.D. Example: A cable with a crash test value of 75 bar in 33 mm I.D. duct,
may have a crash value of only 60 bar in a 40 mm I.D. duct. This is because the
area of lateral movement is larger as the duct size increases.
!CAUTION: Always wear protective equipment: hard hat, safety glasses,
safety shoes and work gloves.
NOTE: The hydraulic motor pressure adjustment will have no effect on the
installation speed of the blowing unit. This is not a flow adjustment. This is a
pressure adjustment to prevent damage to the cable that can be caused by excessive
pushing force.
IMPORTANT: For the Crash Test to work properly use the same size cable and duct
that will be used for the job.
Set the hydraulic motor pressure on your Deluxe Blower using the following
procedure.
1. Attach 12' (4 m) of duct to the Deluxe Blower (Figure 6).
2. Install Conduit Pulling Eye on the receiving end of the duct (Figure 7).
Figure 6. Placement of Conduit in
Conduit Seal & Conduit Clamp
Figure 7. Installing Conduit
Pulling Eye
12
3. Cut a piece of fiber optic cable 15' (5 m) long. This is your test piece of cable.
4. Attach the correct size Venturi to fit the cable being installed (Figure 8).
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
ELECTRICAL HOOK UP
TO POWER SOURCE
Figure 8. Install Venturi
5. Attach Hydraulic Hoses (Figure 9).
The Deluxe Blower’s hydraulic system
uses quick-disconnect couplings.
Keep all connections clean to avoid
contamination and possible system
failure. Use hose end caps (supplied).
A contaminated hydraulic system will
effect the operation of the cable
blower and may invalidate your
product warranty. Take caution in
routing the hoses to prevent a tripping
hazard. Follow these steps to
connect the hydraulic components:
INNERDUCT
DELUXE LW
BLOWER
OPERATOR
AIR HOSE
COMPRESSOR
Figure 9. Typical Set-Up
FIBER
OPTIC CABLE
AIR
CABLE
REEL
A. Attach the quick-disconnect
couplings to the hydraulic power
Figure 10. Attach Hydraulic
Hoses
supply (Figure 10).
B. Start the hydraulic power unit and check all connections for leaks with a
piece of cardboard. In cold weather, run hydraulic power supply until
hydraulic oil warms up.
WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Observe the following precautions to
avoid hydraulic hazards:
•Tightenallconnectionsbeforeapplyingpressure.Relievepressure
before connecting or disconnecting hoses.
•Checkforleakswithapieceofcardboard.Donotusehands!
•Donotexceedworkingpressureofhydraulichoses.Visually
inspect hoses regularly and replace if damaged.
C. Run the blower for approximately 1 minute to remove any trapped air and
then stop the blower and hydraulic power source.
B. ELECTRONIC CRASH TEST
To run the Crash Test utilizing the Electronic Control Boxes PRESSURE LIMIT
feature, follow Crash Test steps 1-5 to set up the blower.
13
6. Press Touch Screen “LIMIT: XXXX” to open the Limit keypad.
7. Enter the desired pressure – suggested starting point is 800 PSI.
8. Place Cable in Blower from Rear Rollers through Tractor Drive. Push cable
through the duct until it stops against the Pulling Eye (Figure 13).
9. Place a mark on the Cable about 2" (51 mm) behind the Rear Rollers
(Figure 14).
Figure 13. Install Cable
Figure 14. Mark the Cable
10. Install top Venturi (Figure 15). Close Air Block and tighten (Figure 16).
Figure 15. Install Top Venturi
Figure 16. Close Air Block
and tighten
11. From the Rear Rollers, pull out approximately 8' (2.4 m) of cable from
the blower.
14
12. To avoid start up pressure spikes, which will register on the pressure
transducer and produce a false pressure error, set the Hydraulic Flow Control
to the lowest speed by rotating the flow control knob clockwise until it stops.
13. Lower the Tractor Drive Cover, and tighten until the tracks make contact
with the cable. Give one additional turn to the clamp screw.
14. Turn on Hydraulic Power, and press the ECB DRIVE button ON.
15. Increase speed as quickly as possible by turning the Hydraulic Flow Control
counter-clockwise. The Cable should be pushed into the duct. Continue to
speed up the tracks until the cable stops and the ECB gives a
HI-PRESSURE ERROR screen.
16. If a HI-PRESSURE ERROR appears, follow the on-screen instructions to
reset the electronics and return to the Operations screen.
17. Raise Tractor Drive Cover. Pull out 8' (2.4m) of cable from the blower.
18. Lower and tighten Tractor Drive Cover. Repeat steps 6-7 to increase the
pressure by 50 PSI.
19. Repeat steps 12-16 until cable damage
is seen – either in the form of jacket
damage or bends in the cable, the
cable folds over, or you reach 1500 psi.
You will notice cable fold-over because
the line drawn on the cable will
disappear inside the machine or duct.
(Figure 17).
20. Repeat steps 6 and 7 to reduce the
PRESSURE LIMIT by 50 PSI.
21. Remove folded fiber and test again at
current PRESSURE LIMIT settings to
ensure no fiber fold over or
Figure 17. Cable folds over
damage occurs.
22. Remove test piece of fiber optic cable.
23. If the re-test is confirms no cable damage, Re-adjust Flow Control setting to
the slowest speed.
24. Remove test duct piece from the Deluxe Blower.
25. Crash test is complete.
15
16
Pressure Test Conduit
The conduit system must be able to withstand a maximum pressure of 175 psi, and
be free of leaks. A Conduit Pressure Test Kit, part number 08761457, is available to
perform this test. Conduit may also be tested for pressure using the Deluxe Blower,
follow the steps below.
1. Loosen the 6 nuts on the Air Block assembly (Figure 20). Open the Conduit
Clamp Cover and Air Block Cover (Figure 21).
Figure 20. Loosen Air
Block Assembly
2. Select the correct Conduit and Cable Components according to conduit and
cable size. Refer to the Conduit and Cable Pack selection charts
(Tables 1 and 2, page 18).
Figure 21. Open Conduit Clamp
Cover & Air Block Cover
7.
3. Choose the correct Conduit Seal and install both halves securely. (Figure 22).
4. Choose the correct Conduit Clamp and install both halves (same color as the
conduit seal). (Figure 23).
Figure 22. Install Conduit Seal
Figure 23. Install Conduit Clamp
17
PACK
1
2
3
4
CABLE PACK VENTURI CABLE SEAL CABLE GRIP
Cable OD P/N Cable OD P/N Cable OD P/N Cable OD P/N
0.23-0.34 08780393 0.23-0.34
(5.8-8.8) Pack #1 (5.8-8.8) 0.29-0.34
08780281
(5.8-7.2) 0.21-0.35 08643754
(7.3-8.8)
0.35-0.42
0.23-0.28
0.35-0.48
(8.9-12.2) 0.43-0.48
08780282
(8.9-10.7) 0.32-0.48 08643755
0.35-0.60 08780394 (10.8-12.2)
(8.9-15.2) Pack #2 0.49-0.55
0.49-0.60
(12.3-15.2) 0.56-0.60
08780283
(12.3-14.0) 0.42-0.61 08643756
(14.1-15.2)
0.61-0.67
0.61-0.73
(15.3-18.5) 0.68-0.73
08780284
(15.3-17.0) 0.53-0.74 08643757
0.61-0.85 08780395 (17.1-18.5)
(15.3-21.6) Pack #3 0.74-0.79
0.74-0.85
(18.6-21.6) 0.80-0.85
08780285
(18.6-20.1) 0.64-0.87 08643758
(20.2-21.6)
0.86-0.92
0.86-0.97
(21.7-24.6) 0.93-0.97
08780286
(21.7-23.4) 0.75-1.00 08643759
0.86-1.13 08780396 (23.5-24.6)
(21.7-28.7) Pack #4 0.98-1.04
0.98-1.13
(24.7-28.7) 1.05-1.13
08780446
(24.7-26.4) 1.00-1.24 08643137
(26.5-28.7)
08780406
08780407
08761424
08761425
08761426
08761427
08761428
08761429
08761430
08761431
08761432
08761433
08761434
08761435
(5.3-8.9) 033-29-1194
(8.1-12.2) 033-29-1195
(10.7-15.5) 033-29-1196
(13.5-18.8) 033-29-1197
(16.3-22.1) 033-29-1198
(19.1-25.4) 033-29-1199
(25.4-31.5) 033-03-013
Table 1. Cable Packs
PACK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DUCT PACK DUCT CLAMP DUCT SEAL CARRIER FOAM CARRIER CABLE GRIP INNERDUCT EYE
Duct Size P/N Duct OD P/N Duct OD P/N Carrier P/N Carrier OD P/N Duct OD P/N P/N and ID Range
1/2" 08780795 0.84
SDR 11-13.5 Pack #1 (21.30) (21.30) (17.50) (19.0) (19-25) 033-03-012
3/4" 08780680 1.050
SDR 11-13.5 Pack #2 (26.6) (26.6) (19.0) (19.0) (25.4-31.5) 033-03-013
1" 08780386 1.315
SDR 11/13.5 Pack #3 (33.4) (33.4) (28.5) (31.8) (25.4-31.5) 033-03-013
1.25" 08780392 1.660
SDR 11/13.5 Pack #4 (42.2) (42.2) (35.9) (38.1) (38.1-50.5) 033-03-016
1.5" 08780397 1.900
SDR 11/13.5 Pack #5 (48.3) (48.3) (41.1) (44.5) (38.1-50.5) 033-03-016
2" 08780930 2.023
SDR 11/13.5 Pack #6 (51.4) (50.8) (50.8-63.2)
25 mm
32 mm
36 mm
37 mm
1.25" TRUE
40 mm
42 mm
44 mm
46 mm
50 mm
08780240 0.984
08780385 1.260
08780387 1.417
08780388 1.457
08780389 1.500
08780390 1.575
Pack #12 (40.0) (40.0) (33.0) (38.1) (38.1-50.5) 033-03-016
08780391 1.653
Pack #13 (42.0) (42.0) (35.0) (38.1) (38.1-50.5) 033-03-016
08780545 1.732
Pack #14 (44.0) (44.0) (38.0) (38.1) (38.1-50.5) 033-03-016
08780460 1.811
Pack #15 (46.0) (46.0) (33.0) (38.1) (38.1-50.5) 033-03-016
08780575 1.969
Pack #16 (50.0) (50.0) (40.0) (50.8) (38.1-50.5) 033-03-016
_______ _______ _______ _______
Pack #7 (25.0) (25.0) (20.0) (31.8) (25.4-31.5) 033-03-013
Pack #8 (32.0) (32.0) (27.0) (31.8) (31.8-37.8) 033-03-015
Pack #9 (36.0) (36.0) 1.220 (31.0) 08761555 (31.8) (31.8-37.8) 033-03-015
Pack #10 (37.0) (37.0) (31.0) (31.8) (31.8-37.8) 033-03-015
Pack #11 (38.1) (38.1) (31.7) (38.1) (31.8-37.8) 033-03-015
08780791
08780682
08780369
08780375
08780404
08780099
08780368
08780370
08780371
08780372
08780373
08780374
08780546
08780466
08780435
0.84
1.050
1.315
1.660
1.900
0.984
1.260
1.417
1.457
1.500
1.575
1.653
1.732
1.811
1.969
08780786
08780685
08780307
08780051
08780398
08780134
08780306
08780308
08780309
08780333
08780334
08780335
08780547
08780461
08780431
0.688
0.75
1.121
1.414
1.618
0.787
1.063
1.181 (30.0) 08761643 1.25
1.220
1.250
1.299
1.378
1.496
1.299
1.606
08780793
08780690
08761250
08761255
08761260
08761265
08780230
08761560
08761555
08761670
08761579
08761660
08761786
08761579
08761579
0.75
0.75
1.25
1.50
1.75
2.00
1.25
1.25
1.25
1.50
1.50
1.50
1.50
1.50
2.00
08078300
08078300
08761439
08761440
08761441
08761442
08761439
08761439
08761439
08761439
08761440
08761440
08761440
08761440
08761440
08761442
.75-.99 08643131
1.00-1.24 08643137
1.00-1.24 08643137
1.50-1.99 08643149
1.50-1.99 08643149
2.00-2.49 08643155
1.00-1.24 08643137
1.25-1.49 08643143
1.25-1.49 08643143
1.25-1.49 08643143
1.25-1.49 08643143
1.50-1.99 08643149
1.50-1.99 08643149
1.50-1.99 08643149
1.50-1.99 08643149
1.50-1.99 08643149
033-03-017
08761840
.78-.87
(20-22)
08761840
.71-.89
(18-22)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761844
1.37-1.68
(35-43)
08761844
1.37-1.68
(35-43)
08761840
.71-.89
(18-22)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761844
1.37-1.68
(35-43)
18
Table 2. Conduit Packs
5. Choose the correct Venturi to fit the cable being installed. Do not install at
this time!
6. Place conduit in the Conduit Seal and Conduit Clamp. Note placement up to
ridge on Conduit Seal (Figure 24).
7. Clamp conduit in place (Figure 25).
Figure 24. Placement of Conduit
in Conduit Seal & Conduit Clamp
Figure 25. Clamp Conduit
in Place
8. Place Seal Disk in Venturi slot. (Figure 26).
9. Close Air Block Cover and secure (Figure 27). Tighten nuts securely, but do
not over tighten. Use a cross-tightening procedure.
Figure 26. Installing Seal Disk
Figure 27. Tighten Air Block
Cover
19
10. Plug receiving end of Conduit with a properly sized Conduit Pulling Eye
(Figure 28) (Appendix R pg. 62).
11. Choose the correct Pulling Grip & install on receiving end of Conduit
(Figure 29).
Figure 28. Installing Conduit
Figure 29. Installing Pulling Grip
Pulling Eye
12. Connect the Air Compressor (Figure 30).
a. Ensure Air Valve is off before connecting air hose.
b. Attach the hose supplied with the air compressor to the air compressor
coupling. The blower air valve assembly is equipped with a claw type
connector. Use safety clips on all pneumatic hose connections (Figure 31).
c. Observe all safety procedures.
d. Route all hoses properly to prevent tripping over them.
!WARNING: Forced air creates flying debris. Always wear personal
protective equipment. Severe personal injury could result.
!WARNING: Ensure no personnel are in the destination access vault
during the blowing operation. Severe personal injury could result.
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
ELECTRICAL HOOK UP
TO POWER SOURCE
20
INNERDUCT
DELUXE LW
BLOWER
OPERATOR
AIR HOSE
OPTIC CABLE
AIR
COMPRESSOR
FIBER
Figure 30. Typical Connections
CABLE
REEL
Figure 31. Installing Air Hose with
Safety Clips
13. Slowly open Air Control Valve. Pressurize conduit to 80-100 psi (5.5-6.9 bar)
(Figure 32).
Figure 32. Open Air Control Valve
Figure 33. Close Air Control Valve
14. Prove conduit integrity.
a. Close Air Control Valve (Figure 33).
b. Conduit must not lose more than 20 psi (1.38 bar) over a 2-minute period.
c. After 2 minutes, relieve air pressure. Open air pressure relief valve by
moving the blower pressure valve handle counter clockwise to the 9 o’clock
position (Figure 34).
d. If conduit fails to hold required pressure, check entire conduit run for leaks
and repair them.
e. Repeat the pressure test until all leaks are found and repaired.
!WARNING: Air Block Assembly contains compressed air when blower is
operated. Opening Air Block while under pressure may cause serious
personal injury. Ensure blower is depressurized before removing Air
Block cover, or removing conduit pulling eye.
15. Decompress the Air Block by
turning the Air Valve to the 9 o’clock
position. Shut off the air at the
compressor, decompress the air
hose and disconnect the air hose
from the fiber blower.
Figure 34. Decompress Air Block
21
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