Condux Winch Line Blower System User Manual
CONDUX USER’S GUIDE & SAFETY MANUAL
WINCH LINE BLOWER SYSTEM
IMPORTANT SAFETY NOTICE
Read and understand all procedures and safety instructions before using a Condux Winch Line 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.
Save this user’s guide for future reference.
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
Table of Contents_________________________
1. GENERAL INFORMATION
Purpose of the Winchline Blower……………………….2
Technical Information…………………………………..2
Safe Operating Practices………………………………...3
Winch Line Blower Selection………..…………………..4
2. OPERATOR’S INSTRUCTION
Winch Line Blower Installation…………………………5
Winch Line Blowing Procedure…………………………11
Winch Line Blower Removal...………………………….12
3. WINCH LINE BLOWER ADAPTER
Purpose of the Winch Line Blower Adapter…………….15
Winch Line Blower Adapter Installation………………...15
Winch Line Blower Adapter Removal…………………...19
4. TROUBLESHOOTING
Solutions to possible problems………………………….21
5. APPENDIX
Winchline Blower Seal-Off Body Assembly……………..23
Condux Control Valve Assembly P/N 08209300……….25
Condux Air Hose Assembly P/N 08209310…………….26
Condux Conduit Missile Wear/Replacement Parts……...27
Winchline Blower Adapter Assembly…………………....28
Warranty Information…………………………………...29
1. General Information
Purpose of the Winch Line Blower
The Condux Winch Line Blower is a unique device for inserting winch lines directly into
underground conduit before cable pulling or conduit proving operations. The winch line blower is
comprised of three main parts that, when used in conjunction with an air compressor and a cable
pulling winch mechanism (truck, trailer, or portable), will propel a standard steel winch cable into
an unobstructed, unoccupied, airtight, plastic conduit run at an average speed of 100 feet per
minute.
The Condux winch line blower will work with nearly all type of existing steel cable winches that
are currently being used for the installation of underground
utility cables.
Because of the unique design of the winch line blower, it will
operate in a wide range of conduit sizes, from 2to 6 inch duct,
and with various diameter winch lines up 7/8” (14mm)
without compromising efficiency.
The three main parts of the winch line blower are the
winchline blower body assembly, the missile and the control valve assembly. When each part of
the system is properly installed and maintained, this provides a means of using existing winch line
equipment to speed up cable installation procedures by as much as 1000 percent.
Technical Information
1. 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 worksite, minimum 200 lux
2. AIR COMPRESSOR REQUIREMENTS
Pneumatic Pressure: 175 psi (12 bar) Maximum
Required Flow Capacity: 375 SCFM (11 m3/min) Maximum
Control valve air hose fittings need to be compatible with Dixon “Air King”
universal couplings.
Safety Pop-off Valve on Control Assembly set for 90 psi.
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Safe Operating Practices
All tools, materials and equipment manufactured and supplied by Condux International are
designed to only be used by trained craft personnel. The information in this manual is essential for
the safe use of the Condux Winch Line Blower.
Operating procedures and guidelines must be read and understood by all personnel prior to using
any tools, materials, or equipment from Condux International.
OPERATOR QUALIFICATIONS
a) Operator in charge of the Winch Line Blower and installation project must be
appropriately dressed.
b) Operator must also wear the necessary protective equipment such as gloves, boots,
helmet, etc.
c) Operator must carefully follow all advisements contained in the instruction manual.
d) Operator must have work area kept clean of obstacles that might inhibit a safe working
area.
Condux will not be held liable for any injury or damage to either persons or property resulting
from the misuse of Condux equipment.
!WARNING: The Condux Winch Line Blower must be properly installed as
instructed. Failure to properly install the Winch Line Blower could result in severe
personal injury or damage to existing cables or conduit in the utility service
access vault.
!CAUTION: The Winch Line Blower is designed for use only in PVC and
polyethylene conduit. It will not operate properly and may cause personal injury
or physical damage if used in fiberglass, steel, concrete or other types of non-
plastic conduits.
This users guide and safety manual is intended to familiarize operators with the use and safety
procedures of the Condux Winch Line Blower.
This manual should be kept available to all operating personnel.
Winch Line Blower Seal-Off Selection
Threaded Adapter
Rope Venturi
Winchline Blower Body
1. Determine type(s) and diameter(s) of conduit in which the winch line will be inserted.
2. Select the correct threaded adpater to cover the range of conduit types and sizes
being used.
3. Select the proper size rope venture. Comes standard with ½” – 9/16” venture.
4. Select the proper missile size for the conduit sizes that are going to be used.
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2. Operator’s Instructions
Winch Line Blower Installation Procedure
!WARNING: Do not use around live circuits. The Winch Line Blower is constructed
of steel and aluminum, as such is highly conductive. Electric shock may occur is
contact is made with live circuits. Always be certain that power has been
disconnected.
!CAUTION: Standard utility service access vault opening procedures must be
followed which include work area protection and gas detection. Hard hats, eye
and ear and foot protection, must be worn whenever working in utility service
access vaults.
1. Clean out the end of the conduit to remove any dirt or gravel that may get between
the conduit and the threaded adapter.
2. Place about ½ quart of cable pulling lubricant (such as Poly J) into the conduit.
While this is not required, it does help in installing the missile and helps to increase
the efficiency of the winch line blower.
3. Attach the missile to the end of the winch line using the connector supplied with the
winch line blower. (See Fig. 1) The large metal disc must be forward in the direction
of winch line travel (as shown by the label on the missile).
Figure 1: ATTACH THE MISSILE
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!CAUTION: Always know approximate length of the conduit runs and make
certain the winch drum contains enough winch line cable to reach the entire
distance before using the winch line blower.
!CAUTION: Inspect the winch line cable or know the condition of the cable before
using the winch line blower. Replace any cables that are kinked or have worn or
broken strands before using the winch line blower.
4. Insert the missile into the conduit and push into the conduit approximately one arms
length. (See Fig. 2)
FIGURE 2: INSERT MISSILE INTO CONDUIT
5. Place split-threaded adapter around winch line and screw threaded adapter into pipe
until tight by hand. Use adjustable wrench and screw threaded adapter one more full
turn. See Figure 3 & 4
!CAUTION: Before each use, visually inspect the Winchline Blower Body,
threaded adapters, and the missiles for signs of wear, fatigue, and/or breakage. If
any of these items show signs of wear, they should be replaced or system
function and efficiency will be affected (Reference Appendix).
Figure 5 7 6 Install Winchline Blower Body onto the Threaded Adapter
Figure 3 Place Threaded Adapter into Duct
Figure 4 Tighten Threaded Adapter Using a Wrench
6. Install winchline blower body onto the threaded adapter by matching the threaded
adapter’s lip to the winchline blower body’s groove. See Figure 5 & 6
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7. Close winchline blower body and secure by tighten the speedball handle securely. do
Figure 7 Close and Secure Winchline Blower Body
not over tighten. See Figure 7
!WARNING: The Threaded Adapters should be screwed tight into the duct to
ensure that the Winchline blower does not blow out of the conduit and severely
injure persons or damage property.
Figure 8: Align The Winch Line
8. Ensure that winchline is entering in a straight line. Check the winch line alignment to
ensure that the winch line is not hung up or restricted and that it will feed through the
winchline blower smoothly. See Figure 8
!CAUTION: Always guide the winch line into the winchline blower parallel with
the center line of the conduit. Use additional sheaves or cable guides if
necessary.
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Figure 9: Attach Air Hose
9. Attach the air hose to the seal-off body assembly and tighten the locking ring on the
air connector. Rotate the 45° angle fitting away from the winch line channel and the
winch line to prevent tangling and wear of the air hose or connectors. See Figure 9
10. Run the air hose out of the utility service access vault, attach to the Control Valve
assembly, and tighten the locking ring on the air connector.
!DANGER: NEVER REMAIN IN EITHER START OR EXIT OF UTILITY SERVICE
ACCESS VAULTS DURING THE BLOWING PROCEDURE. SEVERE PERSONAL
INJURY OR DEATH COULD RESULT.
!WARNING: Do not attempt to operate the winch line blower with a different
control valve than what is supplied with the winch line blower kit. The seal-off
could blow out of the conduit or the conduit itself could rupture.
!WARNING: Check that all air hose connections are securely attached, and that
the locking ring is in place and tight.
11. Turn the control valve to the closed position (see Figure 10). In the closed position,
the valve handle will be turned perpendicular to the air flow through the fitting. Close
the outlet valve on the air compressor.
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