Fremco MiniFlow RAPID Operating Manual

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OPERATING MANUAL

MiniFlow RAPID

Fremco A/S Ellehammervej 14 9900 Frederikshavn Denmark Tel. +45 72 30 12 13

101-10031 Operating Manual 2016-06-15 EN

From Serial No. 9328.1193

Table of Content

Technical Specifications ....................................................................................................................................... 3

MiniFlow RAPID ....................................................................................................................................... 3

Hydraulic Control Unit ............................................................................................................................ 4

Identification .......................................................................................................................................................... 5

Application ............................................................................................................................................................. 5

Mounting ................................................................................................................................................................ 5

Supply of Compressed Air and Hydraulic Pressure .......................................................................................... 5

Fiber Cable Blowing .............................................................................................................................................. 5

Maintenance .......................................................................................................................................................... 6

Safety Directions ................................................................................................................................................... 7

Machine Overview ................................................................................................................................................. 8

Photo Guide, Operation ........................................................................................................................................ 9

Before Operation .................................................................................................................................... 9

Preparing Operation ............................................................................................................................. 10

During Operation .................................................................................................................................. 11

After Operation ..................................................................................................................................... 11

Photo Guide, Chain Maintenance and Adjustment .......................................................................................... 12

Photo Guide, Pushing Power Indicator (PPI) Adjustment .............................................................................. 13

Photo Guide, Changing Adaptor Plates ............................................................................................................ 14

Photo Guide, Changing Chains and/or Chain Support Rails ........................................................................... 15

Photo Guide, Initial Adjustment of Joystick ..................................................................................................... 16

Preparation ............................................................................................................................................ 16

Adjustment ............................................................................................................................................ 17

Photo Guide, Operating the Joystick ................................................................................................................ 19

Preparation ............................................................................................................................................ 19

Start-Up ................................................................................................................................................. 20

IMPORTANT Note regarding POWER and SPEED Adjustment ....................................................................... 21

EC Declaration of Conformity ............................................................................................................................ 22

Technical Specifications

These specifications cover MiniFlow RAPID and the hydraulic control unit.

MiniFlow RAPID

Manufacturer Fremco A/S Ellehammervej 14 9900 Frederikshavn Denmark

Item No. ................................................................................................................................................ 101-10031

Micro cable diameter .............................................................................................................................. 4-12 mm

Micro duct diameter ................................................................................................................................ 7-20 mm

Blowing distance¹ ............................................................................................................................ Up to 3.5 km

Blowing speed¹ ........................................................................................................................ Up to 100 m/min.

Recommended pressure and airflow²: ......................................................................... 8-16 bar (1,000 l/min.)

Weight ............................................................................................................................................................. 24 kg

Length ........................................................................................................................................................ 650 mm

Width .......................................................................................................................................................... 225 mm

Height ......................................................................................................................................................... 210 mm

¹ Depending on type and quality of fiber cable and microduct ² Air must be filtered, cooled and dried

Hydraulic Control Unit

Manufacturer Fremco A/S Ellehammervej 14 9900 Frederikshavn Denmark

Item No. .............................................................................................................................................. 103-10041

Hydraulic connection ......................................................................................................... 0>125 bar, 17 l/min

Manometer ................................................................................................................................................. 160 bar

Hose to fiber blowing machine ........................................................................................................... 1500 mm

Hose to hydraulic pump ........................................................................................................................ 1500 mm

Length ........................................................................................................................................................ 250 mm

Width .......................................................................................................................................................... 250 mm

Height ......................................................................................................................................................... 310 mm

Weight ............................................................................................................................................................... 5 kg

Identification

These instructions have been made to support the users of the cable blowing machine MiniFlow RAPID. The machine type can be identified by the type plate on the machine. The type plate provides information about serial number, year of production and name and address of the manufacturer.

It is recommended to read this instruction carefully and become familiar with the functionality and maintenance of the cable blowing machine before use.

Application

The cable blowing machine MiniFlow RAPID is constructed for blowing fiber optic cables into microducts.

Always use adaptor plates designed for the actual diameter of cable and duct. The adaptor plates are marked with the size for which they are intended.

It is very important to use the correct adaptor plates. If the adaptor plates do not fit the duct, dangerous situations may occur.

Mounting

Make sure to place the machine on a stable foundation and to fasten it to withstand the forces, which occur during use.

Supply of Compressed Air and Hydraulic Pressure

The volume and quality of compressed air is one of the most important parameters in order to achieve good results when blowing fiber optic cables.

The minimum capacity needed is 1,000 l/min. The compressed air must be filtered, cooled and dried to avoid moisture and dirt in the microduct.

NOTE: Do not use compressed air

directly from a compressor unit, since the air can be very hot and can damage microduct, fiber cable and machinery.

The supply of hydraulic pressure must be 110 bar, minimum 17 l/min. It is recommended to use the hydraulic power unit that is designed specifically for use with the Fremco cable blowing machines.

Fiber Cable Blowing

Having set up and connected the hydraulic pump and the air compressor, tighten the chain hand wheel so that the chains do not skid on the cable. The best result is achieved by not tightening too hard.

The hydraulic control unit is used to control direction (forward/back), speed and push/pull force. Use the joystick on the hydraulic control unit to control start/stop and direction.

The speed can be adjusted by turning the valve handle marked ”Speed”. By turning the handle to the left, pressure is reduced.

With the valve handle marked “Power” you can adjust the maximum force to be transferred to the cable. The pressure, and with it the force, is increased when the handle is turned to the right.

When installing the cable it is important to make sure not to push the cable too hard into the duct, because it is the supplied compressed air that must lead the cable forward inside the duct.

Use the Pushing Power Indicator (PPI) on the MiniFlow RAPID to monitor the pushing force on the fiber cable.

There are several things to consider when blowing cables, because they influence the different settings of speed and pressure. For instance the diameter and stiffness of the cable, the force needed to pull the cable forward to the MiniFlow RAPID cable blowing machine as well as the force needed to overcome friction from seals and air pressure inside the blowing junction block.

It is not possible to give exact directions on adjusting the different pressures because it depends on the conditions of the specific job.

Please be aware of the maximum load on the cable and allowed force on the duct as specified by the manufacturers.

Maintenance

The MiniFlow RAPID does not require much maintenance if the following recommendations are followed:

The chains must be kept well lubricated and free from sand and dust. It is recommended to use a chain spray with water-repellent oil.

The chains should be tightened to an extent that the they can be lifted only 3-5 mm from the chain support rail.

The chains and the chain support rails must be replaced timely.

It is very important to avoid any kind of dirt in the hydraulic connectors when mounting the hydraulic hoses.

If the machine is not to be used for a longer period of time, it should be cleaned and the chains should be lubricated. It is also recommended to spray the machine with an anti-corrosion oil. Store the machine in a dry and dust-free environment.

It is strongly recommended to use original spare parts. Repairs should be performed by the manufacturer. Errors and damage caused by unauthorized use and changes or adjustment of the machine are not covered by warranty.

CABLE DAMAGE SAFETY

Miniflow RAPID has a unique monitoring system, which continuously monitors the pushing force applied on the fiber cable, making it possible to stop

before cable damage.

Pushing force in kilogram

0-10 10-20 20-30 30-40

Safety Directions

 Make sure to disconnect the machine from

all power sources, like air compressor and hydraulic pump, before any kind of adjustment and maintenance takes place.

 The hydraulic power supply from the

hydraulic pump for cable blowing machines or from other sources may never exceed the specified maximum pressure.

 The air pressure should never exceed the

recommendations from the suppliers of microducts and fiber cables. The pressure may never exceed 16 bar, which is the maximum pressure for the blowing junction block.

 Observe that the machine is placed on a

stable foundation and secure it before start. Make sure that the blowing junction block is properly connected to the microduct, and that the cable is placed correctly between the chains.

 Make sure you do not touch the cable too

close to the machine because you risk getting your fingers injured, and make sure the cable does not make loops that might be dangerous to persons around the machine.

 Use hearing protection, if the hydraulic

pump or other noisy equipment is placed nearby.

 The joystick on the hydraulic control unit

should never be blocked in a way, where it is unable to return to neutral position.

 The operator must make sure that no

other persons are close to the machine and cable drums in a way that could be dangerous when the machine is started.

 It is always a clear advantage to be well

prepared so that you can run the blowing without interruptions. Pausing in the middle of blowing creates a risk of being unable to start again.

 Make sure the working environment is

clean and tidy to avoid injuries due to stumbling over cables and equipment.

Machine Overview

Digital counter

(speed and distance)

Pushing Power

Indicator (PPI)

Air valve

Connections for

hydraulics and

compressed air

Inlet guide (2 sets)

Adaptor plates

Air flow

regulator

Hand wheel for

chain adjustment

Air pressure manometer

Photo Guide, Operation

Before Operation

Is the chain support rail worn in a way that geometry

is odd?

 Change wear parts, if necessary

Does the diameter of the nylon inlet guide bush fit

the actual fiber cable, ensuring fiber cable entry in

the middle of the chain groove?

 Size can be wrong 

Extensive wear can make the hole oval

 Chain tension can vary on different positions on the

chain. Please rotate chain and check in several positions.

Is chain tension correct? Chains should be tightened

to an extent that they can be lifted only 3-5 mm from the chain support rail.

Preparing Operation

It is recommended to reduce friction between duct and fiber cable by using a suitable lubricant, which can be distributed to the inner surface of the duct using the following procedure:

 Add an appropriate amount of lubricant into

the duct

 Add a foam plug into the duct

 Connect the duct to the machine, and place

the fiber cable in the machine

 Open the air valve. Adjust the air flow

regulator to a sufficient level to let the compressed air push the foam plug through the duct

 Close the air valve when the foam plug is

through the duct

In general, it is recommended to adjust the hydraulic pressure and thereby the pushing power to the lowest level possible, with just enough power to draw the fiber from the drum.

The main work to get the fiber cable through the duct should be done by the compressed air flow.

Activate the joystick

in forward direction. Increase the pressure, until the machine starts to run.

Increase hydraulic pressure a bit more to ensure

continuous running.

If the fiber cable meets extensive resistance, the machine will stop and prevent wheelspin and damage to fiber cable and chains.

Reduce the oil flow

(=machine speed) on the upper valve handle and activate the joystick.

Check, that the chains operate with moderate speed.

Speed can be adjusted later during operation.

Reduce the hydraulic pressure (=machine pushing power) on the lower valve handle.

Lubricate chains

regularly

Check for rubber

particles in this area

During Operation

The chain pressure on the fiber cable should be sufficient to create enough friction.

 Too low pressure can cause “wheel-spin”,

damaging fiber cable and chains.

 Too high pressure can deform the fiber

cable and rubber on chains.

Check the chain pressure on the fiber cable regularly.

Lubricate the chains regularly. Use a chain oil spray of good quality. Spray the chains with oil through the holes in the chain covers. Be careful not to add too much, since lubricant on the chain rubber profile decreases friction between chain and fiber cable dramatically.

Many rubber particles on the machine surface can be a sign of excessive wear.

Check the air pressure regularly. Use the airflow regulator to adjust pressure, if necessary.

After Operation

When the fiber cable is through the duct, turn off the hydraulic power.

The air pressure inside the duct is released by turning the air valve to the left.

Photo Guide, Chain Maintenance and Adjustment

Keep the chains well adjusted and clean from dust and dirt. Lubricate regularly with a waterproof chain oil spray.

Please follow below instructions on both chains.

Tighten the chains

 Remove the chain covers

 Loosen the two Allen screws

 Turn the Allen screw to tighten the

chains

 Tighten the two Allen screws

Check Chain Tension

 The chains should be tightened to an

extent that they can be lifted only 3-5

mm from the chain support rail

 Chain tension can vary on different

positions on the chain

 Rotate chain and check in several

positions

Lubricate the Chain

 Use a good quality water resistant

chain oil spray

 Remove the chain cover  Turn on the machine and let it run

slowly without load

 Spray between the chain and the

chain support rail

 Be careful not to spray oil onto the

chain rubber surface

Photo Guide, Adjustment of Pushing Power Indicator (PPI)

The offset point of the PPI indicator can be adjusted. This can be necessary when the machine has been in operation for some time.

 Use a 5 mm hex key to adjust the Allen screw placed behind the hole above the lifting handle

 Adjust until the indicator is placed at the start of the scale

 Push the blowing junction block in direction away from chains

 Let the blowing junction block return to unloaded position

 Re-adjust, if necessary

Photo Guide, Changing Adaptor Plates

 The brass adaptor plates can be

changed without the use of tools

 Click the adaptor plates into position

Ball lock

top

Ball lock

bottom

 The adaptor plates are locked at the

top and bottom by a spring loaded ball lock

 Check that the groove in the adaptor

plate is aligned with the ball lock

Photo Guide, Changing Chains and/or Chain Support Rails

 Remove the chain support rail

 Check for wear and replace, if necessary

 Remove the chain wheel from its position

 Remove the chain covers

 Remove the upper part by unscrewing the

two Allen screws

 Unscrew the Allen screw in the middle of

the chain wheel

 Replace the chain

 Revert all operations  Follow the instructions in

Photo Guide, Chain Maintenance and Adjustment

Photo Guide, Initial Adjustment of Joystick

Preparation

 Connect the hydraulic MultiPower Pack

to the control valve

 Connect the control valve to the

machine

 Start the hydraulic power unit according

to operating instructions

 Check that there is no fiber cable in the

blowing machine

 Check that the chains are not in contact

with each other

Adjustment

Turn the SPEED valve handle clockwise

to full stop (= zero speed)

Turn the POWER valve handle clockwise

to full stop (= full power)

Activate the joystick to forward

operation

Turn the SPEED valve handle

counterclockwise until the machine starts to run smoothly (approx. 1/3-1/2 turn)

Adjustment

Turn the POWER valve handle

counterclockwise until the machine stops

Turn off the hydraulic MultiPower Pack

Turn the POWER valve handle clockwise

until the machine starts to run smoothly (between 40 and 50 bar on the manometer)

Release the joystick to neutral

Photo Guide, Operating the Joystick

Preparation

 Make sure that the fiber cable and the

duct are in place in the blowing machine

 Start the hydraulic MultiPower Pack

according to operating instructions

 Make sure air supply is connected

Start-Up

Turn the POWER valve handle clockwise

to add power, if necessary

Activate the joystick to forward

operation

Adjust to appropriate speed by turning

the SPEED valve handle (look at speed m/min read-out)

Open the compressed air valve on the

machine after appropriate time

IMPORTANT Note regarding POWER and SPEED Adjustment

Please be aware that POWER (oil pressure) and SPEED (oil flow) can vary during operation due

to various factors like:

 Oil type/viscosity  Oil temperature  Variations in hydraulic power source  Etc.

EC Declaration of Conformity

We hereby declare that

101-10031 Miniflow RAPID Blowing Machine for mini cables

is manufactured in conformity with the EC Directives 2006/42/EC

Fremco A/S Ellehammervej 14 DK-9900 Frederikshavn Denmark

Niels Søgaard Hansen General Manager

01.04.2012

Fremco A/S ● Ellehammervej 14 ● 9900 Frederikshavn ● Denmark ●Tel. +45 72 30 12 13

Fremco MiniFlow RAPID Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual