Fremco PowerFlow Operating Manual

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Page 1

OPERATING MANUAL

PowerFlow

Fremco A/S

Ellehammervej 14 9900 Frederikshavn Denmark Tel. +45 72 30 12 13

101-10001 Operating Manual 2013-01-03 EN

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Table of Content

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

PowerFlow Blowing Machine ................................................................................................................ 3

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

Big Flow Blowing Junction Block ........................................................................................................... 5

Identification .......................................................................................................................................................... 6

Application ............................................................................................................................................................. 6

Mounting ................................................................................................................................................................ 6

Supply of Air or Water Pressure .......................................................................................................................... 7

Blowing a Fiber Cable into a Duct ....................................................................................................................... 7

Preparing for Blowing ............................................................................................................................ 7

Use of Compressed Air for Blowing ...................................................................................................... 8

Use of Water for Blowing ....................................................................................................................... 8

Maintenance .......................................................................................................................................................... 9

Safety Directions ................................................................................................................................................. 10

Format and Wear Parts ...................................................................................................................................... 10

Recommended Accessories .............................................................................................................................. 10

EC Declaration of Conformity ............................................................................................................................ 11

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Technical Specifications

These specifications cover PowerFlow as well as the hydraulic control unit and the blowing junction block for microducts. The blowing junction block is a replaceable format part that must fit the actual size of the fiber cables/microducts and ducts in question.

PowerFlow

Manufacturer Fremco A/S Ellehammervej 14 9900 Frederikshavn Denmark

Item No. ................................................................................................................................................ 101-10001

Cable/microduct diameter ..................................................................................................................... 8-25 mm

Duct diameter ........................................................................................................................................ 18-70 mm

Blowing distance¹ ............................................................................................................................. Up to 10 km

Blowing speed¹ .......................................................................................................................... Up to 80 m/min.

Recommended water pressure ........................................................................................................... 10-20 bar

Recommended pressure and airflow²: ................................................... 8-12 bar (8,000-12,000 l/pr. min.)

Weight ............................................................................................................................................................. 38 kg

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

Width .......................................................................................................................................................... 230 mm

Height ......................................................................................................................................................... 350 mm

¹ Depending on type and quality of fiber cable and microduct ² Cooled and dried air

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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

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Big Flow Blowing Junction Block

For blowing multiple microducts or single cable

Manufacturer Fremco A/S Ellehammervej 14 9900 Frederikshavn Denmark

Item No. ...................................................................................................................................... 103-130424001

Length ........................................................................................................................................................ 270 mm

Width .......................................................................................................................................................... 100 mm

Height without connection pipe .............................................................................................................. 230 mm

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

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Identification

These instructions have been made to support the users of the cable blowing machine PowerFlow. 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 PowerFlow is constructed for blowing fiber optic cables into ducts. An example might be a 12 mm cable into a 40 mm duct.

Always use format parts designed for the actual diameter of cable and duct.

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

Mounting

Depending on the facilities, mount the air compressor or water pump and the hydraulic MultiPower Pack in inserting direction in front of the manhole. Check oil and fuel, and testrun equipment.

Arrange the PowerFlow in front of the manhole and guide the duct out of the hole and into the Powerflow. If the duct cannot reach the PowerFlow, extend the length with an extra piece of duct and a connector. Connect the hydraulic MultiPower Pack to the hydraulic control unit.

Make sure to place the Powerflow machine on a stable foundation and to fasten it to withstand the forces, which occur during use. These push/pull forces can be up to 125 kg.

Be careful to avoid any dirt on the surfaces when mounting the duct into the blowing junction block. Tighten the four screws equally so that the two halves are pressed completely together.

The cable seals in the black nylon part of the blowing junction block must fit tightly around the cable – the hole in the cable seal should be no more than 0.5 mm larger than the diameter of the cable. Use one to three cable seals depending on the expected pressure. New cable seals should always be installed after each cable blowing to secure maximum sealing.

The hydraulic control unit controls the direction (forward/back), speed and push/pull force.

Use the joystick on the hydraulic control unit to control start/stop and direction.

Speed can be adjusted by turning the screw marked “Speed”. By turning the screw to the left, pressure is reduced.

With the screw marked “Force” you can adjust the maximum force to be transferred to the cable. The pressure, and with it the force, is increased when the screw is turned to the right. Use the manometer to read the pressure and thereby the push/pull force.

CAUTION: Do not use excessive force, as this can damage the fiber cable.

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Supply of Air or Water Pressure

It is possible to use compressed air as well as water for blowing cables. Air is best suited for shorter distances (0-500 m) and for jobs where water in the ducts should be avoided. It is very important that the quality and volume of compressed is correct and meets the specifications.

If there is water in the air or too low pressure and volume, it will create insufficient results. The minimum compressor capacity is 8000 l/min. The compressed air must be filtered, cooled and dried to avoid moisture and dirt in the microduct.

Blowing a Fiber Cable into a Duct

Before preparing to blow, make sure that all format parts fit the number and diameter of the microducts/cable and duct.

Preparing for Blowing

 Arrange the cable drum equipment approx. 10 m in front of the Powerflow. Check that the drum

can turn easily and that the setup is stable.

 Start the hydraulic MultiPower Pack for cable blowing machines. Adjust to 50-75% power and

let it run 2-5 minutes.

 Connect the hoses from the hydraulic control unit to the hydraulic pump.

 Adjust the hydraulic control unit to 60-70 bar

 Turn off the hydraulic pump.

 Connect the hoses from the hydraulic control unit to the Powerflow.

 Put the fiber cable through the guide, the chains and the blowing junction block.

 Adjust the blowing junction block vertically to align it with the fiber cable coming through the

chains.

 REMEMBER to tighten the chains around the fiber cable using the handle on top of the machine.

 Attach a cable tip on the fiber cable

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Use of Compressed Air for Blowing

 Add approximately 100-500 ml lubricant to the duct, and then place a foam plug in the

duct as well.

 Connect the duct to the blowing junction block.

 Connect compressed air to the blowing junction block.

 Turn on air to the blowing junction block – only for a short time – until the foam plug comes out

at the other end of the duct.

 Turn on the hydraulic MultiPower Pack and start the Powerflow machine by moving the joystick

on the hydraulic control unit

 Increase air to the blowing junction block gradually.

 CAUTION: Check continuously that the drum turns smoothly. If not, check the pressure of the top

chain on the fiber cable. Intensify if necessary.

Use of Water for Blowing

 Connect the duct to the blowing junction block.

 Connect the suction tube from the water pump to the water supply.

 Start the engine on the water pump and let it run for approximately 4-5 min.

 Connect the pressure tube from the water pump to the blowing junction block.

 Turn on the hydraulic MultiPower Pack and start the machine by moving the joystick on the

hydraulic control unit.

 Increase water to the blowing junction block gradually.

 CAUTION: Check continuously that the drum turns at steady speed. If not, check if the water

pressure and flow is sufficient or/and intensify the pressure of the top chain on the fiber cable.

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Maintenance

The PowerFlow cable blowing machine does not require much maintenance, if a simple set of rules is followed.

See to it that the guide rollers, where the fiber cable enters the chains, are adjusted in a way that the cable is guided directly into the middle of the drive chains.

The chains should be kept well lubricated and free from sand and dirt. Use a good quality chain oil, preferably from a spray.

The chain pressure mechanism should be lubricated regularly with an ordinary grease lubricant.

The chains should be tightened to an extent that the they can be lifted only 5-10 mm from the support rail.

The chain support rails must be replaced when the side plates on the chain touch the support rails.

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 anticorrosion 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 due to unauthorized use, changes or adjustment of the machine are not covered by warranty.

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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 pump

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

 The air or water pressure should never

exceed the recommendations from the suppliers of microducts, fiber cables and duct. The pressure may never exceed 20 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 the blowing junction block is properly connected to the duct and that the microducts/cable are placed correctly between the chains.

 Make sure you do not touch the

microducts/cable too close to the machine because you risk getting your fingers injured, and make sure the microducts or the cable do not make loops that might be dangerous to people 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 process without interruptions. Stopping in the middle of the process 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.

Format and Wear Parts

Please ask your authorized dealer for a complete list.

Recommended Accessories

Using other hydraulic power sources can potentially cause damage on the Powerflow blowing machine. It is highly recommended to use the hydraulic power unit from Fremco:

101-10102 hydraulic MultiPower Pack

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EC Declaration of Conformity

We hereby declare that

101-10001 Powerflow Blowing Machine for 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