General Machine Products 89300 User Manual
CABLE BLOWING MACHINE
Operation and Maintenance
Model 89300
All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form whatsoever without the written permission of General Machine Products Co., Inc.
General Machine Products Co., Inc. • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA
TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com
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REVISION HISTORY:
Rev.no Date Details Author
01 Jul -27-10 Original issue A. Sibun
02 Feb-1-11 Reformat for US A. Konschak
03 May -19-11 Updated photos to newer design A. Konschak
04 Nov-20-12 Update to reflect new design without remote A. Konschak
05 April-09-13
05.1 Feb-28-14 Added location of long inserts A. Konschak
Update grounding and belt replacement info
Various corrections and spec updates
A. Konschak
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CONTENTS
1. Safety Instructions
2. Critical Points
3. General Description
4. Specification
5. Operating procedures
6. Maintenance
7. Procedure for changing inserts in the tube clamp
8. Procedure for changing inserts in the air box
9. Procedure for changing inserts in the infeed and exit guides
10. Procedure for replacing the air box housing seal
11. Procedure for changing the air box infeed guide
12. Procedure for changing the cable drive belts
13. Procedure for tensioning the drive belts
14. Procedure for checking and replacing the motor drive belt
15. Monthly Service – check list
16. Service History Record
17. Tube integrity and Lubrication
18. Recommended Spares List
APPENDICES
Appendix 1 Cable and tube insert selection chart.
Appendix 2 Recommended torque control potentiometer settings
Appendix 3 Counter/Ratemeter Programming Instructions
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1.0 SAFETY INSTRUCTIONS
THIS EQUIPMENT SHOULD BE USED ONLY BY PERSONNEL WHO HAVE BEEN GIVEN THE
APPROPRIATE TRAINING, AND WHO ARE COMPETENT TO USE IT.
THESE INSTRUCTIONS ARE TO BE MADE AVAILABLE TO OPERATORS OF THIS EQUIPMENT
AT ALL TIMES, FAILURE TO OBSERVE THESE SAFETY INSTRUCTIONS COULD RESULT IN
SERIOUS PERSONAL INJURY AND/OR PROPERTY DAMAGE.
WORK AREA AND GENERAL SAFETY
1. Read and understand the operation and maintenance manual supplied with this equipment. Keep it in a
convenient place for future reference.
2. Keep children and untrained personnel away from this equipment while in operation.
3. Keep all guards and safety devices in place. Do not operate this equipment with guards removed or
damaged.
4. Keep hands, feet and loose clothing away from moving parts, especially at cable entry points.
5. Always stop the machine and isolate compressed air and electrical services to carry out lubrication and
servicing.
6. Check machine before starting for worn or damaged parts. Check for signs of loose nuts and bolts etc.
7. If machine is left unattended, ensure that unauthorized use is prevented.
8. Never leave the machine unattended while in use.
9. Consider the use of safety barriers, especially when used in public places, observe all statutory
requirements for working environments.
10. Beware of pinch points involved with rotating components,
11. Beware of hot surfaces, machine uses compressed air.
12. When operating machine always wear appropriate safety clothing, ear defenders, eye protection, hard hat,
safety shoes and leather gloves, machine operates with compressed air at up to 15 Bar.
13. Prior to installation ensure the tube route is connected properly.
14. Beware of exposed electrical contacts. Do not touch, or allow metal objects to come into contact.
15. Machine may cause additional fire hazard if involved in an existing fire due to compressed air.
16. No personnel are to be in manholes or ducts when the Cable Blowing Machine is being operated.
17. The machine must be operated on firm ground.
18. Stay clear of cables or lines under tension.
19. Stay clear of pressurized air line and tube.
20. Only use the machine for its intended purpose, do not use the roller drive without the air chamber to push
or to retrieve cable, blow air in the far end to help cable recovery.
21. Do not place cable drum too close to the Cable Blowing Machine.
22. The compressed air supply must not be allowed to enter the air chamber or tube before the rollers have
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been closed on to the cable. Do not turn the air on until a reasonable length of cable 150 ft. (50m) has
been installed into the tube.
23. Ensure the cable drum rotates freely on its stand, the cable should leave from the top of the drum.
24. The cable should enter the machine in a clean and dry condition. In damp, dusty atmospheres, the cable
should be cleaned continuously as it enters the machine.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, AS THE CABLE
COULD BE EJECTED FROM THE CABLE BLOWING MACHINE WITH HIGH
FORCE AND VELOCITY.
If the connecting plug on the power lead to the generator / (or supply) supplied with the Airstream machine is
unsuitable and requires replacement, the new plug must be correctly connected observing the color codes as
below.
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE CONNECTIONS MEET THE
ELECTRICAL REGULATIONS FOR THE RELEVANT COUNTRY.
Alternative Wiring
Black (Live)
White (Neutral)
Green (Earth)
Brown (Live)
Yellow & Green (Earth)
Blue (Neutral)
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GENERAL PNEUMATIC SAFETY INSTRUCTIONS
The GMP Fiber Optic Cable Blowing Machine is a pneumatic device, using pressurized air to project cable at
high velocities. Please observe the following precautions when operating the Cable Blowing Machine:
► Compressed air can cause flying debris. This could cause personal injury. Always wear personal protective
equipment.
► Ensure no personnel are in the manhole at the far end of the cable run. Severe personal injury may result.
► Never open the air chamber when pressurized.
► Only authorized, fully trained personnel should operate the air compressor.
GENERAL ELECTRICAL SAFETY INSTRUCTIONS
The machine has electronic and electrical power and control circuits. Electric shock hazards exist that could
result in severe personal injury. Observe the following precautions to avoid electrical hazards:
► Do not operate in water. Do not expose the machine to rain.
► Do not remove cover of electronic control panel or power supply unit. There are no user serviceable parts
inside. Refer servicing to qualified service personnel.
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2.0 CRITICAL POINTS THAT DRAMATICALLY AFFECT THE
OPERATION OF THE CABLE BLOWING MACHINE
► PRESSURE ON THE CABLE (POSITION OF THE CLOSE ARM ASSY) SHOULD BE SET AS
PER THE INSTRUCTIONS
► BELTS TO BE CLOSED AT ALL TIMES WHEN CABLE IS INSTALLED INTO MACHINE.
► CORD SEALS IN AIR CHAMBER IN GOOD CONDITION AND CORRECTLY INSTALLED TO
PROVIDE GOOD SEALING.
► CORRECT CABLE SEAL INSTALLED.
► TUBE FULLY CONNECTED AND PRESSURE-TESTED.
► TUBE AND CONNECTING FITTINGS ARE SUITABLE FOR OPERATING AT 15 BAR AIR
PRESSURE.
► TUBE CLAMP SECURELY TIGHTENED.
► COMPRESSOR CAPACITY 15 BAR AND SUITABLE FOR SIZE OF TUBE BEING USED.
► CABLE DRUM MUST BE LOCATED DIRECTLY BEHIND AND IN LINE WITH THE BLOWING
MACHINE.
► AIR CHAMBER, DRIVE BELTS AND PULLEYS, CABLE GUIDES, MUST BE CLEAN AND
FREE FROM DEBRIS, SLUDGE, DIRT, WATER AND LUBRICANT.
► THE CABLE MUST BE HAND GUIDED INTO THE BLOWING MACHINE THROUGH A DRY
CLEAN CLOTH BY THE OPERATOR WEARING WORK GLOVES.
► ENSURE THE COMPRESSED AIR SUPPLY IS NOT APPLIED TO THE CABLE UNTIL
APPROXIMATELY 150 FEET OF CABLE HAS BEEN INSTALLED OR THE MOTOR BEGINS
TO LABOR.
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DISCLAIMER
General Machine Products Co., Inc. takes care in the design of its products to
insure that the cable is protected during installation. Due to the variety and
different methods of cable manufacture the responsibility of checking the cable
compatibility with the equipment lies with the operator. Therefore, General
Machine Products cannot accept liability for any damage to the cable.
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3.0 GENERAL DESCRIPTION
The GMP AirStream machine is designed to install small diameter cable into underground tubes.
The machine uses a DC servo motor and reduction gearing to drive a pair of flexible belts (both belts are
driven).
The belts are covered with a soft pliable coating to prevent damage to the cable. A range of different coatings
and profiles are available depending on the surface texture of the cable being installed. The belts offer a large
surface area in contact with the cable ensuring high grip with reduced compressive loading.
During installation, the torque applied to the cable by the rollers can be adjusted to prevent the cable buckling
and to prevent damage to the cable. A full range of accessories is available to allow the machine to handle a
wide range of cables and tubes. This machine has the added function of high/low torque selection; this has
been developed to give greater sensitivity when operating in the low torque region aiding the installation of
small cables.
The machine may be placed on the ground or on a support to bring the cable to a suitable height. A separate
reinforced transit housing is provided, this will protect the machine from damage during transit and can be used
as a support for the machine when being used to install cable.
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4.0 SPECIFICATION
Cable size: 2.5 to 11.0mm 0.118” to 0.433”
Tube size: (OD) 5 to 18.0mm 0.197” to 0.708”
Cable speed: 0-80m/min. 0-262 ft/min
Maximum pushing force: 20 Kg. 44 lb.
Maximum air pressure: 15 bar. 210 psi.
Power requirements:*
Weight 14Kg approx. 31 lbs. approx.
Weight inc case 31 Kg approx. 68 lbs. approx.
Dimensions (ht x length x width) 266mmx460mmx305mm 10 1/2”x18 1/8” x12”
Ambient Temperature Range 0-40° C 32-104° F
100-277Vac 50/60 Hz
(power supply input)
48Vdc, 250W
(power supply output)
* The sensitive electronics needed to give the desired control over the installation speed and torque
require a certain electrical supply quality. Should a generator be necessary General Machine
recommends the use of an inverter type generator with a pure sine wave output. Please contact
General Machine Products Co., Inc. should you require further assistance.
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5.0 OPERATING PROCEDURE
IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS CABLE
BLOWING MACHINE:
▪ HAVE RECEIVED COMPREHENSIVE TRAINING IN THE USE OF THIS MACHINE.
▪ ARE COMPETENT TO USE IT,
▪ AUTHORIZED TO USE IT AND
▪ HAVE READ AND UNDERSTOOD THIS MANUAL
▪ GENERAL MACHINE PRODUCTS CO., INC. CANNOT BE HELD RESPONSIBLE FOR
MISUSE OF THIS EQUIPMENT.
Set up for installing cable with the machine mounted above ground:
Position the machine in line with the route of the duct.
Position the cable drum behind the machine and in line with the machine. See sketch below (this shows a plan
view of the recommended set up).
Tube Route
Ensure the machine is secure (either on its own stand or a separate suitable stand).
Ensure the machine is fitted with the appropriate guides and collets to suit the cable being installed and tubes
into which the cable is to be installed. (See Appendix 1 for details of interchangeable parts).
Ensure the remote is plugged in.
Note: The machine will not operate without the remote and will stop if it is accidentally pulled out or
the cable severed.
To set the machine up to install cable it will be necessary to:
Select the appropriate torque setting for the cable being installed, if in doubt start with the low torque setting.
Fit the tube into which the cable is to be installed into the air box and tube clamp.
Fit the cable through the machine.
Connect the air supply to the machine.
Connect the electrical power input to the machine.
Cable Drum
AirStream Machine
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Fit the tube into which the cable is to be installed into the air box and tube
clamp.
It is recommended that a length of tube similar in size to the tube into which the cable is to be installed be fitted
in the tube clamp. This length of tube may then be connected to the installed tube (the length of tube
underground into which the cable is to be installed) using a suitable connector.
Slide a suitable size O ring over the end of the tube.
Fit the tube into the end of the air box housing so that it protrudes approx. half way into the housing, position
the O ring so that it sits against the seal face, as shown in the illustration below.
Once the tube has been positioned, the
tube clamp may be closed, the swing
bolt swung down and the thumb nut
tightened, the tube is now secure.
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Fit the cable through the machine.
It is now possible to insert the cable in the machine, this can be carried out in 2 ways.
Method 1:
This method is only suitable if the machine has been previously set up with the correct infeed and exit guides
from the belts to suit the cable being installed, see section 9 for the procedure for changing the guides.
• Turn the speed control to zero.
• Turn the torque control to approx. ¼ turn from zero.
• Open the close assembly arm fully to the right.
• Ensure the direction switch is in the forward position.
• Select the appropriate split cable seal (see appendix 1) and position it in the groove in the seal housing.
• Press Start and slowly turn the speed control clockwise until the belts are just moving.
• Take the cable to be installed and pass it through the infeed guide so that the end is between the belts.
• Close the close arm to the left gently until the cable is gripped (there is no need to apply the full
installation pressure to the cable at this stage) – the cable should now feed slowly through the belts, cable
seal, air box and into the tube.
• Press Stop.
• Close and tighten the thumb nut securing the airbox.
• Set the machine up to install the cable into the duct.
Move the close assembly
to the far right to fully
open the drive belts
Loosen the thumb
nut and open the
seal housing
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Method 2:
• Open the close assembly arm fully to the right.
• Remove the top halves of the belt infeed and exit guides using the knurled screws (screwdriver slots are
provided if necessary). Ensure the correct guides are fitted for the cable (see appendix 1)
• Select the appropriate split cable seal (see appendix 1) and position it round the cable.
• Take the cable and simultaneously place it into the tube in the air box and thread it through the gaps in
the belts guards and between the belts. Ensure the cable seal seats in the appropriate groove in the seal
housing.
• Replace the top halves of the belt infeed and exit guides.
• Close the airbox
• Set the machine up to install the cable in the duct.
Setting the clamp force:
Close the drive roller assembly onto the cable as
follows:
The photo shows the drive roller close thumb screw
slightly loosened. (The assembly is free to move).
This thumb screw is attached to the clamp arm lever.
The clamp arm lever controls the position of the roller
assembly.
As the clamp arm is moved around the quadrant the
belts move together and apart.
When the clamp arm is furthest to the right, the gap
between the belts is at a maximum. And vice versa.
When preparing the machine to insert the cable, the clamp arm is positioned at its furthest point to the right
(rollers open). Once the cable has been positioned in the machine the rollers must be closed on the cable in
order to drive the cable. (And to stop the cable being dragged back out of the machine by any tension in the
cable).
The amount of pressure on the cable can be varied simply by loosening the thumb nut, moving the clamp arm
lever to the right or left; as required, and tightening the thumbscrew.
As more experience is gained using the machine, the amount of compression required will become clear.
Note:
An alternative method of setting the compression force is detailed in the note at the end of Appendix 2.
Close assembly
clamp lever
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