101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH

Operating Manual
MinifIow RAPID
MinifIow RAPID

World-wide dealer:
Tygesen Energi A/S
Strandvejen 33
5300 Kerteminde
Denmark
Phone: +45 6532 4380
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Index
Technical specifications.........................................................................................................3
Miniflow RAPD...................................................................................................................3
Hydraulic control unit..........................................................................................................4
dentification...........................................................................................................................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
Photo guide, chain maintenance and adjustment................................................................12
Photo guide, Pushing Power ndicator (PP) adjustment.....................................................13
Photo guide, changing format parts.....................................................................................14
Photo guide, changing chains and/or chain support rails....................................................15
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
TechnicaI specifications
These specifications covers Miniflow RAPD and the hydraulic control unit.
Miniflow RAPID
Manufacturer Fremco A/S
Toftegrdsvej 28
9900 Frederikshavn
DENMARK
tem no. 101-10031
Micro cable diameter 5 > 10 mm
Micro duct diameter 7 > 20 mm
Blowing distance (1) Up to 2 km
Blowing speed (1) Up to 80 m/min
Recommended maximum air pressure (2) 12 bar
Weight xx kg
Length xx mm
Width xx mm
Height xx mm
(1) Depending on type and quality of fiber cable and micro duct
(2) The air must be filtered, cooled and dried
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Hydraulic control unit
Manufacturer Fremco A/S
Toftegrdsvej 28
9900 Frederikshavn
DENMARK
tem no. 103-10041
Hydraulic connection 0>125 bar, 17 l/min
Manometer 160 bar
Tube to cable blowing machine 1500 mm
Tube to hydraulic pump 1500 mm
Length 250 mm
Width 250 mm
Height 310 mm
Weight 5 kg
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Identification
These instructions has been made to support the users of the cable blowing machine Mini-
flow RAPD. The identification of the machine can be seen at the type plate, which is
placed at the machine. At the type plate, the serial number, year of production and the
name and address of the manufacturer can be found.
t is recommended to read this instruction carefully and become familiar with the function-
ality and maintenance of the cable blowing machine before use.
AppIication
The cable blowing machine Miniflow RAPD is constructed for blowing fiber optic cables
into micro ducts.
Format parts, designed for the actual diameter of cable and duct, are always to be used.
The format parts are marked with the size for which they are intended.
t is very important that the correct format parts are used. f the duct and the format parts
do not fit, dangerous situations may occur.
Mounting
Please secure that the machine is placed on a stable foundation and that it has been
fastened to resist the forces, which occur during use.
SuppIy of compressed air and hydrauIic pressure
The volume and quality of compressed air are some of the most important parameters in
order to achieve good results when blowing fiber optic cables. The minimum capacity is
1.000 l/min at a pressure of 12 bar. The compressed air must be filtered, cooled and dried
to avoid moisture and dirt in the micro duct.
NOTE: Do not use compressed air directly from a compressor unit, since the air can be
very hot and can make damages to microduct, fiber cable and machinery.
The supply of hydraulic pressure must be 110 bar, minimum 17 l/min. t is recommended
to use the hydraulic station that is designed specifically for use with Fremco's cable blow-
ing machines.
Fiber cabIe bIowing
After the hydraulic pump and the air compressor have been set up and connected, the
chain tightening wheel is tightened so that the chains do not skid on the cable. The best
result is achieved by not tightening too hard.
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
The hydraulic control unit is used to control the direction (forward/back), speed and
push/pull force. Use the joystick on the hydraulic control unit to control start/stop and direc-
tion.
The speed can be adjusted by turning the screw marked Speed. By turning the screw to
the left, the pressure is reduced.
With the screw marked Force you are able to adjust the maximum force to be transferred
to the cable. The pressure, and with it the force, are increased when the screw is turned to
the right.
When installing the cable it is important to make sure that you do not push the cable too
hard into the duct, because it is the supplied compressed air that must lead the cable for-
ward inside the duct.
Use the Pushing Power ndicator (PP) on the Miniflow RAPD to monitor the pushing
power on the fiber cable.
There are several things to consider when blowing cables because they influence the dif-
ferent 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 RAPD cable blowing machine as
well as the force needed by seals and pressure inside the blowing junction block.
t is not possible to give directions on adjusting the different pressures because it depends
on the conditions of the specific job. For instance cable diameter and stiffness, duct dia-
meter and allowed pressure.
Please be aware of the maximum load of the cable specified by the cable manufacturer.
Maintenance
The Miniflow RAPD does not require much maintenance if the below mentioned recom-
mendations are followed:
The chains must be kept well lubricated and free from sand and dust. t is recommended
to use a chain spray with water-repellent oil.
The chains should be tightened to an extend that the chains can be lifted only 3-5 mm
from the chain support rail.
The chains and the chain support rails must be replaced timely.
t is very important to avoid any kind of dirt in the hydraulic connectors, when mounting the
hydraulic tubes.
f the machine is not to be used for a longer period of time, it should be cleaned and the
chains should be lubricated. t is also recommended to spray the machine with a anti-cor-
rosion oil. Store the machine in a dry and dust-free environment.
t is strongly recommended to use original spare parts. Repairs should be performed by
the manufacturer. Errors and damages due to unauthorized use, changes or adjustment of
the machine is not covered by the guarantee.
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Safety directions
Make sure that the machine is disconnected from all power sources, like the air
compressor and the hydraulic pump, before any kind of adjustment and mainten-
ance takes place.
The hydraulic power source, from the hydraulic pump for cable blowing machines or
from other sources, must never exceed the specified maximum pressure.
The air pressure should never exceed the recommendations from the suppliers of
micro ducts and fiber cables. The pressure must never exceed 12 bar, which is the
maximum pressure for the blowing junction block.
Observe that the machine is placed on a stable foundation and that it has been se-
cured before start. Make sure that the blowing junction block has been properly
connected to the micro duct 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 people around the machine.
Use hearing protection, if the hydraulic pump or other noisy equipment are 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 secure, that no other people are close to the machine and cable
drums in a way that could be dangerous when the machine is started.
t is always a clear advantage to be properly prepared in a way that makes it pos-
sible to run the blowing without interruptions. Pausing in the middle of blowing cre-
ates a risk of being unable to start again.
Make sure the working environment is clean and tidy to avoid injuries due to stum-
bling over cables and equipment.
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Machine overview
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Air pressure
manometer
Air regulator
handle
Hand wheel Ior
Chain adjustment
Pushing Power
Indicator (PPI)
Connection
For
Hydraulics
And
Compressed
Air
Meter
Counter
Format
parts
Inled guide
(two pairs)
101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Photo guide, operation
Before operation
Does the Nylon inlet guide bush diameter fits the
actual fiber cable, to secure fiber cable entry in the
middle of the chain groove?
Size can be wrong.
Extensive wear can make the hole oval
s the chain tension correct? The chains should be
tightened to an extend that the chains can be lifted
only 3-5 mm from the chain support rail.
Chain tension can vary on different positions
on the chain, please rotate chain and check
in several positions.
s the chain support rail worn in a way that the geo-
metry is odd?
Change wear parts, if necessary
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Preparing operation
t is recommended to reduce friction between duct and fiber cable by using a suitable lub-
ricant, which can be distributed to the inner surface of the duct in this way:
Add a appropriate amount of lubricant in the duct
Add a foam plug in the duct
Connect the duct to the machine, as well as the fiber cable
Open the air valve to let the compressed air push the foam plug through the duct
Close the air valve, when the foam plug is through the duct
n 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.
Turn down the oil flow (=machine speed) on the
joy-stick, and activate the joy-stick. Check, that the
chains operate with moderate speed. The speed
can be adjusted later during operation.
Turn down the hydraulic pressure (=machine push-
ing power) on the joy-stick.
Activate the joy-stick in forward direction. ncrease the pressure, until the machine starts
to run.
ncrease hydraulic pressure a bit more to ensure continuously running.
This secures, that if the fiber cable meets extensive resistance, the machine will
stop instead of making wheel-spin, damaging fiber cable and chains.
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Speed
Power
101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
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.
Many rubber particles on the machine surface can be a sign of excessive wear.
Check the air pressure regulary
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Check Ior rubber
Particles
Lubricate chains
regulary
101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Photo guide, chain maintenance and adjustment
Keep the chains well adjusted and clean from dust and dirt. Lubricate regularly with a wa-
ter proof chain oil spray
Tightening of the chains:
Loosen the two unbrako screws
Tighten the unbrako middle eccentric
Tighten the two unbrako screws
Check the chain tension:
The chains should be tightened to an extend
that the chains 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 shield
Turn on the machine to run slowly without
load
Spray between the chain and the chain sup-
port rail
Take care, that no oil escapes to the rubber
surface on the chain
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Photo guide, Pushing Power Indicator (PPI) adjustment
The offset point of the PP indicator can be adjusted. This can be necessary when the ma-
chine has been in operation for some time
Use a 5 mm hexagon key and find the ad-
justing unbrako screw behind the hole in
front of the machine
Adjust, until the indicator is placed in the
start of the scale
Push the blowing junction block in direction
away from chains
Let the blowing junction block return to un-
loaded position
Re-adjust, if necessary
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Photo guide, changing format parts
Loosen the unbrako screw in the bottom part
by using a hexagon key
Remove the format part
Repeat the operation for the top part (the lid)
Replace the format parts
Tighten the unbrako screws just enough to
hold the format parts
Close the lid firmly
Tighten the unbrako screws firmly
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101-10031 Miniflow RAPD Operating Manual 2012-02 ENGLSH
Photo guide, changing chains and/or chain support raiIs
Remove the chain shields
Remove the upper part by unscrewing the
two unbrako bolts
Remove the chain support rail
Check for wear and replace, if necessary
Unscrew the unbrako bolt in the middle of
the chain wheel
Remove the chain wheel from its position
Be careful not to lose the spacer below the
chain wheel
Replace the chain
Revert all the operations
Follow the instructions in Photo guide, chain
maintenance and adjustment
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