Condux Gulfstream™ 400 Owner's manual

Patent # 6264171

Gulfstream™400 with Electrical Counter

USER'S GUIDE & SAFETY MANUAL

2

Read and understand all procedures and safety instructions before using the Gulfstream™ 400. 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.

Important Safety Notice

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.

If you have questions on:

SAFETY - OPERATIONS - APPLICATIONS

CALL 1-800-533-2077

Save this user’s guide for future reference.

COMMUNICATIONS WITH THE MANUFACTURER

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: [email protected]om

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Table of Contents

1

2

5

6

7

9

8

General Information ...................................................................................................4

Technical Specifications ................................................................................................6

A. Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

B. Condition of Use ............................................................................................6

C. Air Compression Requirements ..............................................................................6

D. Operational Capacities ......................................................................................8

E. Electronic Control Box .......................................................................................8

F. Physical Specifications .......................................................................................8

G. Acoustic Emission ...........................................................................................8

H. Caterpillar Drive Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

I. Conduit Coupling Requirements ..............................................................................8

Safe Operating Procedures .............................................................................................9

A. Work Area Safety ............................................................................................9

B. Hydraulic Devices ...........................................................................................9

C. Pneumatic Devices ..........................................................................................9

D. Electric Devices ........................................................................................... 10

Unpacking the Gulfstream™400 ...................................................................................... 10

A. Blower Components ....................................................................................... 10

B. Tools and Materials ........................................................................................ 10

Set Up the Blower .................................................................................................... 11

A. Attach Blower to Job Box .................................................................................. 11

Cable Crash Test ..................................................................................................... 12

Pressure Test Conduit ................................................................................................ 17

Prepare Conduit for Cable ............................................................................................ 22

Prepare Cable ........................................................................................................ 25

Final Set-Up ......................................................................................................... 27

A. Final Inspection ........................................................................................... 28

Blower Operating Instructions ........................................................................................ 28

A. Observer at Exit Pit ........................................................................................ 28

B. Connect Hydraulic Systems ................................................................................ 28

C. Set up the Electronic Control Box .......................................................................... 29

D. Panel Layout .............................................................................................. 30

E. Traction Control ........................................................................................... 32

F. Operation ................................................................................................. 32

Tear Down Procedures ............................................................................................... 34

A. Remove Power from Unit .................................................................................. 34

B. Remove Cable from Blower ................................................................................ 35

C. Separate Unit from Conduit ................................................................................ 35

Maintenance ......................................................................................................... 36

A. Track Cleaning & Tightening ............................................................................... 36

B. Replacement of Drive Belt ................................................................................. 36

Troubleshooting Guide ............................................................................................... 38

Appendices .......................................................................................................... 39

A. Blower with Job Box ....................................................................................... 39

B. Upper Drive Shaft Replacement Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

C. Lower Drive Shaft Replacement Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

D. Hydraulic Motor Replacement Kit .......................................................................... 42

E. Idler Bracket Bushing & Idler Bracket Screw Replacement Kits ............................................... 43

F. Air Block Assembly Replacement Kits ....................................................................... 44

G. Counter Clamp Roller & Cable Guide Replacement Kits ..................................................... 46

H. Timing & Takeup Roller & Idler Roller Replacement Kits ..................................................... 47

I. Hydraulic Coupler (Male) Replacement Kit .................................................................. 48

J. Hydraulic Coupler (Female) Replacement Kit ................................................................ 49

K. Clamp Adjustment Replacement Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

L. Lower Counter Roller Replacement Kit ..................................................................... 51

M. RH Cable Guide Roller Replacement Kit .................................................................... 52

N. LH Cable Guide Roller Replacement Kit .................................................................... 53

O. Counter Spring Replacement Kit ........................................................................... 54

P. Base Mount ............................................................................................... 55

Q. Pneumatic & Electrical Circuits ............................................................................. 56

R. Hydraulic Circuit ........................................................................................... 57

S. Hydraulic Flow Control Valve ............................................................................... 58

T. Possible Wear & Replacement Parts & Accessories ........................................................... 59

Warranty Information ................................................................................................ 67

3

4

10

11

12

13

15

14

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4

General Information

The operating instructions contain a full description of the Gulfstream™400, which has been

designed for the purpose of feeding fiber optic cable through round conduits of

uniform cross section. The conduit must previously have been installed underground

or overhead to receive the fiber optic cable and must be of sufficient length on exit to

be received by the machine. The conduit must be made of material with sufficient

compression strength for it to be adequately sealed in the exit of a machine. The

conduit must be airtight up to a pressure of 175 psi (12 bar). For this purpose,

connectors of screw, compression or fusion type must be used. Conduits from

(10 mm) to 1.97" (50.00 mm) and fiber optic cables from 1/4" (6 mm) to 1.13"

(28.7 mm) diameter can be accepted by the machine.

Fiber optic cable is fed into the conduit by combining pulling and pushing forces,

which draw the fiber optic cable through the conduit. The pulling force is achieved

by connecting the leading end of the fiber optic cable to a piston or carrier, which

fits exactly into the conduit to make an airtight seal. Air under pressure is fed in

behind the carrier causing it to be forced through the conduit. As the carrier moves

through the conduit, it pulls the fiber optic cable behind it. The fiber optic cable is

continuously pushed into the conduit by a tractor drive. This consists of two

caterpillar tracks, which grip the top and bottom of the fiber optic cable moving it into

the conduit. This ensures the fiber optic cable is always free as it moves into the

conduit and reduces the magnitude of the pulling forces needed to carry the leading

end through. Special lubricants are used to make it easier for the carrier to pass

through the conduit.

The exit of the machine consists of an air box that is made in two halves that clamp

together. The air box contains special removable seals on entry and exit, which

clamp around either the end of the conduit or the fiber optic cable to be fed into the

conduit. The seals can be changed to accommodate different conduit and fiber optic

cable sizes. The conduit is clamped between a pair of seals at the entrance to the

air block. A clamp located in front of the entrance to the air block holds the conduit

mechanically to prevent it from moving axially. The fiber optic cable enters through

two seals located in an aluminum nozzle that splits in half. The aluminum nozzle is

located in the entrance to the air box and is shaped to ensure an airtight seal around

the fiber optic cable. When the two halves of the air box are closed, air pressure is

admitted into the space between the seals on entry and exit.

The use of the Gulfsteam™400 for operations different from those discussed in this manual

are considered extremely dangerous and thus forbidden. The use of the Gulfstream™400

for purposes other than the one's described in this manual will result in improper use and

relieves the manufacturer from any responsibility, civil or penal. The manufacturer’s

responsibility declines even when one of the following happens:

a. The consequences caused by tampering and/or modifications carried out

without the manufacturer’s written acceptance.

b. The use of imitative spare parts.

c. Bad maintenance.

d. Use with disconnected safety devices.

e. The connection to machine and/or parts not produced and not directly

authorized by the manufacturer in a written acceptance.

1.

5

Designed to reduce stress on the fiber optic cable during installation The Gulfstream™ 400

is a unique device intended for inserting fiber optic cable directly into conduit with out the

use of pull tape and pulling machines.

Comprised of an air block and a tractor drive that, when combined with an air compressor

and a hydraulic power unit, will propel fiber optic cable measuring from 1⁄4" to 1.13" (6 mm

to 28.7 mm) into an unobstructed, unoccupied, airtight conduit run at speeds of 0 to 300

feet per minute (0-91 m/min). A cable carrier must be placed at the front end of the cable.

The Gulfstream™400 comes standard with job box, hydraulic hoses with couplings, digital

LCD electronic counter box, and an adjustable control valve to the tractor drive for speed

adjustment.

GENERAL MACHINE USE

a. Only qualified operators should use the machine. The operator should only be

the person who received qualified training from the product owning company or

trained by the manufacturer.

b. Machine must only be used for the work it was designed for.

c. Machine is not to be used with unauthorized personnel on the job site.

d. Should there be any doubt concerning use, functioning, maintenance or

anything else, please contact the factory or factory representative.

OPERATOR QUALIFICATIONS

a. Operator must know the required safety directives to run the machine that are

pertinent to the country where it is being used.

b. Operator in charge of the machine and installation project must be appropriately

dressed, avoiding large clothes, hanging jewelry or whatever might become

entangled in the moving parts.

c. Operator must also wear the necessary protective equipment such as gloves,

boots, helmet, etc.

d. Operator must carefully follow all advisements contained in the instruction

manual or on the machine.

e. Operator must have work area kept clean of obstacles that might inhibit a safe

working area.

MAINTENANCE QUALIFICATION

a. All of the machine maintenance must be carried out with the machine on a level

surface and not attached to any form of power source: electrical, pneumatic, nor

hydraulic.

b. Authorized and trained personnel must do all maintenance operations. Trained

personnel are defined as people who have received qualified training from the using

company or from the manufacturer.

6

Technical Information

A. HYDRAULIC SYSTEM REQUIREMENTS

• Hydraulic Operating Pressure: 1500 psi (103 bar) maximum

• Hydraulic Flow: 6.8 gpm (20.8 l/m) maximum

• Hydraulic Circuit Type: Open Center

• 5 micron filtration

• Fitted with BHTMA standard 1/2" flat faced quick release couplings

• Proper sized power unit should be used to run the blower machine to

prevent overheating

IMPORTANT: Operators must take any precautions that may have been

recommended by the suppliers of lubricants or hydraulic fluids. This applies to

the use and disposal of lubricants and hydraulic fluids including the

lubricant used to ease the passage of fiber optic cables through conduits.

B. 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 work site, minimum 200 lux

C. AIR COMPRESSOR REQUIREMENTS

• Pneumatic Pressure: 175 psi (12 bar) Maximum

• Required Flow Capacity: 375 SCFM (11 m3/min) Maximum

• Conduit Size: 10 mm-1.97" (50 mm) OD

• Air coolers are recommended for blowing fiber

• Compressor flow may need to be doubled if blowing distance is greater than

3,500 feet (1,067 meters)

• Air hose fittings need to be compatible with Dixon “Air King” universal

couplings.

The following charts help to determine the compressor size requirement based on

testing the conduit system (Figures 1-3).

1. Pressurize the conduit up to the maximum compressor pressure. That is the

Pstart - value.

2. Time for 10 seconds and record the ending pressure, Pend.

3. Subtract Pstart-Pend and divide by 10.

4. Find the appropriate x value and approximate length of conduit run then correlate that

information with the size of the conduit on the graph. The resulting zone is the approxi-

mate compressor requirement.

D. OPERATIONAL CAPACITIES

2.

7

Figure 1. Compressor Sizing for 3,280 ft (1,000 m) of Conduit Run

Figure 2. Compressor Sizing for 4,921 ft (1,500 m) of Conduit Run

Figure 3. Compressor Sizing for 8,202 ft (2,500 m) of Conduit Run

OUT OF RANGE

8

• Pushing Force: 175 lbs (778 N) maximum

• Pushing Speed: 300 ft/min (91 m/min) maximum

• Cable Sizes: .25" to 1.13" (6 mm to 28.7 mm)

• Conduit Sizes: 1/2", 3/4", 1", 1-1/4" TRUE, 1-1/4", 1-1/2" SDR 11 & 13.5,

2" and metric O.D. conduit; 10 & 12 mm, 12.7 mm, 14 mm, 16 mm,

18 mm, 25 mm, 32 mm, 36 mm, 37 mm, 40 mm, 42 mm, 44 mm, 46 mm

and 50 mm

E. ELECTRONIC CONTROL BOX

• Power Requirements: 12 volts DC

• Power consumption is 24 Watts

• Power connection must be to automotive power point or power point

connection on Condux hydraulic power unit

• Fused with a 2.5 amp fuse, 250 volt-5x20mm-GMA type

• Displays: Total Machine Distance, Distance of Run, Operational Speed,

Errors Descriptions

• Automatic Shutdown Speeds: 300 ft/min (91 m/min) maximum

F. PHYSICAL SPECIFICATIONS DOES NOT INCLUDE LEGS OR JOB BOX

• Height 16.5" (419 mm)

• Length 30" (761 mm)

• Width 14.8" (375 mm)

• Weight 82 lbs (37 kg)

G. ACOUSTIC EMISSION

• Level of max. sound pressure to the operator seat (ISO 11202) Lep=85 dB(A)

H. CATERPILLAR DRIVE SPECIFICATIONS

• Maximum pushing force: 175 lbs (778 N), depending on cable diameter

• Maximum pushing speed: 300 ft/min (91.5 m/min)

• Maximum clamping force: <114 lbf/in (20 N/mm)

• Independent pushing drive belts with polyurethane pads profiled for cable

0.23" (5.8 mm) to 1.13" (28.7 mm)

• Mechanical gas charged shock absorber clamp to prevent cable crush.

• Side guards.

I. CONDUIT COUPLING REQUIREMENTS

• Must withstand maximum air pressure of 175 psi (12 bar).

• Must withstand axial loading and vibration.

• Must be screw type, compression type, or fusion type.

• Sight Holes must be sealed.

• Must fit snugly.

• Conduit ends must be cut off squarely and deburred.

• Conduit must be fully seated into the coupler.

• Couplers should be installed in a straight section of conduit.

• Must be same size as conduit.

9

Safe Operating Practices

Read and understand all procedures and safety instructions before using the Gulfstream™

400. Observe all safety information on this page and note specific safety

requirements as explained by procedures called out in this manual. Failure to follow these

instructions could result in serious personal injury, property damage or death.

A. WORK AREA SAFETY

1. Wear personal protective equipment: hard hat, safety glasses, safety shoes, and

leather work gloves.

2. The safe operation of this equipment requires that the operators be on

stable footing.

3. Stay clear of cables or lines under tension.

4. Stay clear of pressurized line and conduit.

5. Stay out of manhole while blower is in use.

6. Use the blower only for its intended purpose. Do not use the tractor drive

without the air block to push or pull cable.

7. Do not place cable reel too close to unit. Place the reel far enough away from

the unit to ensure proper control.

8. Do not tamper with relief valves or pressure reducing valves.

9. Place cable grip on end of conduit to catch cable carrier and cable.

10. Keep hands away from tractor drive while blower is in operation.

B. HYDRAULIC DEVICES

Escaping fluids under pressure can penetrate the skin and cause serious personal

injury. Observe the following precautions to avoid hydraulic hazards:

1. Tighten all connections before applying pressure. Relieve pressure when

connecting or disconnecting hoses when servicing the unit.

2. Check for leaks with a piece of cardboard. Do not use your hands!

3. Do not exceed working pressure of hydraulic hoses.

4. Visually inspect hoses regularly and replace if damaged.

C. PNEUMATIC DEVICES

The Gulfstream™ 400 is a pneumatic device, using pressurized air to project cable at high

velocities. Please observe the following precautions when operating the blower:

1. Forced air creates flying debris. Always wear personal protective equipment.

Severe personal injury could result.

2. Ensure no personnel are in the destination access vault during the blowing

operation. Severe personal injury could result.

3.

10

D. ELECTRIC DEVICES

The electronic counter box and power supply are electrical devices. Electric shock hazards

exist that could result in severe personal injury or death. Observe the

following precautions to avoid electrical hazards:

1. Do not operate in or near water. This includes setting the electronic counter box or

battery pack on a wet surface or exposing them to rain.

2. Do not remove cover of electronic counter box. There are no user-serviceable

parts inside. Refer servicing to qualified service personnel.

3. The electronic counter box power switch should be in the off position before

connecting or disconnecting any cords.

11

4.

Unpacking the Blower

A. BLOWER COMPONENTS

Each Gulfstream™ 400 Package contains the following items.

• Hydraulic hose from hydraulic control assembly to hydraulic power unit

• Owner’s Manual

• Shipping Crate

• Metric & Standard Allen Wrench Set

•

3⁄8" Drive Ratchet & 9⁄16" Deep Well Socket

•

5⁄8" x 600 lb. Swivel

• Venturi Air Plug

• Plastic Divided Case w/Parts Label

• Parts and User Manual

• 1 Qt. Blowing Lubricant

• Capscrew Set (10) (M04-0.7’s)

• O-Ring Seal Kit

NOTE: If any parts are missing: please contact your Condux representative or call Condux

International at 1-800-533-2077 (USA or CANADA), or 1-507-387-6576.

B. TOOLS AND MATERIALS REQUIRED

The tools and materials are necessary to connect the Gulfstream™ 400 to a hydraulic power

source, and to change the inserts:

1. Allen Wrench (3⁄32")

2. Allen Wrench (2.5 mm)

3. Allen Wrench (5 mm)

4. Screwdriver, Flat

5. Screwdriver, Phillips

6.

3⁄8" Drive Ratchet

7.

9⁄16" Deep Well Socket

12 12

Set Up the Blower

This manual contains setup and operating instructions for the Gulfstream™400 with

job box.

IMPORTANT: The Deluxe Blower must not be located below overhead gantries, power lines

or walkways where there might be a risk of falling objects. The operator must be wearing

recommended protective gear before operating the blower. Operating light levels should

be at least 200 lux of light intensity.

A. ATTACH BLOWER TO JOB BOX

CAUTION: The machine should be removed with two people or lifted mechanically

by the lift rings located on the top of the machine (Figure 4).

IMPORTANT: The Gulfstream™400 should not be parked on a slope in excess of 13°. It

should not be parked on a side hill of more that 15°.

Remove the ball detent pin from the bottom of the blower. Attach the Gulfstream™400 to

the job box by aligning the guide tracks on the bottom of the blower with the

channel on the top of the box. Holes in the box channel need to align with holes on the

blower guide track. Once aligned, replace ball detent pin so it locks the blower in place

(Figure 5).

Lift

Rings

Figure 4. Lift out Blower with

Lift Rings

Figure 5. Replace Ball Detent Pin

5.

1313

Cable Crash Test

Cable Crash Testing is a very quick and easy step to be completed before attempting the

installation of cable with the Gulfstream™400. This test is necessary to set the hydraulic

motor pressure of the blower below the point that it may cause cable

damage as a result of over pushing or encountering an obstruction in the

sub-duct system.

Every cable has different pushing values and these values vary depending on

duct I.D. Example: A cable with a crash test value of 75 bar in 33 mm I.D. duct,

may have a crash value of only 60 bar in a 40 mm I.D. duct. This is because the

area of lateral movement is larger as the duct size increases.

!CAUTION: Always wear protective equipment: hard hat, safety glasses,

safety shoes and work gloves.

NOTE: The hydraulic motor pressure adjustment will have no effect on the

installation speed of the blowing unit. This is not a flow adjustment. This is a

pressure adjustment to prevent damage to the cable that can be caused by excessive

pushing force.

IMPORTANT: For the Crash Test to work properly use the same size cable and duct

that will be used for the job.

Set the hydraulic motor pressure on your Gulfstream™400 using the following

procedure.

1. Attach 12' (4 m) of duct to the Gulfstream™400 (Figure 6).

2. Install Conduit Pulling Eye on the receiving end of the duct (Figure 7).

3. Cut a piece of fiber optic cable 15' (5 m)

long. This is your test piece of cable.

4. Attach the correct size Venturi to fit the cable being installed (Figure 8).

Figure 6. Placement of Conduit in

Conduit Seal & Conduit Clamp Figure 7. Installing Conduit

Pulling Eye

6.

14

5. Attach Hydraulic Hoses (Figure 9). The Gulfstream™400’s hydraulic system uses quick-dis-

connect couplings. Keep all connections clean to avoid contamination and possible sys-

tem failure. Use hose end caps (supplied). A contaminated hydraulic system will effect the

operation of the cable blower and may invalidate your product warranty. Take caution in

routing the hoses to prevent a tripping hazard. Follow these steps to connect the hydrau-

lic components:

A. Attach the quick-disconnectcouplings to the hydraulic powersupply (Figure 10).

B. Start the hydraulic power unit and check all connections for leaks with a piece of card-

board. In cold weather, run hydraulic power supply until hydraulic oil warms up.

WARNING: Escaping fluids under pressure can penetrate the skin and cause serious per-

sonal injury. Observe the following precautions to avoid hydraulic hazards:

• Tighten all connections before applying pressure. Relieve pressure before

connecting or disconnecting hoses.

• Check for leaks with a piece of cardboard. Do not use hands!

• Do not exceed working pressure of hydraulic hoses. Visually

inspect hoses regularly and replace if damaged.

C. Run the blower for approximately 1 minute to remove any trapped air and then stop

the blower and hydraulic power source.

14

OPERATOR

HYDRAULIC

POWER

SOURCE

INNERDUCT

AIR HOSE

FIBER

OPTIC CABLE

ELECTRICAL HOOK UP

TO POWER SOURCE

CABLE

REEL

HYDRAULIC

HOSES

DELUXE LW

BLOWER

AIR

COMPRESSOR

Figure 8. Install Venturi Figure 9. Typical Set-Up

Figure 10. Attach Hydraulic Hoses

15

ELECTRONIC CRASH TEST

To run the Crash Test utilizing the Electronic Control Boxes PRESSURE LIMIT feature,

follow Crash Test steps 1-5 to set up the blower.

6. Press Touch Screen “LIMIT: XXXX” to open the Limit keypad.

7. Enter the desired pressure – suggested starting point is 800 PSI.

8. Place Cable in Blower from Rear Rollers through Tractor Drive. Push cable through

the duct until it stops against the Pulling Eye (Figure 13).

9. Place a mark on the Cable about 2" (51 mm) behind the Rear Rollers (Figure 14).

10. Install top Venturi (Figure 15). Close Air Block and tighten (Figure 16).

11. From the Rear Rollers, pull out apprmately 8' (2.4 m) of cable from the blower.

12. To avoid start up pressure spikes, which will register on the pressure

transducer and produce a false pressure error, set the Hydraulic Flow Control to

the lowest speed by rotating the flow control knob clockwise until it stops.

15

Figure 13. Install Cable Figure 14. Mark the Cable

Figure 15. Install Top Venturi Figure 16. Close Air Block

and tighten

16

13. Lower the Tractor Drive Cover, and tighten until the tracks make contact with the

cable. Give one additional turn to the clamp screw.

14. Turn on Hydraulic Power, and press the ECB DRIVE button ON.

15. Increase speed as quickly as possible by turning the Hydraulic Flow Control coun-

ter-clockwise. The Cable should be pushed into the duct. Continue to speed up

the tracks until the cable stops and the ECB gives a HI-PRESSURE ERROR screen.

16. If a HI-PRESSURE ERROR appears, follow the on-screen instructions to reset the

electronics and return to the Operations screen.

17. Raise Tractor Drive Cover. Pull out 8' (2.4m) of cable from the blower.

18. Lower and tighten Tractor Drive Cover. Repeat steps 6-7 to increase the

pressure by 50 PSI.

19. Repeat steps 12-16 until cable damage is

seen – either in the form of jacket dam-

age or bends in the cable, the cable folds

over, or you reach 1500 psi. You will

notice cable fold-over because the line

drawn on the cable will

disappear inside the machine or duct.

(Figure 17).

20. Repeat steps 6 and 7 to reduce the

PRESSURE LIMIT by 50 PSI.

21. Remove folded fiber and test again at cur-

rent PRESSURE LIMIT settings to ensure

no fiber fold over or

damage occurs.

22. Remove test piece of fiber optic cable.

23. If the re-test is confirms no cable damage, Re-adjust Flow Control setting to the

slowest speed.

24. Remove test duct piece from the Deluxe Blower.

25. Crash test is complete.

16

Figure 17. Cable folds over

17

Pressure Test Conduit

The conduit system must be able to withstand a maximum pressure of 175 psi, and

be free of leaks. A Conduit Pressure Test Kit, part number 08761457, is available to

perform this test. Conduit may also be tested for pressure using the Gulfstream™400,

follow the steps below.

1. Loosen the 6 nuts on the Air Block assembly (Figure 20). Open the Conduit Clamp

Cover and Air Block Cover (Figure 21).

2. Select the correct Conduit and Cable Components according to conduit and cable

size. Refer to the Conduit and Cable Pack selection charts

(Tables 1 and 2, page 18).

3. Choose the correct Conduit Seal and install both halves securely. (Figure 22).

4. Choose the correct Conduit Clamp and install both halves (Figure 23).

Figure 20. Loosen Air

Block Assembly

Figure 21. Open Conduit Clamp

Cover & Air Block Cover

Figure 22. Install Conduit Seal Figure 23. Install Conduit Clamp

7.

18

Table 1. Cable Packs

Table 2. Conduit Packs

P/N Cable OD P/N Cable OD P/N Cable OD P/N Cable OD

Inch/mm Inch/mm Inch/mm Inch/mm

08780406 0.23-0.28 (5.8-7.2)

08780407 0.29-0.34 (7.3-8.8)

08761424 0.35-0.42 (8.9-10.7)

08761425 0.43-0.48 (10.8-12.2)

08761426 0.49-0.55 (12.3-14.0)

08761427 0.56-0.60 (14.1-15.2)

08761428 0.61-0.67 (15.3- 17.0)

08761429 0.68-0.73 (17.1-18.5)

08761430 0.74-0.79 (18.6-20.1)

08761431 0.80-0.85 (20.2-21.6)

08761432 0.86-0.92 (21.7-23.4)

08761433 0.93-0.97 (23.5-24.6)

08761434 0.98-1.04 (24.7-26.4)

08761435 1.05-1.13 (26.5-28.7)

08780395

PACKAGE

08643754

033-29-1194

08643755

033-29-1195

08643756

033-29-1196

08643757

033-29-1197

08781116

0.35-0.48 (8.9-12.2)

0.49-0.60 (12.3-15.2)

08780284 0.61-0.73 (15.3-18.5)

CABLE SEAL

CABLE GRIP

1

08781115

CABLE PACK

VENTURI

075-1.00 (19.1-25.4)

1.00-1.24 (25.4-31.5)

2

3

08780393

40.86-1.13 (21.7-28.7)08780396

0.35-0.60 (8.9-15.2)

0.61-0.85 (15.3-21.6)

08780285 0.74-0.85 (18.6-21.6)

0.23-0.34 (5.8-8.8) 08780281 0.23-0.34 (5.8-8.8)

08780394

0.21-0.35 (5.3-8.9)

0.32-0.48 (8.1-12.2)

0.42-0.61 (10.7-15.5)

0.53-0.74 (13.5-18.8)

0.64-0.87 (16.3-22.1)

08780286 0.86-0.97 (21.7-24.6)

08780446 0.98-1.13 (24.7-28.7)

08643758

033-29-1198

08643759

033-29-1199

08643137

033-03-013

P/N Duct Size P/N Duct OD P/N Duct OD P/N Carrier P/N Carrier OD P/N Duct OD P/N ID Range

Inch/mm Inch/mm Inch/mm Inch/mm Inch/mm Inch/mm Inch/mm

108780795

0.50"

SDR 11-13.5

08780791

0.84

(21.30)

08780786

0.84

(21.30)

08780793

0.688

(17.50)

08078300

0.75

(19.0)

08643131

033-03-012

.75-.99

(19-25)

08761840

.76-.87

(20-22)

208780680

0.75"

SDR 11-13.5

08780682

1.050

(26.6)

08780685

1.050

(26.6)

08780690

0.75

(19.0)

08078300

0.75

(19.0)

08643137

033-03-013

1.00-1.24

(25.4-31.5)

08761840

.71-.89

(16-22)

308780386

1.00"

SDR 11-13.5

08780369

1.315

(33.4)

08780307

1.315

(33.4)

08761250

1.121

(28.5)

08761439

1.25

(31.8)

08643149

033-03-016

1.00-1.24

(25.4-31.5)

08761842

1.06-1.43

(27-37)

408780392

1.25"

SDR 11-13.5

08780375

1.660

(42.2)

08780051

1.660

(42.2)

08761255

1.414

(35.9)

08761440

1.50

(38.1)

08643149

033-03-016

1.50-1.99

(38.1-50.5)

08761842

1.06-1.43

(27-37)

508780397

1.50"

SDR 11-13.5

08780404

1.900

(48.3)

08780398

1.900

(48.3)

08761260

1.618

(41.1)

08761441

1.75

(44.5)

08643149

033-03-016

1.50-1.99

(38.1-50.5)

08761844

1.37-1.68

(35-43)

608780930

2.00"

SDR 11-13.5

_____ _____ ______ ______ 08761265

2.023

(51.4)

08761442

2.00

(50.8)

08643155

033-03-017

2.00-2.49

(50.8-63.2)

08761846 2"

708781120 20mm 08781122

0.787

(20.0)

08781121

0.787

(20.0)

08780793

0.688

(17.5)

08761444

1.00

(25.4)

08643131

(033-03-012

.75-.99

(19.0-25.1)

08914007

.551-.813

(14-20.65)

808780240 25mm 08780099

0.984 (25.0

08780134

0.984

(25.0)

08780230

0.787

(20.0)

08761439

1.25

(31.8)

08643137

033-03-013

1.00-1.24

(25.4-31.5)

08761840

.71-.89

(18-22)

908780385 32mm 08780368

1.260

(32.0)

08761560

1.260

(32.0)

08761560

1.063

(27.0)

08761439

1.25

(31.8)

08643143

033-03-15

1.25-1.49

(31.8-37.8)

08761842

1.06-1.43

(27-37)

10 08780387 36mm 08780370 1.417

(36.0)

08761643

08761555

1.417

(36.0)

08761643

08761555

1.181

(30.0)

1.220

08761439 1.25

(31.8)

08643143

033-03-15

1.25-1.49

(31.8-37.8) 08761842

1.06-1.43

(27-37)

11 08780388 37mm 08780371

1.457

(37.0)

08761555

1.457

(37.0)

08761555

1.220

(31.0)

08761439

1.25

(31.8)

08643143

033-03-15

1.25-1.49

(31.8-37.8)

08761842

1.06-1.43

(27-37)

12 08780389 1.25" TRUE 08780372

1.500

(38.1)

08761670

1.500

(38.1)

08761670

1.250

(31.0)

08761440

1.50

(38.1)

08643143

033-03-15

1.25-1.49

(31.8-37.8)

08761842

1.06-1.43

(27-37)

13 08780390 40mm 08780373

1.575

(40.0)

08761579

1.575

(40.0)

08761579

1.299

(33.0)

08761440

1.50

(38.1)

08643149

033-03-016

1.50-1.99

(38.1-50.5)

08761842

1.06-1.43

(27-37)

14 08780391 42mm 08780374

1.653

(42.0)

08761660

1.653

(42.0)

08761660

1.378

(35.0)

08761440

1.50

(38.1)

08643149

033-03-016

1.50-1.99

(38.1-50.5)

08761842

1.06-1.43

(27-37)

15 08780545 44mm 08780546

1.732

(44.0)

08761786

1.732

(44.0)

08761786

1.496

(38.0)

08761440

1.50

(38.1)

08643149

033-03-016

1.50-1.99

(38.1-50.5)

08761842

1.06-1.43

(27-37)

16 08780575 50mm 08780435

1.969

(50.0)

08761579

1.969

(50.0)

08761579

1.606

(40.0)

08761442

2.00

(50.8)

08643149

033-03-016

1.50-1.99

(38.1-50.5)

08761844

1.37-1.68

(35-43)

INNERDUCT EYE

PACKAGE

DUCT PACK

DUCT CLAMP

DUCT SEAL

CARRIE

FOAM CARRIER

CABLE GRIP

19

5. Choose the correct Venturi to fit the cable being installed. Do not install at this time!

6. Place conduit in the Conduit Seal and Conduit Clamp. Note placement up to ridge

on Conduit Seal (Figure 24).

7. Clamp conduit in place (Figure 25).

8. Place Seal Disk in Venturi slot. (Figure 26).

9. Close Air Block Cover and secure (Figure 27). Tighten nuts securely, but do not over

tighten. Use a cross-tightening procedure.

Figure 24. Placement of Conduit

in Conduit Seal & Conduit Clamp

Figure 25. Clamp Conduit

in Place

Figure 26. Installing Seal Disk Figure 27. Tighten Air Block

Cover

20

10. Plug receiving end of Conduit with a properly sized Conduit Pulling Eye (Figure 28)

(Appendix R pg. 62).

11. Choose the correct Pulling Grip & install on receiving end of Conduit

(Figure 29).

12. Connect the Air Compressor (Figure 30).

a. Ensure Air Valve is off before connecting air hose.

b. Attach the hose supplied with the air compressor to the air compressor

coupling. The blower air valve assembly is equipped with a claw type

connector. Use safety clips on all pneumatic hose connections (Figure 31).

c. Observe all safety procedures.

d. Route all hoses properly to prevent tripping over them.

!WARNING: Forced air creates flying debris. Always wear personal

protective equipment. Severe personal injury could result.

!WARNING: Ensure no personnel are in the destination access vault dur-

ing the blowing operation. Severe personal injury could result.

Figure 28. Installing Conduit

Pulling Eye

Figure 29. Installing Pulling Grip

OPERATOR

HYDRAULIC

POWER

SOURCE

INNERDUCT

AIR HOSE

FIBER

OPTIC CABLE

ELECTRICAL HOOK UP

TO POWER SOURCE

CABLE

REEL

HYDRAULIC

HOSES

DELUXE LW

BLOWER

AIR

COMPRESSOR

Figure 30. Typical Connections Figure 31. Installing Air Hose with

Safety Clips

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Condux Gulfstream™ 400 Owner's manual

Condux Gulfstream™ 400 Owner's manual

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