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Condux Gulfstream 350 User's Manual & Safety Manual

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USER'S GUIDE & SAFETY MANUAL
Gulfstream™ 350

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Summary of Contents for Condux Gulfstream 350

  • Page 1 USER'S GUIDE & SAFETY MANUAL Gulfstream™ 350...
  • Page 3 Notes...
  • Page 4 For any information related to the machine (use, maintenance, spare parts) always state Model, Serial Number, and Manufacturing Year. This data can be found in the machine identification table. Manufacturer: Condux International Inc. 145 Kingswood Drive Mankato, MN United States 56001...

  • Page 5: Table Of Contents

    Table of Contents General Information ..................6 Technical Information .

  • Page 6: General Information

    GENERAL INFORMATION The operating instructions contain a full description of the Gulfstream™ 350, 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 from HDPE material to be adequately sealed in the exit of a machine. The conduit must be air tight up to a pressure of 215 psi (15 bar). For this purpose, connectors of screw, compression or fusion type must be used. Conduits from (8 mm) to 1.25" (42 mm) and fiber optic cables from 5/32" (4 mm) to 5/8" (16 mm) diameter can be accepted by the machine. TRADITIONAL DUCT 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...
  • Page 7 Machine must only be used for the work it was designed for. c. Machine is not to be used by unauthorized personnel in any application. d. Should there be any doubt concerning use, maintenance or anything else, please contact the factory or authorized Condux Supplier. OPERATOR QUALIFICATIONS a. Operator in charge of the machine and installation project must be appropriately dressed, avoiding loose clothes, hanging jewelry or whatever might become entangled in the moving parts.

  • Page 8: Technical Information

    TECHNICAL INFORMATION A. 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 conditionsNatural and/or artificial lighting of the work site, minimum 200 lux B. AIR COMPRESSOR REQUIREMENTS • Pneumatic Pressure: 215 psi (15 bar) Maximum • Required Flow Capacity: 35 SCFM(1 m3/min) to 375 SCFM (11 m3/min) •...

  • Page 9: Safe Operating Procedures

    SAFE OPERATING PROCEDURES Read and understand all procedures and safety instructions before using the Gulfstream™ 350. 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 ground. 3. Stay clear of cables or lines under tension. 4. Stay clear of pressurized line and conduit. 5.

  • Page 10: Unpacking The Gulfstream™ 350

    • 9/16 Stubby Ratchet Wrench (14.288 mm) • 5⁄8 " x 600 lb. Swivel (15.875 mm) • Venturi Air Plug • Plastic Divided Case w/Parts Label, Capscrew Set (10x) (M04-0.7’s) • BSP to NPT Pipe Fitting • Double Lock Claw Fitting • Machine Screw Kit • Allen Wrench (3⁄32") (2.681 mm) • Allen Wrench (2.5 mm) • Replacement 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. Figure 2. Unpacking the GS 350 Figure 3. Common Parts Kit...

  • Page 11: Set Up The Blower

    SET UP THE BLOWER This manual contains setup and operating instructions for the Gulfstream™ 350. IMPORTANT: The GS 350 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 (See page 9). Operating light levels should be at least 200 lux of light intensity. IMPORTANT: The Gulfstream™ 350 should not be positioned on a slope in excess of 13°. Remove the GS 350 from the storage box using the handle provided on the top of the machine.

  • Page 12: Cable Crash Test

    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™350. This test is necessary to set the air 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. It is also a necessary step to set the proper clamp force on the cable so there is no damage caused by slippage of the tractor drive at the desired air motor pressure.
  • Page 13 4. Cut a piece of fiber optic cable 15' (5 m)long. This is your test piece of cable. 5. Install the correct size Venturi to fit the cable being installed. (Figure 8) Figure 8. Install Venturi 6. Attach the Air Hose. The Gulfstream™ 350’s air system uses a Universal Claw (Figure 27) fitting(US). Take caution in routing the hose to prevent a tripping hazard. Follow these steps to connect the air hose: A. Attach the Universal claw fitting to the compressor to the machine. (Figure 9) Make sure valve is in off or exhaust position. (Figure 10) Figure 9. Attach Claw Fitting Figure 10. Air Valve B. Start the compressor and check all connections for leaks . In cold weather, run compressor until it is warmed up. Observe the following precautions to avoid pnuematic hazards: • Tighten all connections before applying pressure. Relieve pressure before connecting or disconnecting hose. • Do not exceed working pressure of pneumatic hose (not supplied). Visually inspect hose regularly and replace if damaged.
  • Page 14 7. Feed fiber through the machine, seals, and venturi into the duct. (Figure 11) 8. Feed fiber through machine and mark the fiber at the back end of the GS 350. (Figure 12) Figure 12. Mark the Fiber Figure 11. Run the Fiber 9. Pull 10' (3 m) of fiber back out of the duct. (Figure 13) 10. Set the motor pressure and clamp pressure. With small fiber, start at 20psi. (Figure 14) Figure 14. Set Pressure Figure 13. Pull Back Fiber 11. Belts should be in the open position and air valve should be off. (Figure 27) 12. Lower the belts to engage the fiber. Turn air on and engage belts, which will start the belts. Fiber should be installing. (Figure 16) Figure 16. Lower Belts Figure 15. E-Stop On...
  • Page 15 13. Repeat crash test until fiber doesn't slip and max force is achieved. A. If fiber slips, pull back and increase the clamp force. (Figure A) B. If fiber comes off the tracks or folds past mark at back end, decrease the motor force. (Figure B) Figure B Figure A C. If fiber stops and you are satisfied, mark down both the motor psi (or Bar) and clamp force psi (or Bar). Do not exceed these pressures during your install, as fiber integrity will be compromised. 14. Proceed to Pressure Test.

  • Page 16: Pressure Test Conduit

    PRESSURE TEST CONDUIT The conduit system must be able to withstand a maximum pressure of 215 psi (15 Bar), and be free of leaks. Pressure test products are available to perform this test. Conduit may also be tested using the Gulfstream™ 350. Follow the steps below: 1.
  • Page 17 5. Choose the correct Venturi to fit the cable being installed. Do not install at this time! 6. Clamp conduit in place. (Figure 21) Figure 21. Clamp Conduit 7. Place Seal Disk in Venturi slot. (Figure 22) 8. Close Air Block Cover and secure. (Figure 23) Tighten nuts securely, but do not overtighten (SNUG). Use a cross-tightening procedure. Figure 22. Place Venturi Figure 23.
  • Page 18 GULFSTREAM™ 350 CABLE PACKS & DUCT PACKS Gulfstream 350 Cable Packs Cable Pack Venturi Cable Seal Cable Grip Pack Cable OD Part Number Cable OD Part Number Cable OD Part Number Cable OD Part Number 0.16" - 0.17" 08780516 (4.1 - 4.3mm) 0.18" - 0.19" 08780517 (4.6 - 4.8mm)
  • Page 19 GULFSTREAM 350™ DUCT PACKS Gulfstream 350 Duct Packs (continued) Duct Pack Duct Clamp Duct Seal Carrier Foam Carrier Cable Grip Innerduct Eye Duct Size Part Duct Part Duct Part Carrier Part Carrier Part Duct Part Part Number Pack Number Number...
  • Page 20 9. Plug receiving end of Conduit with a suitable sized Conduit Pulling Eye or micro duct end stop. (Figure 24) 10. Choose the correct Pulling Grip & install on receiving end of Conduit over pulling eye or end cap. (Figure 25) Figure 25.
  • Page 21 12. Slowly open Air Block Control Valve. Pressurize conduit to 80-100 psi (5.5-6.9 bar). (Figure 28) and open Air Block Control Valve (Figure 29). Figure 28. Open Valve Figure 29. Open Air Block Control Valve 13. Prove conduit integrity. a. Close Air Control Valve. b.

  • Page 22: Prepare Conduit For Proof & Prepare Conduit For Install

    PREPARE CONDUIT PROOF & PREPARE CONDUIT FOR INSTALL 1. Remove Conduit Pulling Eye or End Stop and Pulling Grip from exiting end of Conduit. After removing pulling eye or end stop, re-install pulling grip in order to catch Foam Carrier during conduit lubrication. (Figure 30) 2. Open the Air Block Cover. (Figure 31) Figure 30. Install Pulling Grip Figure 31. Air Block Cover 3. Pour recommended (silicon-based) lubricant into Conduit opening before Foam Carrier: 1 quart/6000 feet (1 liter/2 km). (See Page 37 for lubricant chart) 4. Foam Carrier comes with Traditional Duct Packs. Micro Ducts you will need a pressure and proofing kit. Insert Foam Carrier (selected according to conduit size) into Conduit.
  • Page 23 6. Close the Air Block Cover. Tighten nuts securely, but do not over tighten. (Figure 34) Use cross tightening procedure with the rachet to secure completely. Figure 34. Close Air Block Figure 35. Connect Air 7. Spread lubricant through Conduit. a. Re-connect the air hose to the fiber blower and attach all safety clips (Figure 35). b. Turn the Air Control Valve handle to the 9 o’clock position and turn on the air from the compressor. (Figure 36) c. Slowly open Air Control Valve by turning to the 9 o’clock position. d. Make sure air block valve is open. (Figure 35) e. Blow Foam Carrier through conduit to spread lubricant and check for blockage (Figure 28). Follow all safety precautions.
  • Page 24 8. Ensure Air Block is depressurized. Open air pressure relief valve by moving the blower pressure valve handle counter clockwise to the 3 o’clock position. (Figure 37) Shut off the air from the compressor, decompress the air in the hose and disconnect the hose from the blower. 9. Remove Seal Disk and install Venturi. (Figure 38) Figure 38.

  • Page 25: Prepare Cable For Traditional Duct

    PREPARE CABLE FOR TRADITIONAL DUCT The GS 350 is designed so cable may be installed into the machine from the side. Follow these steps so cable is properly positioned to begin operation. 1. Choose the correct Cable Grip and install on fiber optic cable. (Figure 40) 2. Install 5/8" (16 mm) Swivel on Cable Grip. Grip must be firmly secured to cable. (Figure 41) Note: The eye on the grip can be compressed to fit smaller diameter conduits. The eye of a new grip can be taped with electrical tape in order to make it narrower and travel more easily through the conduit.
  • Page 26 Figure 44. Add Lubricant Figure 45. Feed Carrier Assembly into duct. Figure 46. Install Cable into Blower 5. Add silicone lubricant (PL5000) for micro duct and (PL2000) for traditional duct into Conduit before Carrier: 1/2 quart/6000 feet (.5 liter/2 km). (Figure 44) 6. Push Carrier, Swivel and Grip into Conduit. (Figure 45) 7. Feed cable into the counter rollers and tractor drive belts. Reinstall cable guides. (Figure 45)
  • Page 27 Figure 47. Add Lubricant Figure 48. Choose Cable Seals 8. Add lubricant to Conduit behind Cable Assembly: 1/2 quart/6000 feet (.5 liter/1 km). (Figure 47) 9. Choose the correct Cable Seals and install on cable. Cone side of Cable Seal faces conduit.

  • Page 28: Prepare Cable For Micro Duct

    PREPARE CABLE FOR MICRO DUCT 1. Install optional cable tips onto end of fiber to be installed. (Figure 50) 2. Feed cable through counter rollers and tractor drive belts. Reinstall cable guides. (Figure 51) 3. Choose the correct cable seals and install on cable. Cone side of cable seal faces conduit. Place cable seals into venturi grooves, split side down. (Figure 52) 4. Close air block cover. Tighten nuts securely, but do not over-tighten. Use cross tightening procesure to completely secure. (Figure 53) Figure 50.

  • Page 29: Final Set-Up

    FINAL SET-UP 1. Make sure Clear Guard is installed on GS 350. (Figure 54) 2. Lower Tractor Drive Cover by pushing the clamp button. (Figure 55) 3. Notify crew that preparations are complete and cable blowing is to begin. IMPORTANT: It is recommended that if a reel-tensioning unit is not being used, the cable reel should then be kept under control by a second operator who is required to wear proper safety equipment and maintain a proper distance from the cable (See page 9).

  • Page 30: Blower Operating Instructions

    BLOWER OPERATING INSTRUCTIONS A. OBSERVER AT EXIT PIT Station an observer with a 2-way communication device, at the far end of the Conduit, where the Cable carrier will exit. B. SET UP THE COUNTER BOX 1. Insert the battery into the battery clip 12 volt power supply (not supplied). (Figure 56) 2. Place Battery onto Magnetic Base. (Figure 57) Figure 56. Insert Battery Figure 57. Magnetic Base 3. You will need to buy: US Dewalt DCB 120 battery and DCB 101 Charger 12V INTL Dewalt DCB 127 battery and DCB 112 Charger 10.8V C.

  • Page 31: Changing From Feet To Meters And Resetting To Zero

    D. CHANGING FROM FEET TO METERS AND RESETTING TO ZERO. 1. To change to feet to meters or meters to feet. (Figure 59) a. Press Menu 2. Highlight the feet or meters and use the left and right arrow to change. Hit the okay button and hit the menu to get back to the main screen.
  • Page 32 4. Maintain control of cable reel to ensure smooth, stable flow. Failure to do so may cause cable to unwind too quickly. Continue to control cable speed with the flow control knob. 5. For Micro Duct, slowly rotate the motor regulator knob counter clockwise to engage tractor drive and increase speed.

  • Page 33: Preparation For Storage

    PREPARATION FOR STORAGE !WARNING: Air Block Assembly contains compressed air when blower isoperated. Opening Air Block while under pressure may cause serious personal injury. Ensure blower is depressurized before removing Air Block cover. A. REMOVE POWER FROM UNIT 1. Pull Button to Raise Tractor Drive. (Figure 66) 2. Turn off compressed air by closing the Air Control Valve at the blower. (Figure 67) Shut off air at the compressor and decompress air hose. Depressurize the air block exhaust by turning the air control valve to the 3 o’clock position. (Figure 68) Remove air hose when system is relieved of pressure.

  • Page 34: Maintenance

    MAINTENANCE GUIDE Procedure Daily Weekly Monthly 60 Days 90 Days Clean all assemblies and components thoroughly Inspect hoses for cracks and leaks. Inspect fasteners and screws. Check belts. Replace if excess wear has occurred. Motor Maintenace Return to Factory. Recommended Yearly.

  • Page 35: Troubleshooting Guide

    TROUBLE SHOOTING GUIDE Problem Solution Cable becomes jammed in the conduit 1. Inform the people at the other end system of the conduit that a problem has been experienced and the operator is going to shut down the system. 2. Shut off the pneumatic air supply with the Air Control Valve turning it to the 9 o’clock position, allowing the air pressure to be depressurized from the conduit and the...

  • Page 36: Warranty Information

    Listed wear parts as called out in the User’s Guide are not covered under the warranty. Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any and all claims arising from the purchase and use of the goods, shall be limited to the repair and replacement of the goods that do not conform to this warranty.
  • Page 37 TRADITIONAL DUCT SIZE LUBRICANT AMOUNT MICRODUCT SIZE LUBRICANT AMOUNT...
  • Page 38 Condux International, Inc. P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA © Copyright 2018, Condux International, Inc. 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Printed in USA Internet: http://www.condux.com • e-mail: cndxinfo@condux.com Literature Part Number: 91000023v2 Revision Number: 1.0...

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