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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...
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.
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 ⁄...
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 •...
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Figure 1. Compressor Sizing for 3,280 ft (1,000 m) of Conduit Run OUT OF RANGE Figure 2. Compressor Sizing for 4,921 ft (1,500 m) of Conduit Run OUT OF RANGE Figure 3. Compressor Sizing for 8,202 ft (2,500 m) of Conduit Run...
• 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 •...
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.
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.
• 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™...
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.
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.
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HYDRAULIC POWER SOURCE ELECTRICAL HOOK UP TO POWER SOURCE HYDRAULIC HOSES INNERDUCT DELUXE LW BLOWER FIBER CABLE OPTIC CABLE REEL OPERATOR AIR HOSE COMPRESSOR Figure 9. Typical Set-Up Figure 8. Install Venturi Figure 10. Attach Hydraulic Hoses 5. Attach Hydraulic Hoses (Figure 9). The Gulfstream™400’s hydraulic system uses quick-dis- connect couplings.
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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.
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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.
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.
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CABLE PACK VENTURI CABLE SEAL CABLE GRIP PACKAGE Cable OD Cable OD Cable OD Cable OD Inch/mm Inch/mm Inch/mm Inch/mm 08780406 0.23-0.28 (5.8-7.2) 08643754 08780393 0.23-0.34 (5.8-8.8) 08780281 0.23-0.34 (5.8-8.8) 0.21-0.35 (5.3-8.9) 033-29-1194 08780407 0.29-0.34 (7.3-8.8) 08761424 0.35-0.42 (8.9-10.7) 08643755 08781115 0.35-0.48 (8.9-12.2) 0.32-0.48 (8.1-12.2)
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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). Figure 24.
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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). Figure 28. Installing Conduit Figure 29. Installing Pulling Grip Pulling Eye 12.
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13. Slowly open Air Control Valve. Pressurize conduit to 80-100 psi (5.5-6.9 bar) (Figure 32). Figure 32. Open Air Control Valve Figure 33. Close Air Control Valve 14. Prove conduit integrity. a. Close Air Control Valve (Figure 33). b. Conduit must not lose more than 20 psi (1.38 bar) over a 2-minute period. c.
Prepare Conduit for Cable 1. Remove Conduit Pulling Eye and Pulling Grip from receiving end of Conduit. After removing pulling eye, re-install pulling grip in order to catch Foam Carrier during conduit lubrication (Figure 35). 2. Open the Air Block Cover (Figure 36). Figure 35.
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Figure 39. Insert Foam Carrier Figure 40. Insert Seal Disk 7. Close the Air Block Cover. Tighten spanner nuts securely, but do not over tighten (Figure 41). Use cross tightening procedure with the rachet to secure completely. Figure 41. Tighten Air Block Figure 42.
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9. Ensure Air Block is depressurized. Open air pressure relief valve by moving the blow- er pressure valve handle counter clockwise to the 9 o’clock position (Figure 43). Shut off the air from the compressor, decompress the air in the hose and disconnect the hose from the blower.
Prepare Cable The Deluxe Blower is designed so cable may be installed 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 46) (See Tables 1 &...
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Figure 50. Open Rollers Figure 51. Tilt Blower 6. Add lubricant to Conduit before Carrier: 1/2 quart/6000 feet (.5 liter/2 km) (Figure 52). 7. Feed Cable Assembly through the counter rollers by lifting the Counter Roller Bracket. Lock the Rear Cable Guide Roller into place, and feed the cable through the Tractor Feed.
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Figure 54. Add Lubricant Behind Figure 55. Install Cable Seals Cable Assembly 9. Add lubricant to Conduit behind Cable Assembly: 1/2 quart/3000 feet (.5 liter/1 km) (Figure 54). 10. Choose the correct Cable Seals and install on cable. Grooved side of Cable Seal faces conduit.
Final Set-Up 1. Lower Tractor Drive Cover with turn crank until the cover reaches the stopper-bush- ing. The stopper-bushing will prevent the tractor cover from being clamped too tightly on the cable (Figure 57). 2. Level the height of Air Block’s Venturi Tube with Tractor Drive and the approximate center line of the cable (Figure 58).
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. CONNECT THE HYDRAULIC SYSTEMS (Figure 59) The Deluxe Blower’s hydraulic system uses quick-disconnect couplings. Keep all connections clean to avoid contamination and possible system failure.
Figure 61. Install Electronic Control Box Figure 62. Attach Power Cord C. SET UP THE ELECTRONIC CONTROL BOX 1. Install Electronic Control Box on blower and secure with 1/4 turn fasteners (Figure 61). 2. Attach Power Cord and plug into 12 volt power supply (Figure 62). Take caution in routing the electrical cord to prevent a tripping hazard.
Figure 65. Control Panel ON/F2: Engages Hydraulics to the Blower. The ON touch screen button will be highlight ed when the unit is running. The operator can use either the touch screen button of the Function button. CAUTION! Make sure the Hydraulic Flow Control Knob is turned all the way in before switching electronics to ON.
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Figure 66A. Emergency Stop Figure 66. Hi-Pressure Error PRSSR: Displays hydraulic working pressure in PSI or BAR. This pressure should match the pres sure shown on the analog pressure gauge. LIMIT: Displays the pressure limit set point in PSI or BAR. When the PRSSR value exceeds this set limit, the tractor drive will be stopped.
Figure 68. Rotate Hydraulic Flow Figure 67. Turn on Hydraulics Control Knob Figure 69. Turn On Air Figure 70. Turn Off Air at the Air Block E. TRACTION CONTROL Once activated, the traction control will stop the blower’s tractor drive if track speed goes above the maximum speed setting of 300 ft/min.
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Compressor and Hydraulic Power Supply. Refer to respective manufacturers operat- ing instructions for these units. 2. Make sure Electronics DRIVE is switched to ON. ON will be highlighted. Introduce a small amount of air to the system in order to straighten out the cable carrier inside the conduit.
NOTE: If the TRACTION CONTROL (TRAC CTRL) is set to OFF, the Tractor Drive will continue to operate regardless of the slippage and speed parameters. 6. Turn off compressed air flow to the Air Block (Figure 70). !WARNING: Air Block Assembly contains compressed air when blower operated.
13°. It should not be parked on a side hill of more that 15°. Maintenance CAUTION: Operators are not permitted to perform maintenance tasks unless Condux personnel or representatives have appropriately trained them. Disconnect the machine from its electrical, pneumatic, and hydraulic power sources before servicing.
• Pressure wash if necessary 3. To compensate for normal belt stretching, there is a rubber dampening bushing part number 08780028, which is lobed larger on one side than the other, located at the pivot position of the idler skid part number 08780105. It is in the smaller lobe position when it leaves the factory.
Troubleshooting Guide Problem Solution Cable becomes jammed in the conduit 1. Inform the people at the other end of system. the conduit that a problem has been experienced and the operator is going to shut down the system. 2. Shut off the hydraulic valve at the blower. 3.
Blower with Job Box APPENDIX Blower with Job Box ITEM PART NO DESCRIPTION 02288701 Pin, Hitch Cotterless 3/8 x 4.50 08780195 Cart, Job Box LW FO Blower-Assy 08782000 Blower, LW Fiber Optic-Deluxe ITEMS 1, 2 ARE NOT INCLUDED WITH 08782000 Parts List, Blower with Job Box...
Hydraulic Coupler (Male) Kit APPENDIX Hydraulic Coupler (Male) Replacement Kit 08780634 REQUIRED ITEM PART NO DESCRIPTION 02260200 Cap, Dust (Male Flat Face Cplrs) 02286710 Hose 06 x 22.0-06sw 02288620 Coupler, Male-Flat Face Metric 02288643 Hose 06 x 21.0-06sw 02288643 Hose 06 x 21.0-06sw 02288703 Ftg, Hyd 18mm-Thread Bond Seal ITEMS 2, 4, 5 ARE NOT INCLUDED IN KIT 08780634...
Hydraulic Coupler (Female) Kit APPENDIX Hydraulic Coupler (Female) Replacement Kit 08780635 REQUIRED ITEM PART NO DESCRIPTION 02260201 Cap, Dust (Fem Flat Face Cplrs) 02286710 Hose 06 x 22.0-06sw 02288619 Coupler, Female-Flt Face Metric 02288643 Hose 06 x 21.0-06sw 02288643 Hose 06 x 21.0-06sw 02288703 Ftg, Hyd 18mm-Thread Bond Seal ITEMS 2, 4, 5 ARE NOT INCLUDED IN KIT 08780634...
Base Mount APPENDIX ITEM PART NO DESCRIPTION 02288654 Handle, Adjustable Clamping 02288701 Pin, Hitch Cotterless 3/8 x 4.50 08780160 Base, Adjustable Assy-LW FO Blowr ITEMS 1 AND 2 INCLUDED WITH ITEM 3 Base Mount Individual Replacement Parts...
Possible Wear & Replacement Parts For replacement parts please contact the factory or Condux representative. List of possible wear items: Part Number Description 08780904 Belt, Cable 50MM X 260MM Center See Table 1, pg 18 for Cable Seals APPENDIX correct cable seal size...
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Possible Wear & Replacement Parts CABLE PACK WEAR PARTS Part Number Description 08780406 SEAL,CABLE 0.23-0.28 (5.8-7.3 ) OD CABLE 08780407 SEAL,CABLE 0.29-0.34 (7.4-8.8 ) OD CABLE 08761424 SEAL,CABLE 0.35-0.42 (8.9-10.7 ) OD CABLE 08761425 SEAL,CABLE 0.43-0.48 (10.8-12.2 ) OD CABLE 08761426 SEAL,CABLE 0.49-0.55 (12.3-14.0 ) OD CABLE...
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Replacement Parts & Accessories DUCT PACK WEAR PARTS Part Number Description 08078300 CARRIERS,FOAM 0.75 OD 08761439 CARRIERS,FOAM 1-1/4 OD 08761440 CARRIERS,FOAM 1-1/2 OD 08761441 CARRIERS,FOAM 1-3/4 OD 08761442 CARRIERS,FOAM 2 OD CARRIER ASSEMBLIES 08780793 CARRIER ASSY-0.688 OD 08780690 CARRIER ASSY-0.750 OD 08780230 CARRIER ASSY-0.787 OD 08761560...
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Replacement Parts & Accessories REPLACEMENT DISCS FOR CARRIERS 08780794 DISC CARRIER-0.688 OD 08780691 DISC CARRIER-0.750 OD 08780235 DISC CARRIER-0.787 OD 08761558 DISC CARRIER-1.063 OD 08761144 DISC CARRIER-1.121 OD 08761646 DISC CARRIER-1.181 OD 08761553 DISC CARRIER-1.220 OD 08761671 DISC CARRIER-1.250 OD 08761528 DISC CARRIER-1.299 OD 08761661...
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FIXED HEAD INNERDUCT PULLING EYE Tapered buttress threads thread into the innerduct for maximum pulling strength. These eyes connect directly to a Condux swivel. When properly sized and installed, these eyes will not pull out of the innerduct until the pulling tensions have greatly exceeded the maximum pulling tensions recommended by the innerduct manufacturers.
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Innerduct Slitter 08013101 Replacement Blade TURBOSLITTER™ The TurboSlitter from Condux can easily split HDPE pipe with wall 08010210 thicknesses ranging from 0.097 to 0.216 inches! The unit quickly adjusts to fit almost any rechargeable drill, 14-volt and larger. Save time and effort on the job with the TurboSlitter from Condux.
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Replacement Parts & Accessories INNERDUCT PRESSURE TEST KIT Use the Innerduct Pressure Test Kit to pressure test innerduct before setting Deluxe Blower. conduit system must be able to withstand and hold 150 psi (10.3 bar) for the Cable Blower to work properly. Part Number Description 08761457...
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.
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