Belden PPC HAPI Miniflex User manual
HAPI™ Tool User Manual
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HAPI™ Miniex® Cable
Installation Tool
User Manual
Scan for access to the HAPI Tool webpage
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HAPI™ Miniex® Cable
Installation Tool
User Manual
Table of Contents
Safety Information
1. Parts
1.1 HAPI Tool Box
1.2 HAPI Tool Kit
1.3 Spare Parts
2. Assembly
2.1 Tool Setup
2.2CuandGripAdjustment
2.3InsertingtheMonopod
2.4UsingaSuitablePay-O
3. Using the Tool
3.1 Crash Test
3.2CableandMicroductSizeChart
3.3Distance/BendChart
3.4 Inserting the Cable
3.5MicroductConnection
3.5.1 MicroductConnection(option1)
3.5.2 MicroductConnection(option2)
3.6 Correct use of the Tensioning Knob
3.7CrankingtheHandle
4. Troubleshooting
5. Tool Maintenance
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5
5
5
6
7
8
9
10
11
12
12
13
13
14
15
16
17
18
19
20
21
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HAPI™ Miniex® Cable
Installation Tool
User Manual
Safety Information
When using ber optic equipment, basic precautions should always be followed to reduce the risk of injury to
persons, including the following:
1. Follow all warning and instructions marked on the product.
2. Laser light can be visible or invisible and can cause serious eye injury.
a. Do not look directly into the end of a ber optic connector.
b. Do not look directly into the end of a ber optic adapter having a ber optic connector.
3. Install dust caps or plugs onto unused ber optic connectors or non-shuttered ber optic adapters.
4. Open microducts should be capped o with suitable dust caps or gas block connectors when not in use.
The HAPI™ tool allows Miniex® cables to be pushed into microduct signicantly faster and with less eort than
traditional hand pushing. While installation distances are not necessarily longer, the time to deploy ber and the
risk of cable damage are greatly reduced.
The tool is quick and easy to assemble and use, featuring functionality to set up the tool for both left and right handed
operation. The HAPI is light weight, ergonomic and low maintenance. This user guide gives a comprehensive
overview of what is included in the kit, setting the tool up, using the tool, trouble shooting installation problems and
details how to maintain the HAPI.
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HAPI™ Miniex® Cable
Installation Tool
User Manual
Olives
HandGrip
ToolBody
ArmCu
HAPI Kit in Case
Monopod
Description Part Number
Miniex® Cable Installation Tool 10-HAPI-01
Olives for 5 mm Microduct 10-HAPI-Olive05
Olives for 7 mm Microduct 10-HAPI-Olive07
Olives for 8 mm Microduct 10-HAPI-Olive08
Olives for 10 mm Microduct 10-HAPI-Olive10
Monopod 10-HAPI-MONOPOD
NOTE: The HAPI Tool comes with an Arm Cu and Hand Grip included (see illustrations below)
1.1 What’s in the HAPI Tool Box
1.2 HAPI Tool Kit
1.0 HAPI™ Tool Parts
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HAPI™ Miniex® Cable
Installation Tool
User Manual
The HAPI™ Tool is manufactured to last and should not need any consumables for at least 50,000 m/1,000
installations, assuming the tool is used properly and operated with care.
In addition to the Tool Kit, the following components can be re-ordered for the HAPI Tool.
Description Part Number
Miniex® Cable Installation Tool 10-HAPI-01
Olives
5mm Microduct Olives 10-HAPI-Olive05
7mm Microduct Olives 10-HAPI-Olive07
8mm Microduct Olives 10-HAPI-Olive08
10mm Microduct Olives 10-HAPI-Olive10
Monopod 10-HAPI-MONOPOD
Adapter for Camera Tripod 10-HAPI-Adapter
Tyre/Wheel Assembly 10-HAPI-WHEEL
Microduct Olive Set: 5-10mm (2 pairs each) 10-HAPI-OLIVESET
Cable Guide 10-HAPI-GUIDE
1.3 Spare Parts
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HAPI™ Miniex® Cable
Installation Tool
User Manual
2.0 How to Assemble the HAPI Tool
The HAPI™ Tool is supplied in a ruggedized case which contains all of the parts required to assemble and use it
(see page 5 for identifying these). It can also be used with an optional camera tripod.
See the following pages for setting up the HAPI and using it.
HAPI Tool with the
case open showing
the contents
Optional camera tripod
on which the HAPI can
be mounted using the
supplied adaptor
Tripod adaptor
7
HAPI Tool Kit with the
case open, showing the
contents
Tripod adapter Optional camera tripod
for mounting the HAPI
with the supplied adapter
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HAPI™ Miniex® Cable
Installation Tool
User Manual
The HAPI™ Tool can be congured for left- and right-handed operation.. The default setup is right handed (crank
handle is operated by the right hand). For left handed operation, the cable guide and microduct clamp orientation is
swapped, as illustrated in the image below.
Left-handed set up
Right-handed set up
2.1 Tool Set Up
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HAPI™ Miniex® Cable
Installation Tool
User Manual
To operate the tool, the arm cu and hand grip must be tted to the tool body as shown below. Both parts are xed
to the main body via index plungers.
A series of holes located on the underside of the arm cu allow for multi-positioning of the cu and grip. This
provides the best possible ergonomics and it is advisable to rst nd the most comfortable position.
Assembled with arm cu & hand grip
Arm Cu
Tool Body
Hand Grip
2.2CuandGripAdjustment
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HAPI™ Miniex® Cable
Installation Tool
User Manual
For extended periods of use, the HAPI™ Tool is supplied with a height adjustable monopod.
The pole is inserted into the base of the main body into the tapered hole.
The height is adjusted by opening the latch, sliding the pole upward or downward and locking the latch when the
pole is at the desired height.
Latch open Latch closed
2.3InsertingtheMonopod
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HAPI™ Miniex® Cable
Installation Tool
User Manual
The cable being installed should be placed onto a zero/low tension payo stand to prevent unnecessary tyre wear.
The PPC Spool Sleeve, Reel Bag, Pizza Box and Cable Caddie are ideal cable payos for use with the HAPI™ Tool.
Dispense the cable from the top of the reel to oer the best height alignment into the HAPI cable guide.
2.4UsingaSuitablePay-O
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HAPI™ Miniex® Cable
Installation Tool
User Manual
3.0 Using The Tool
There are a number of considerations to take into account when planning to use the HAPI™ Tool to install Miniex®
cable into microducts. These are considered below and in the following pages.
Before using the HAPI tool, it is recommended that a crash test be performed to determine the maximum force/
torque that can be safely applied to the cable. A crash test helps the operator to understand how much force can be
safely applied to the crank handle without causing the cable to slip or become damaged.
The distances quoted in the chart (see 3.3 on pg. 13) are benchmark guidelines but should not be considered exact.
Depending on the nature of the route and the performance of the microduct, shorter or longer distances might be
achieved. The operator should not simply assume that the cable can be installed a certain distance without rst
performing a crash test.
The crash test will indicate to the operator the safe level of force to use when turning the drive wheel. The crash test
should be undertaken whenever a dierent size/type/ber count of cable or microduct is used.
The steps below outline a simple way to perform a crash test to prevent excessive force being applied.
CrashTestMethod
1. Cut a short length of microduct (the length should be long enough to allow acceleration of the cable to achieve
a realistic pushing speed).
2. Block the end of the duct with a suitable end cap or plug. Kinking the end of the microduct will have the same
eect if no end cap is available.
3. Using a scrap length of cable that is at least 0.5 m longer than the microduct, set the tool up as outlined in
sections 3.4 to 3.6 of this user guide.
4. Crank the handle as detailed in section 3.6. When the cable meets resistance at the end of the microduct,
gradually apply more force until the cable slips or becomes damaged. If necessary, tighten the tensioning knob
to provide maximum grip from the drive wheel.
5. When no more tension/grip can be applied and the drive wheel continues to slip or the Miniex cable becomes
damaged, the maximum pushing force has been witnessed.
6. Take note of the force being applied before the cable slipped or became damaged. This represents the maximum
pushing force and should be recalled when using the HAPI tool to prevent undesirable cable damage.
7. Remember that using a dierent cable construction or microduct will require further crash testing.
3.1 Crash Test
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HAPI™ Miniex® Cable
Installation Tool
User Manual
The Miniex® cable should be installed into a suitable-sized microduct.
Pushing Miniex into an oversized duct (too large an ID) can result in cable buckling if the pushing force it too high.
Pushing into an undersized duct can limit the installation distance.
Aim to use the optimum cable and duct combination – see chart below. When the combination is not optimum, use
caution when installing the cable to prevent potential ber damage.
MicroductInnerDiameter/BoreSize
Miniex Cable 3.0 - 3.5 mm 3.5 - 4.5 mm 5.0 - 6.0 mm 6.0 - 7.0 mm
2.2mm Yes Yes Not Optimum No
3.0mm No Not Optimum Yes Yes
Installation distance is dependent on a number of factors including the eciency of the microduct (low friction), the
size combination (see chart in section 3.2 above) and the number of bends in the route (quantity and radius).
The distances expressed in the table below are approximations based on a low friction microduct (such as PPC
Microduct) and bends not less than 200mm radius.
3.2CableandMicroductSizeChart
3.3Distance/BendChart
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HAPI™ Miniex® Cable
Installation Tool
User Manual
The cable must pass through the Cable Guide and between the large (drive) wheel and the small (auxiliary) wheel.
The steps below are guidelines only.
It is recommended to insert the cable prior to connecting the microduct but operators should nd a practice that
suits them best. Instructions for connecting the microduct to the HAPI™ Tool are detailed in the section 3.5 of this
document.
1. Turn the tensioning knob to raise the auxiliary wheel and allow the cable to pass between the auxiliary wheel and
the drive wheel.
2. Hold the cable and thread it through or press it into the cable guide.
3. Pull about 1 m (approx. 3 ft) of cable through the tool and between the two wheels.
4. Turn the tensioning knob to lower the auxiliary wheel onto the cable.
3.4 Inserting the Cable
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HAPI™ Miniex® Cable
Installation Tool
User Manual
Connecting the microduct is a process of attaching the pair of adapters/olives to the end of the microduct and
retaining them in the clamp mechanism.
The HAPI™ Tool is supplied with four sizes of olive to cater for a range of common microduct sizes:
The olives have internal ribs to grip the microduct. In the case of PPC Miniex® microduct these ribs align with the
Miniex grooves.
Ensure that the microduct bore is clean, dry and empty before proceeding with the installation. There are two main
approached to connecting the microduct - see sections 3.5.1 and 3.5.2 that follow. It is recommended that the
operator nds the method which best suits them.
MicroductSize Olive Color
5.0 mm Black
7.0 mm Green
8.0 mm Blue
10.0 mm Red
3.5MicroductConnection
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HAPI™ Miniex® Cable
Installation Tool
User Manual
1. Feed approx. 1 m of cable
into the microduct.
2. Select the appropriate size pair
of olives and position them over
the end of the microduct.
3. Seat the olives into the open
microduct clamp.
4. Close the clamp and lock
the latch.
Option 1 – Duct into Olive then Olive into Clamp
3.5.1MicroductConnection
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HAPI™ Miniex® Cable
Installation Tool
User Manual
Option 2 – Olive into Clamp then Duct in Olive
1. Feed approx. 1 m of cable
into the microduct.
2. Seat one of the olives into the
open microduct clamp.
3. Position the microduct into the
seated olive.
4. Place the second olive onto the microduct.
5. Close the clamp and lock
the latch.
3.5.2MicroductConnection
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HAPI™ Miniex® Cable
Installation Tool
User Manual
The tensioning system is maintained by a coil spring to balance the load placed on the cable.
Tension is required to prevent excessive cable slip and tyre wear, however, it is not necessary to apply excessive
force on the cable to install successfully.
Over-tightening the tensioning knob increases the force required to turn the drive wheel and result in excessive eort
being required to turn the crank handle.
The auxiliary wheel is lowered and raised by turning the Tensioning
Knob — Clockwise to lower the wheel and counter-clockwise to raise
the wheel.
During setup, the wheel must be raised to allow the cable to be inserted,
then lowered to retain the cable in its correct position between the
auxiliary and drive wheels.
Auxiliary wheel in open position Auxiliary wheel in closed position
3.6 Correct Use of the Tensioning Knob
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HAPI™ Miniex® Cable
Installation Tool
User Manual
After the cable and microduct setup is complete and the cu and grip are positioned for maximum comfort, it is time
to install the cable.
It is recommended:
• Not to exceed 120 revolutions per minute (2 per second)
• Maintain a constant speed and force throughout the pushing phase
– The speed should be gradually decreased as the distance increases. Operators should nd that this is a natural
response as the force required to push the cable increases.
– The operator should look for feedback from the crank handle throughout the installation to help determine if the
cable is installing correctly.
– Cable slip, a badly prepared microduct route, inappropriate cable pay-o and suboptimal cable / microduct
combinations can all be identied by the kinesthetic feedback from the HAPI™ Tool.
– As soon as the maximum pushing force is felt or if the cable begins to slip on the drive wheel, immediately stop
turning the handle to prevent tyre wear. Consult the troubleshooting section of this user guide.
3.7CrankingtheHandle
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HAPI™ Miniex® Cable
Installation Tool
User Manual
4.0 Troubleshooting
This can indicate cable slip which would require the tension to be increased via the tensioning knob.
This can indicate high friction within the route and undulations/macro bending of the cable inside the microduct. Best
practice is to reduce the speed and not force the crank handle to turn.
Check that the correct size microduct olives have been selected (see table in Section 3.5).
Check that the tensioning knob is not overtightened. The maximum installation distance may be close (see chart in
Section 3.3 on pg. 13). Do not force the crank handle, especially if the cable/duct size combination is not optimum
(see Table in Section 3.2 on page 13).
Check that the tensioning knob is tightened suciently and applying enough compression onto the cable. Check that
the tyre is clean and dry. Check that the tyre is not damaged or with at spots. Replace the drive wheel if necessary
(spare drive wheels can be ordered separately).
Disconnect the microduct from the HAPI™ Tool and push the cable by hand. If the cable cannot be installed any
further, the maximum installable distance has been achieved or the cable has met an obstacle/impassable bend in
the microduct.
This can be caused by misalignment of the microduct clamp. To remedy, follow the steps outlined below:
1. Place a pair of olives into the clamp and close the latch
2. Loosen the 2 x 3mm hex screws on the reverse of the clamp assembly
3. Realign the clamp by pressing the olives in an upward direction, relative to the drive wheel
4. While maintaining this upward pressure on the olives, retighten the hex screws
4.1Judderingandjerkingofthedrivewheelduringoperation
4.2Tapping/crackingnoiseduringthepushingprocess
4.3Microductclampwillnotclose
4.4CrankHandleishardtoturn
4.5 Cable is slipping
4.6 Olive is clashing on Drive Wheel
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