Condux Gulfstream 350 Instruction Manual
Gulfstream™350
USER'S GUIDE & SAFETY MANUAL
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Notes
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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 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
U.S. CALL 1-800-533-2077
EU Call your Local Representative
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, 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
1-507-387-6576
Fax 1-507-387-1442
Internet: http://www.condux.com
E-mail: cndxinf[email protected]
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Table of Contents
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2
5
6
7
9
8
General Information .......................................................................................6
Technical Information ......................................................................................8
A. Condition of Use .................................................................................8
B. Air Compressor Requirements ......................................................................8
C. Operational Capacities ............................................................................8
D. Distance and Speed Box ...........................................................................8
E. Physical Specifications.............................................................................8
F. Acoustic Emission.................................................................................8
G. Caterpillar Drive Specifications .....................................................................8
H. Conduit Coupling Requirements ....................................................................8
Safe Operating Procedures ..................................................................................9
A. Work Area Safety ................................................................................9
B. Pneumatic Devices ...............................................................................9
C. Electric Devices ..................................................................................9
Unpacking the Gulfstream™ 350 ............................................................................10
A. Blower Components .............................................................................10
Set Up the Blower ........................................................................................11
Cable Crash Test..........................................................................................12
Pressure Test Conduit .....................................................................................16
Prepare Conduit for Proof & Prepare Conduit for Install.........................................................22
Prepare Cable for Traditional Duct...........................................................................25
Prepare Cable for Micro Duct...............................................................................28
Final Set-Up .............................................................................................29
A. Final Inspection .................................................................................29
Blower Operating Instructions ..............................................................................30
A. Observer at Exit Pit ..............................................................................30
B. Set up the Counter Box...........................................................................30
C. Panel Layout ...................................................................................30
D. Changing from feet to meters and resetting to zero ...................................................31
E. Operation ......................................................................................31
Preparation for Storage....................................................................................33
.........................................................................33
B. Remove Cable from Blower .......................................................................33
C. Separate Unit from Conduit .......................................................................33
Maintenance ............................................................................................34
A. Track Cleaning ..................................................................................34
B. Motor Maintenance .............................................................................34
C. Change Belts ...................................................................................34
Troubleshooting Guide ....................................................................................35
Warranty Information .....................................................................................36
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4
10
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15
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1.
to be received by the machine. The conduit must be made from HDPE material to
pressure of 215 psi (15 bar). For this purpose, connectors of screw, compression or
from 5/32" (4 mm) to 5/8" (16 mm) diameter can be accepted by the machine.
TRADITIONAL DUCT
in behind the carrier causing it to be forced through the conduit. As the carrier moves
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.
MICRO DUCT
pushing force. The pulling force is achieved when pressurized air is fed into the air block
The pushing force is created by engaging the tractor drive system. As the tractor drive
The exit of the machine consists of an air box (Figure 34) that is made in two halves that
clamp together. The air box contains special removable seals (Figure 48) on entry and
the air block. A clamp located in front of the entrance to the air block holds the conduit
seals located in an aluminum venturi that splits in half. The aluminum venturi is located
the space between the seals on entry and exit.
GENERAL INFORMATION
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other than the ones 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:
b. The use of inappropriate spare parts.
c. Inadequate maintenance.
d. Use with bypassed safety devices.
machines.
Comprised of an air block and a tractor drive that, when combined with an air compressor , will propel
conduit run at speeds of 0 to 330 feet per minute (0-100 m/min). A cable carrier must be placed at the
The Gulfstream™ 350 comes standard with case, digital counter, and common parts kit (Figure 2 and 3).
GENERAL MACHINE USE
b. Machine must only be used for the work it was designed for.
d. Should there be any doubt concerning use, maintenance or anything else, please contact the factory or
authorized Condux Supplier.
OPERATOR QUALIFICATIONS
loose clothes, hanging jewelry or whatever might become entangled in the moving parts.
d. Operator must have work area kept clean of obstacles that might inhibit a safeworking area.
MAINTENANCE QUALIFICATION
a. All of the machine maintenance must be carried out with the machine on a level surface and not
manufacturer.
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2. A. CONDITION OF USE
Temperature from 21° F ( -6° C) to 110° F (+43° C)Humidity from 30% to 90% +/- 5%
the work site, minimum 200 lux
B. AIR COMPRESSOR REQUIREMENTS
• Required Flow Capacity: 35 SCFM(1 m3/min) to 375 SCFM (11 m3/min)
• Conduit Size: 8 mm-1.25" (42mm) OD
C. OPERATIONAL CAPACITIES
• Pushing Force: 70lbs (310 N) maximum
• Cable Sizes: .1575" to .6299" (4 mm to 16 mm)
• Conduit Sizes: 3/4" - 1.25 " 8 mm, 8.5 mm, 10 mm, 12 mm, 12.7 mm, 14 mm,
16 mm, 18 mm, 25 mm, 27 mm, 32 mm, 36 mm, 37 mm, 40 mm, 42 mm
D. DISTANCE AND SPEED BOX
E. PHYSICAL SPECIFICATIONS
• Height: 11.8" (300 mm) • Weight: 56 lbs (28 Kg)
• Length: 23" (338 mm) • Weight with case: 76 lbs (34 Kg)
• Width: 13.3" (338 mm)
F. ACOUSTIC EMISSION
• Level of max. sound pressure to the operator seat (ISO 11202) Lep=85 dB(A)
G. CATERPILLAR DRIVE SPECIFICATIONS
• Maximum pushing force: 70 lbs (310 N), depending on cable diameter
• Side guards.
• Adjustable air clamp force 0 - 12.5 lbs/in(2.2 N/mm)
H. CONDUIT COUPLING REQUIREMENTS
• Must withstand maximum air pressure of 215 psi (15 bar).
• Must be screw type, compression type, or fusion type.
• Conduit must be fully seated into the coupler.
• Must be same size as conduit.
TECHNICAL INFORMATION
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3.
SAFE OPERATING PROCEDURES
requirements as explained by procedures called out in this manual. Failure to follow
A. WORK AREA SAFETY
leather work gloves.
ground.
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.
B. PNEUMATIC DEVICES
C. ELECTRIC DEVICES
personnel.
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4.
UNPACKING THE GOLFSTREAM™ 350
A. BLOWER COMPONENTS
Each Gulfstream™ 350 Package contains the following items: (Figure 2)
• User and Parts Manual
• Molded Case with Foam Insert
• Base GS 350
• Common Parts Kit Which Includes: (Figure 3)
• Metric & Standard Allen Wrench Set
• Fiber Guides 4-8 mm, 8-12 mm, 12-16 mm
• 9/16 Stubby Ratchet Wrench (14.288 mm)
• Venturi Air Plug
• Machine Screw Kit
• Allen Wrench (2.5 mm)
• Replacement Seal Kit
Figure 2. Unpacking the GS 350 Figure 3. Common Parts Kit
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5.
SET UP THE BLOWER
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
13°.
Remove the GS 350 from the storage box using the handle provided on the top of
the machine. Place on ground or on a sturdy surface. (Figure 4)
Figure 4. Lift out Blower with
Handle
Figure 5. Remove plastic guard
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6.
CABLE CRASH TEST
air motor pressure of the blower below the point that it may cause cable damage
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.
duct they are installed into. Example: A cable with a crash test value of 80 psi (5.51
bar) in 33 mm I.D. duct, may have a crash value of only 60 psi (4.13 bar) in a 40
mm I.D. duct. This is because the area of lateral movement is larger as the duct size
increases.
and work gloves.
adjustment to prevent damage to the cable that can be caused by excessive pushing
force.
For the Crash Test to work properly use the same size cable and duct
that will be used for the job.
1. Select appropriate duct clamp and duct seal, install in the airblock.
duct or a micro duct end stop. (Figure 7)
Figure 6. Placement of Conduit in
Conduit Seal & Conduit Clamp Figure 7. Installing Conduit
Pulling Eye
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these steps to connect the air hose:
inspect hose regularly and replace if damaged.
Figure 9. Attach Claw Fitting Figure 10. Air Valve
Figure 8. Install Venturi
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belts. Fiber should be installing. (Figure 16)
Figure 11. Run the Fiber Figure 12. Mark the Fiber
Figure 13. Pull Back Fiber Figure 14. Set Pressure
Figure 15. E-Stop On Figure 16. Lower Belts
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force. (Figure B)
integrity will be compromised.
14. Proceed to Pressure Test.
Figure A Figure B
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7.
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. Loosen the 6 nuts on the Air Block assembly. (Figure 17)
Open the Conduit Clamp Cover and Air Block Cover. (Figure 18)
2. Select the correct Conduit and Cable Components according to conduit and cable
3. Choose the correct Conduit Seal and install both halves securely. (Figure 19)
4. Choose the correct Conduit Clamp and install both halves. (Figure 20)
Figure 17. Loosen Nuts Figure 18. Open Clamp
Figure 19. Choose Seal Figure 20. Choose Clamp
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6. Clamp conduit in place. (Figure 21)
7. Place Seal Disk in Venturi slot. (Figure 22)
8. Close Air Block Cover and secure. (Figure 23) Tighten nuts securely, but do not
Figure 21. Clamp Conduit
Figure 22. Place Venturi Figure 23. Close Air Block
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Duct Size OD
(MM)
Part
Number
Duct
Clamp Duct Seal
Innerduct Eye
ID Range P/N
10 08764140 08764142 08764143 5 - 9mm 08913547
12 08764110 08764112 08764113 10 - 13mm 08913545
12.7 08764150 08764151 08764153 10 - 13mm 08913545
14 08764120 08764122 08764123 10 - 13mm 08913545
16 08764130 08764132 08764133 10 - 13mm 08913545
18 08781110 08781106 08781101 13 - 15mm 08913538
Pack
Cable Pack Venturi Cable Seal Cable Grip
Cable OD Part Number Cable OD Part Number Cable OD Part Number Cable OD Part Number
10.16" - 0.23"
(4.0 - 5.8mm) 08780511 0.16" - 0.23"
(4.0 - 5.8mm) 08780507
0.16" - 0.17"
(4.1 - 4.3mm) 08780516
0.10 - 0.22
(3 - 6mm) 08643753
033-29-1193
0.18" - 0.19"
(4.6 - 4.8mm) 08780517
0.20" - 0.21"
(5.1 - 5.3mm) 08780518
0.22" - 0.23"
(5.6 - 5.8mm) 08780519
20.23" - 0.34"
(5.8 - 8.8mm) 08780393 0.23" - 0.34"
(5.8 - 8.8mm) 08780281
0.23" - .028"
(5.8 - 7.2mm) 08780406
0.21" - 0.35"
(5.3 - 8.9mm)
08643754
033-29-1194
0.29" - 0.34"
(7.3mm - 8.8mm) 08780407
30.35" - 0.48"
(8.9 - 15.2mm) 08780394 0.35" - 0.48"
(8.9 - 12.2mm) 08781115
0.35" - 0.42"
(8.9 - 10.7mm) 08761424
0.32" - 0.48"
(8.1 - 12.2mm)
08643755
033-29-1195
0.43" - 0.48"
(10.8 - 12.2mm) 08761425
40.49" - 0.60"
(12.3 - 15.2mm) 08780512 0.49" - 0.60"
(12.3 - 15.2mm) 08781116
0.49" - 0.55"
(12.3 - 14.0mm) 08761426
0.42" - 0.61"
(10.7 - 15.5mm)
08643756
033-29-1196
0.56"- 0.60"
(14.1 - 15.2mm) 08761427
50.61" - 0.73"
(15.3 - 18.5mm) 08780395 0.61" - 0.73"
(15.3 - 18.5mm) 08780284
0.61" - 0.67"
(15.3 - 17.0mm) 08761428
0.53" - 0.74"
(13.5 - 18.8mm)
08643757
033-29-1197
0.68" - 0.73"
(17.1 - 18.5mm) 08761429
910.4 x 5.5mm 08781117 (Nylatron venturi for flat fiber cables)
10 15.2 x 6.7mm 08781118 (Nylatron venturi for flat fiber cables)
Gulfstream 350 Cable Packs
Gulfstream 350 Duct Packs
Duct Size OD
(MM)
Part
Number
Duct
Clamp
Duct
Seal
End Stop
Connector
8 08764160 08764162 08764163 02291146
8.5 08764175 08764169 08764171 08566336
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Pack
Duct Pack Duct Clamp Duct Seal Carrier Foam Carrier Cable Grip Innerduct Eye
Duct Size Part
Number
Duct
OD
(mm)
Part
Number
Duct
OD
(mm)
Part
Number
Carrier
OD
(mm)
Part
Number
Carrier
OD
(mm)
Part
Number
Duct
OD
(mm)
Part
Number
Part Number
and ID Range
(mm)
11/2"
SDR 11-13.5
08780795
Pack #1
0.84"
(21.30) 08780791 0.84"
(21.30) 08780786 0.688"
(17.50) 08780793 0.75"
(19.0) 08078300 .75-.99"
(19-25)
08643131
033-03-012
08913342
.71-.77"
(18-20)
23/4" (27mm)
SDR 11-13.5
08780680
Pack #2
1.050"
(26.6) 08780682 1.050"
(26.6) 08780685 0.75"
(19.0) 08780690 0.75"
(19.0) 08078300 1.00-1.24"
(25.4-31.5)
08643137
033-03-013
08761840
.71-.87"
(18-22)
31"
SDR 11/13.5
08780386
Pack #3
1.315"
(33.4) 08780369 1.315"
(33.4) 08780307 1.121"
(28.5) 08761250 1.25"
(31.8) 08761439 1.25-1.49"
(32-38)
08643143
033-03-015
08913343
.75-1.00"
(19-25)
41.25"
SDR 11/13.5
08780392
Pack #4
1.660"
(42.2) 08780375 1.660"
(42.2) 08780051 1.414"
(35.9) 08761255 1.50"
(38.1) 08761440 1.50-1.99"
(38.1-50.5)
08643149
033-03-016
08761842
1.06-1.43"
(27-37)
720mm 08781120
Pack #7
0.787"
(20.0) 08781122 0.787"
(20.0) 08781121 0.688"
(17.5) 08780793 1.00"
(25.4) 08761444 .75-.99"
(19.0-25.1)
08643131
033-03-017
08914007
.551-.813"
(14-20)
822mm 08781153
Pack #8
.866"
(22.0) 08781154 .866"
(22.0) 08781155 0.688"
(17.5) 08780793 1.00"
(25.4) 08761444 .75-.99"
(19.0-25.1)
08643131
033-03-012
08914007
.551-.813"
(14-20)
925mm 08780240
Pack #8
0.984"
(25.0) 08780099 0.984"
(25.0) 08780134 0.787"
(20.0) 08780230 1.25"
(31.8) 08761439 1.25-1.49"
(31.8-37.8)
08643137
033-03-013
08761840
.71-.87"
(18-22)
10 32mm 08780385
Pack #9
1.260"
(32.0) 08780368 1.260"
(32.0) 08780306 1.063"
(27.0) 08761560 1.25"
(31.8) 08761439 1.25-1.49"
(31.8-37.8)
08643143
033-03-015
08761842
1.06-1.43"
(27-37)
11 36mm 08780387
Pack #10
1.417"
(36.0) 08780370 1.417"
(36.0) 08780308
1.181"
(30.0)
1.220"
(31.0)
08761643
08761555
1.25"
(31.8) 08761439 1.25-1.49"
(31.8-37.8)
08643143
033-03-015
08761842
1.06-1.43"
(27-37)
12 37mm 08780388
Pack #11
1.457"
(37.0) 08780371 1.457"
(37.0) 08780309 1.220"
(31.0) 08761555 1.25"
(31.8) 08761439 1.25-1.49"
(31.8-37.8)
08643143
033-03-015
08761842
1.06-1.43"
(27-37)
13 1.25" TRUE 08780389
Pack #12
1.500"
(38.1) 08780372 1.500"
(38.1) 08780333 1.250"
(31.7) 08761670 1.50"
(38.1) 08761440 1.25-1.49"
(31.8-37.8)
08643143
033-03-015
08761842
1.06-1.43"
(27-37)
14 40mm 08780390
Pack #13
1.575"
(40.0) 08780373 1.575"
(40.0) 08780334 1.299"
(33.0) 08761525 1.50"
(38.1) 08761440 1.50-1.99"
(38.1-50.5)
08643149
033-03-016
08761842
1.06-1.43"
(27-37)
15 42mm 08780391
Pack #14
1.653"
(42.0) 08780374 1.653"
(42.0) 08780335 1.378"
(35.0) 08761660 1.50"
(38.1) 08761440 1.50-1.99"
(38.1-50.5)
08643149
033-03-016
08761844
1.37-1.68"
(35-43)
Gulfstream 350 Duct Packs (continued)
GULFSTREAM 350™ DUCT PACKS
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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)
11. Connect the Air Compressor. (Figure 26)
air valve assembly is equipped with a claw type connector. Use safety clips on all
c. Observe all safety procedures (See page 9).
d. Route all hoses properly to prevent tripping over them.
Figure 24. Install End Stop Figure 25. Install Pulling Grip
Figure 26. Connect Air Compressor Figure 27. Air in the Off Position
Table of contents
