Fremco EasyFlow SMART User manual

Valid from 19.09.2022 | Rev. 1.0
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
THIS MATERIAL IS COPYRIGHT PROTECTED
Operating Manual
Responsible manufacturer: Fremco A/S
Machine: EasyFlow SMART
This is the original operating manual for EasyFlow SMART from Fremco.
EasyFlow SMART
For single cable installation

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
TABLE OF CONTENTS
1. INTRODUCTION ..........................................................................................................6
2. GENERAL....................................................................................................................7
2.1. MANUFACTURER........................................................................................................7
2.2. THE MACHINE’S DESIGNATION.................................................................................7
2.3. MACHINE PLATE.........................................................................................................7
2.4. MACHINE MARKINGS .................................................................................................8
3. TECHNICAL SPECIFICATIONS...................................................................................9
3.1. EASYFLOW SMART.....................................................................................................9
4. SAFETY INSTRUCTIONS AND RESIDUAL RISKS...................................................11
4.1. BUILT-IN SAFETY MEASURES .................................................................................11
4.1.1. SAFETY FUNCTIONS................................................................................................11
4.2. WARNING - FORESEEABLE MISUSE.......................................................................11
4.3. SAFETY MEASURES, TO BE TAKEN BY THE USER...............................................12
4.3.1. CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE).............................12
4.3.2. HANDLING OF DANGEROUS SUBSTANCES AND MATERIALS .............................13
4.3.3. RESIDUAL RISKS ......................................................................................................13
4.3.4. WORK PROCEDURES...............................................................................................14
4.3.5. IN CASE OF EMERGENCY........................................................................................14
4.3.6. VIOLATION OF SAFETY REGULATIONS..................................................................14
5. OVERVIEW AND APPLICATION...............................................................................15
5.1. GENERAL DESCRIPTION .........................................................................................15
5.2. THE MACHINE’S PURPOSE AND INTENDED USE ..................................................16
5.3. OPERATING POSITIONS, LOCATION AND ARRANGEMENT..................................16
5.4. USER INTERFACE.....................................................................................................17
5.5. MACHINE ASSEMBLY AND ADJUSTMENT..............................................................19
7. TRAINING ..................................................................................................................21
7.1. OPERATORS.............................................................................................................21
7.2. MAINTENANCE PERSONNEL...................................................................................21
8. OPERATION ..............................................................................................................22

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
8.1. TRANSPORTING THE MACHINE..............................................................................22
8.2. START/STOP .............................................................................................................22
8.3. WORK AREA..............................................................................................................22
8.4. ENERGY SUPPLY CONNECTION/DISCONNECTION ..............................................23
8.5. OVERVIEW OF THE JOB AND SETUP MENU..........................................................23
8.5.1. SETUP MENU ............................................................................................................23
8.5.2. JOB MENU.................................................................................................................24
8.5.3. SWITCHING BETWEEN JOB MENU AND SETUP MENU.........................................26
8.6. SELECTING AND CHANGING THRESHOLD PARAMETERS ON THE CONTROL
PANEL ...................................................................................................................................26
8.7. OPERATIONS MODE.................................................................................................27
8.7.1. AUTOMATIC MODE...................................................................................................27
8.7.2. MANUAL MODE.........................................................................................................28
8.7.3. SEMIAUTOMATIC......................................................................................................28
8.8. FEEDING AND REMOVING CABLES AND FIBERS..................................................28
8.8.1. CLOSING AND OPENING CHAINS............................................................................29
8.9. STARTING, PAUSING AND STOPPING A FIBER BLOWING PROCESS..................30
8.9.1. START, STARTING THE FIBER BLOWING PROCESS.............................................31
8.9.2. PAUSE, TEMPORARILY STOPPING THE BLOWING PROCESS.............................31
8.9.3. STOP, STOPPING THE FIBER BLOWING PROCESS ..............................................31
8.10. CHANGING THRESHOLD AND SETPOINT VALUES DURING FIBER BLOWING
PROCESS..................................................................................................................................32
8.10.1. SPEED ADJUSTMENT DURING FIBER BLOWING PROCESS.................................32
8.10.2. CHANGING PUSH FORCE SETTING........................................................................32
8.10.3. CHANGING GRIP FORCE SETTING.........................................................................32
8.10.4. CHANGING DISTANCE..............................................................................................33
8.10.5. CHANGING MAXIMUM ALLOWED PRESSURE THRESHOLD OR AIR PRESSURE
SETPOINT..................................................................................................................................33
9. MAINTENANCE, TROUBLESHOOTING AND REPAIR.............................................34
9.1. QUICK GUIDE TO MAINTENANCE, TROUBLESHOOTING AND REPAIR................34
9.1.1. CLEANING .................................................................................................................34
9.1.2. CORRECTIVE MAINTENANCE..................................................................................34
9.1.3. REPAIR ......................................................................................................................35
9.2. SERVICE AND REPAIR ADDRESS ...........................................................................35
9.3. DISCONNECTION AND DEPRESSURIZATION OF ENERGY SOURCES ................35

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
9.4. DISCONNECTION OF 110/230V POWER SUPPLY...................................................36
9.5. MAINTENANCE SCHEDULE......................................................................................37
9.5.1. VISUAL INSPECTION ................................................................................................39
10. BLOWING TECHNIQUE.............................................................................................40
10.1. BEFORE FIBER BLOWING........................................................................................40
10.2. PREPARING THE DUCTS FOR FIBER BLOWING....................................................40
10.2.1. CLEANING THE DUCT...............................................................................................40
10.2.2. PERFORM A PRESSURE TEST................................................................................41
10.2.3. LUBRICATING THE DUCT.........................................................................................41
11. CESSATION OF USE.................................................................................................42
11.1. DISMANTLING ...........................................................................................................42
11.2. SCRAPPING...............................................................................................................42
12. EC DECLARATION OF CONFORMITY .....................................................................43
13. UKCA DECLARATION OF CONFORMITY................................................................44
14. APPENDIXES.............................................................................................................45
14.1. PNEUMATICS SCHEMATICS....................................................................................45
14.1. DRAWING OF MECHANICAL SYSTEM.....................................................................46

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
BEST EXTENDED WARRANTY
IN THE BUSINESS
The most expensive machine is the one not in use.
We offer a unique service agreement with up to 60 months warranty on all our fiber blowing
machines*, securing quality service of your machine from day one.
When you purchase your Fremco fiber blowing machine, you automatically get 12 months factory
warranty. Within the month of your purchase, you can purchase a service agreement with
extended warranty from our webpage and obtain the best cost-beneficial warranty in the business.
To maintain your warranty and the benefits of the service agreement, you must meet the given
annual service and maintenance requirements for each machine as described in the operating
manual.
Learn more at www.fremco.dk/products/service-agreement/ and
get the best warranty and service agreement in the business today!
*The service agreement with extended warranty is only available for purchase in EU countries or countries with an official
Fremco Service Center.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
1. INTRODUCTION
Original instructions
These instructions are Fremco A/S’ original instructions for the EasyFlow SMART (hereafter called
the machine).
Purpose
The purpose of these instructions is to ensure correct installation, use, handling and maintenance
of the machine.
Accessibility
The instructions are to be kept in a location known to the staff and must be easily accessible for
the operators and maintenance personnel.
Knowledge
It is the duty of the employer (the owner of the machine) to ensure that everybody operating,
servicing, maintaining, or repairing the machine reads and understands the instructions. As a
minimum, they should read the safety instructions and part(s) relevant to their work.
In addition to this, everybody operating, servicing, maintaining, or repairing the machine is obliged
to seek out information in the operating manual when needed.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
2. GENERAL
2.1. MANUFACTURER
The machine is manufactured by
Company name: Fremco A/S
Company address: Ellehammervej 14
DK-9900 Frederikshavn
2.2. THE MACHINE’S DESIGNATION
The machine’s complete designation is EasyFlow SMART.
2.3. MACHINE PLATE
The machine plate is situated on the side of the machine:
Figure 1: Location of machine plate

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
2.4. MACHINE MARKINGS
•Max. air pressure on the Connection point for air hose

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3. TECHNICAL SPECIFICATIONS
3.1.EasyFlow SMART
Manufacturer Fremco A/S
Ellehammervej 14
9900 Frederikshavn
Denmark
Item No. ................................................................................................................................................................................101-211129001
Cable diameter1...............................................................................................................................................................................4-16 mm
Duct diameter2.................................................................................................................................................................................8-40 mm
Blowing distance3.............................................................................................................................................Up to 3,500 m (16404 ft)
Blowing speed3...................................................................................................................................................Up to 80 m/min. (262 ft)
Pushing force ...................................................................................................................................................................0-30 kg (0-66 Ibs)
Max. pressure and airflow4: .......................................................................16 bar (232 psi), 1,000-12,000 l/min. (35.1-423.7 cfm)
Weight ...................................................................................................................................................................................... 45 kg (99 Ibs)
Length...................................................................................................................................................................................... 400 mm (38”)
Width ........................................................................................................................................................................................621 mm (16”)
Height........................................................................................................................................................................................340 mm (20”)
1
Depending on type of cable, duct and installation method. Performance can be limited when blowing cable from 13-16 mm.
2 Depending on type and quality of fiber cable and microduct
3Air must be filtered, cooled and dried
4
Recommended power supply min. 1000W
.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
PNEUMATICS
Air consumption: up to 12 m3/min free air per minute at max. 16 bar
The quality of compressed air must at least comply with the requirements of ISO 8573-1:2010
“Compressed air - Part 1: Contaminants and purity classes”.
Particles: Class 5
Water: Class 7
Oil: Class 4
The compressed air temperature should not exceed 8°C above the ambient temperature.
NOISE
Airborne noise emitted by the machine:
Measured sound pressure level: 80 dB(A)
Necessary measures must be taken to reduce noise at the workplace to an acceptable level. The discharge
of compressed air from the machine may cause noise level to increase. This can be reduced by using the
correct gasket size.
Worn gaskets can also result in an increased noise level. In addition to noise generated by the machine, the
noise produces by additional process equipment (e.g. the compressor or power generator).

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
4. SAFETY INSTRUCTIONS AND RESIDUAL RISKS
This information is relevant for both operators and maintenance personnel.
4.1. BUILT-IN SAFETY MEASURES
The machine has been fitted with guards for the safety of personnel/operators.
To prevent unsafe situations with over pressurizing the pneumatic system, the machine is equipped with an
over pressure relief valve.
4.1.1. SAFETY FUNCTIONS
Safety Function 1
Safety function
Description
Monitored guards over moving parts
The Machine is prevented from operation with either the
chain guard or the Adaptor plate holder opened.
Over pressure relief valve for the
pneumatic system
The machine is equipped with an over pressure relief valve,
to prevent over pressurizing the pneumatic system.
These safety features must always be active and must not be overridden.
Test intervals:
If the below test limits are exceeded, consider the safety features to be invalid and unable to protect
operators from the hazards of the machine. Safety features must be tested several times a year.
4.2. WARNING - FORESEEABLE MISUSE
Before using the machine, operators must ensure that:
•The guarding over chain drive is intact
•The operator can monitor all machine movements
•The Electrical supply cable and pneumatic hoses are undamaged
•There is no damage to any pressure carrying component

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
•The machine is mounted/placed in a stable and secure manner regarding its foundation and general
surroundings
•The required energy supply is available
•All safety functions are active and functional
•Duct holders are of the correct size for the duct used.
•Discharge end of the duct is in control and under supervision, and that any discharged object is
contained.
The operator must NOT under any circumstances:
•Reach into/touch the chain drive while the machine is in operation
•Exceed the maximum pneumatic supply pressure of 16 Bar.
•Unmount any covers or shielding.
•Use any other blowing media than compressed Air.
•Blow any type of steel balls or steel cylinders through the duct.
•Initiate any blowing process of sponges, FlowLUB or Fiber blowing, without a trained operator at
the discharge end of the duct
•Open the duct clamp during fiber blowing or any other situation where the duct is pressurized.
Machine surfaces must be kept clear of clutter and must not be used as work surfaces.
4.3. SAFETY MEASURES, TO BE TAKEN BY THE USER
4.3.1. CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT
(PPE)
During daily use:
The designated PPE must always be used in accordance with Fremco A/S’ guidelines and safety data sheets
and according to the applicable national regulations.
•PPE, in the form of protective glasses and protective shoes must be used during daily operation of
the machine.
Do NOT wear any loose clothing, jewelry, scarves, etc. while operating the machine.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
During maintenance and repair:
Appropriate PPE must be used for repair and maintenance work. Keep the working area clean.
Maintenance on electronic and electrical supply units must be conducted by trained personnel at a certified
Fremco Service center. Do not open the cabinet for the electronics without proper training.
The manufacturer's instructions must be followed when replacing a machine component.
•PPE in the form of work gloves, protective shoes and head protection must be worn when
transporting parts.
•Approved lifting equipment in the form of a crane and hoist must be used when handling heavy
parts.
4.3.2. HANDLING OF DANGEROUS SUBSTANCES AND
MATERIALS
Chemicals, lubricants, and batteries:
The machine contains no hydraulic fluids ore dangerous substances.
Electronic board contains batteries.
Disposal of products and other waste must be done in accordance with the guidelines for the materials in
question.
4.3.3. RESIDUAL RISKS
Consider the following residual risks during maintenance and repair:
•Accumulated energy in pneumatics.
•Accumulated energy in electronics.
Before service and repair or maintenance, ensure the following:
•The machine has been disconnected from its energy supplies, both Electric and Pneumatic.
•Accumulated energy has been relieved
•The proper PPE is being used.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
4.3.4. WORK PROCEDURES
Before operating the machine, the following must be ensured:
•The site of operation is suitable and has been made safe for operation
•The area adjacent to the machine is kept clean and free from objects that may cause the operator
to slip and fall or getting caught in the machine’s cables
•The area adjacent to the machine is kept free from unnecessary personnel and public access.
•There is adequate lighting to safely operate the machine
•All machine components and energy supplies have been correctly installed.
•The ducts and fibers have been properly connected and adequately secured
•Inspect the machine for leaking air before use
•Do not operate the machine submerged in water or exposed to heavy rain.
•Always secure a working ground connection on the electrical supply.
Start up and operation to be performed under the following conditions:
•Operations are initiated and monitored by trained personnel.
•Operation can be ceased from one side of the machine.
4.3.5. IN CASE OF EMERGENCY
In case of emergency, follow these three steps:
1. Turn off the machine
2. Disconnect all power sources (compressor and electric supply)
3. Call for help
4.3.6. VIOLATION OF SAFETY REGULATIONS
Any violation of the safety regulations can result in serious personal injury and possible
machine damage.
Accessing the electronics cabinet without proper training and proper tools. May cause
electric shock.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
5. OVERVIEW AND APPLICATION
5.1. GENERAL DESCRIPTION
The machine consists of:
•Control Panel allowing for setup and operating the machine
•Toolless operated chain drive
•Toolless operated Adaptor plate holder with fiber and duct gaskets
•Toolless operated duct holder
•Carrying frame
Control panel unit
Cable Drive Adaptor
Adaptor plate holder unit
Duct holder
Carry frame

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
5.2. THE MACHINE’S PURPOSE AND INTENDED USE
The machine is constructed for blowing fiber optic cables into micro ducts. The machine may only be used
for these exact purposes.
EasyFlow SMART has a fiber/cable OD of 4-16 mm and a duct size OD of 8-40 mm.
Only instructed operators may operate the machine. Similarly, only qualified personnel may perform
service, maintenance, and repairs on the machine. The machine is suited for use in an outdoor
environment. However, if used outside, the machine must be covered from rain, snow and thunderstorms.
Only suitable equipment, approved for use in the region of usage (pneumatic compressor and power
generator) may be connected to the machine.
The machine is not to be used for any other purpose than those provided above.
5.3. OPERATING POSITIONS, LOCATION AND ARRANGEMENT
The operator’s workstation is located at the front of the machine.
During maintenance and repair:
-The area adjacent to the machine should also be considered as the workstation.
Space requirements:
There must be sufficient space in the workplace for the operator to operate the machine unrestrictedly
and comfortably.
It is recommended to maintain a space of at least 700 mm between barriers (walls, building parts. Etc.) and
controls.
Operation and storage limits:
Ambient temperatures
-5 °C to 40 °C
Relative humidity (non-condensing)
Min. 10 % RH
Max. 80 % RH
Service life expectancy
Maintenance and replacement of machine parts and safety-related components must be carried out on a
routine basis. This must be done in accordance with the operating instructions of the individual component.
See paragraph 9. Maintenance, Troubleshooting and Repair for further elaboration. You must meet the given
annual service and maintenance requirements to maintain your warranty.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
5.4. USER INTERFACE
Below, you will find all operating handles and a short description of their use:
Emergency stop
The emergency stop button is located on
the left side of the machine, next to the
power inlet.
The emergency stop immediately stops all
operations and cuts off air supply.
The emergency stop is not to be used to
stop the machine during normal
operation.
Control panel
Used to set up the machine parameters
and operate the machine.
Vent valve
The vent valve releases air pressure from
the duct and blowing chamber before
opening the Adaptor plate holder.
Picture shows the CLOSED position, turn
anticlockwise to open.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
Quick coupling (air)
The quick coupling connects the EU claw
coupling to the air hose.
The EU (DIN 3238) claw coupling is
mounted by default.
Safety valve
Pressure relief valve. Set to release
pressure above 16 BAR/230 PSI.
The valve is placed inside the machine.
Manometer
Provides readout of current pressure in
the Adaptor plate holder
Maximum pressure 16BAR/230 PSI.
Inlet guide holder
•Has a built-in digital distance and
speed counter
•Tracks the cables movement.
•Speed and distance can be seen in
the display on the Fremco SMART
app

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
5.5. MACHINE ASSEMBLY AND ADJUSTMENT
Parts in the Adaptor plate
holder
The Adaptor plate holder is
configured with an adaptor plate for
the specific duct size.
A gasket is inserted to seal the air
chamber around the duct.
For the cable, a cable guide is
inserted to direct the cable, along
with a gasket to seal around the
cable.
This is done for both top and
bottom.
Duct gasket
Adaptor plate
holder (top)
Duct clamp
Cable gasket
Adaptor plate holder
(bottom)
Cable guide (bottom)

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
Parts in the inlet
Change the inlet guide to the
correct size according to cable
dimension. Ensure cable moves
freely in the inlet guides.
Control that each of the counter
wheels on the inlet guide holder
is in contact with the cable.
Digital speed and
meter counter
Inlet guide (top)
Counter wheel