Fremco MiniFlow RAPID User manual

Valid from 01.07.2021 | Rev. 1.0
From Serial No. 9328.1193
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
THIS MATERIAL IS COPYRIGHT PROTECTED
Responsible manufacturer: Fremco A/S
Machine: MiniFlow RAPID
This is the original operating manual for MiniFlow RAPID from Fremco.
MiniFlow RAPID
For fiber dimension 3-12 mm
Operating manual
101-10031 Operating Manual
2016-06-15 EN
From Serial No. 9328.1193

Page | 2 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................4
2. GENERAL..................................................................................................................5
2.1. MANUFACTURER............................................................................................................... 5
2.2. THE MACHINE’S DESIGNATION....................................................................................... 5
2.3. MACHINE PLATE................................................................................................................ 5
3. TECHNICAL SPECIFICATIONS.................................................................................6
3.1. MINIFLOW RAPID............................................................................................................... 6
3.2. HYDRAULIC CONTROL UNIT............................................................................................ 7
4. SAFETY DIRECTIONS...............................................................................................8
5. IDENTIFICATION .......................................................................................................9
6. APPLICATION............................................................................................................9
7. MOUNTING ................................................................................................................9
8. SUPPLY OF COMPRESSED AIR AND HYDRAULIC PRESSURE............................9
9. FIBER CABLE BLOWING........................................................................................10
10. MAINTENANCE .......................................................................................................11
10.1. CHAIN MAINTENANCE AND ADJUSTMENT ................................................................ 11
11. MACHINE OVERVIEW.............................................................................................13
12. OPERATION ............................................................................................................14
12.1. PREPARING OPERATION ............................................................................................. 15
12.2. DURING OPERATION .................................................................................................... 16
12.3. AFTER OPERATION....................................................................................................... 16
13. ADJUSTMENT OF PUSHING POWER INDICATOR (PPI).......................................17
14. CHANGING ADAPTOR PLATES.............................................................................18
15. CHANGING CHAINS AND CHAIN SUPPORT RAILS .............................................19
16. INITIAL ADJUSTMENT OF JOYSTICK....................................................................20
16.1. PREPARATION............................................................................................................... 20
16.2. ADJUSTMENT................................................................................................................. 21
17. OPERATING THE JOYSTICK..................................................................................23
17.1. IMPORTANT NOTE REGARDING POWER AND SPEED ADJUSTMENT.................... 25
18. EC DECLARATION OF CONFORMITY.........................................................................26
19. UKCA DECLARATION OF CONFORMITY....................................................................27

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
BEST WARRANTY IN THE BUSINESS
We offer a unique 36 months warranty on all our fiber blowing machines resulting,
guaranteeing you the best value for your money.
Our 12 months warranty is automatically included when you purchase your Fremco fiber
blowing machine, you automatically get our 12 months warranty. You can then claim your
additional 24 months warranty at any point during the following three months in order to
obtain the best cost-beneficial warranty in the business.
To maintain your 36 months warranty, 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/warranty and
get the best factory warranty in the business today!

Page | 4 of 27
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 MiniFlow RAPID (hereafter
called the machine).
Purpose
The purpose of these instructions is to ensure correct installation, use, handling and
maintenance of the machine. Applicable from machine serial number 9328.1193.
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 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.

Page | 5 of 27
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 MiniFlow RAPID.
2.3. MACHINE PLATE
The machine plate is situated on the back of the machine:
Model: MiniFlow RAPID
Year: 2020 Serial No.: 1234.1234
Pmax hyd: 110 (1595) Pmax air: 16 (230)
Bar (psi) Bar (psi)
Figure 1: Location of machine plate
Figure 2: Location of the UKCA sticker is
placed next to the machine plate

Page | 6 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3. TECHNICAL SPECIFICATIONS
3.1. MINIFLOW RAPID
Manufacturer Fremco A/S
Ellehammervej 14
9900 Frederikshavn
Denmark
Item No...................................................................................................................101-10031
Micro cable diameter............................................................................................... 3-12 mm
Micro duct diameter ................................................................................................ 7-20 mm
Blowing distance¹ ............................................................................ Up to 3.5 km (11485 ft)
Blowing speed¹ .............................................................................Up to 100 m/min. (325 ft)
Pushing force ........................................................................................................................................................................ 0-40 kg
Max air temperature....................................................................................................................................................60°c (104°f)
Max. pressure and airflow²:.................................................................................... 16 bar (230 psi), 1,000 l/min. (35.3 cfm)
Max. hydraulic pressure.................................................................................................................................. 110 bar (1595 psi)
Weight............................................................................................................................24 kg
Length........................................................................................................................650 mm
Width..........................................................................................................................225 mm
Height.........................................................................................................................210 mm
¹ Depending on type and quality of fiber cable and microduct
² Air must be filtered, cooled and dried

Page | 7 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3.2. HYDRAULIC CONTROL UNIT
Manufacturer Fremco A/S
Ellehammervej 14
9900 Frederikshavn
Denmark
Item No.................................................................................................................. 103-10041
Hydraulic connection............................................................................ 0>125 bar, 17 l/min
Max pressure ......................................................................................................................................................................... 125 bar
Manometer................................................................................................................. 160 bar
Hose to fiber blowing machine ..............................................................................1500 mm
Hose to hydraulic pump..........................................................................................1500 mm
Length .....................................................................................................................................................................................250 mm
Width..........................................................................................................................250 mm
Height.........................................................................................................................310 mm
Weight..............................................................................................................................5 kg

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
4. SAFETY DIRECTIONS
•Make sure to disconnect the machine from all power sources, like air compressor and hydraulic pump,
before any kind of adjustment and maintenance takes place.
•The hydraulic power supply from the hydraulic pump for cable blowing machines or from other sources
may never exceed the specified maximum pressure.
•The air pressure should never exceed the recommendations from the suppliers of microducts and fiber
cables. The pressure may never exceed 16 bar, which is the maximum pressure for the blowing junction
block.
•Observe that the machine is placed on a stable foundation and secure it before start. Make sure that the
blowing junction block is properly connected to the microduct, and that the cable is placed correctly
between the chains.
•Make sure you do not touch the cable too close to the machine because you risk getting your fingers
injured, and make sure the cable does not make loops that might be dangerous to persons around the
machine.
•Use hearing protection if the hydraulic pump or other noisy equipment is placed nearby.
•The joystick on the hydraulic control unit should never be blocked in a way, where it is unable to return to
neutral position.
•The operator must make sure that no other persons are close to the machine and cable drums in a way
that could be dangerous when the machine is started.
•It is always a clear advantage to be well prepared so that you can run the blowing without interruptions.
Pausing in the middle of blowing creates a risk of being unable to start again.
•Make sure the working environment is clean and tidy to avoid injuries due to stumbling over cables and
equipment.

Page | 9 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
5. IDENTIFICATION
These instructions have been made to support the users of the cable blowing machine MiniFlow RAPID. The
machine type can be identified by the type plate on the machine. The type plate provides information about
serial number, year of production and name and address of the manufacturer.
It is recommended to read this instruction carefully and become familiar with the functionality and maintenance
of the cable blowing machine before use.
6. APPLICATION
The cable blowing machine MiniFlow RAPID is constructed for blowing fiber optic cables into microducts.
Always use adaptor plates designed for the actual diameter of cable and duct. The adaptor plates are marked
with the size for which they are intended.
It is very important to use the correct adaptor plates. If the adaptor plates do not fit the duct, dangerous
situations may occur.
7. MOUNTING
Make sure to place the machine on a stable foundation and to fasten it to withstand the forces, which occur
during use. With the MiniFlow RAPID it is possible to purchase a trolley, which gives the machines a stable
foundation during use.
8. SUPPLY OF COMPRESSED AIR AND HYDRAULIC
PRESSURE
The volume and quality of compressed air is one of the most important parameters in order to achieve good
results when blowing fiber optic cables. The minimum capacity needed is 1,000 l/min. The compressed air must
be filtered, cooled and dried to avoid moisture and dirt in the microduct.
NOTE: Do not use compressed air directly from a compressor unit, since the air can be very hot
and can damage microduct, fiber cable and machinery.
The supply of hydraulic pressure must be 110 bar, 17 l/min. It is recommended to use the
hydraulic power unit that is designed specifically for use with the Fremco cable blowing machines.

Page | 10 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
9. FIBER CABLE BLOWING
Having set up and connected the hydraulic pump
and the air compressor, tighten the chains with
the chain hand wheel so that the chains do not
skid on the cable. The best result is achieved by
not tightening too hard.
The hydraulic control unit is used to control
direction (forward/back), speed and push/pull
force. Use the joystick on the hydraulic control
unit to control start/stop and direction.
The speed can be adjusted by turning the valve
handle marked ”Speed”.
With the valve handle marked “Power” you can
adjust the maximum force to be transferred to the cable. The pressure, and with it the force, is increased when
the handle is turned to the right.
When installing the cable, it is important to make sure not to push the cable too hard into the duct, because it
is the supplied compressed air that must lead the cable forward inside the duct.
Use the Pushing Power Indicator (PPI) on the MiniFlow RAPID to monitor the pushing force on the fiber cable.
There are several things to consider when blowing cables, because they influence the different settings of speed
and pressure. For instance, the diameter and stiffness of the cable, the force needed to pull the cable forward
to the MiniFlow RAPID cable blowing machine as well as the force needed to overcome friction from seals and
air pressure inside the blowing junction block.
It is not possible to give exact directions on adjusting the different pressures because it depends on the
conditions of the specific job.
Please be aware of the maximum load on the cable and allowed force on the duct as specified by the
manufacturers.
CABLE DAMAGE SAFETY
Miniflow RAPID has a unique
monitoring system, which con-
tenuously monitors the pushing
force applied on the fiber cable,
making it possible to stop
before cable damage.
Pushing force in
kilogram
0-10 10-20 20-30 30-40

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
10. MAINTENANCE
The chains must be kept well lubricated and free from sand and dust. It is recommended to use a chain spray
with water-repellent oil.
The chains should be tightened to an extent that they can be lifted only 3-5 mm from the chain support rail.
The chains and the chain support rails must be replaced timely.
It is very important to avoid any kind of dirt in the hydraulic connectors when mounting the hydraulic hoses.
If the machine is not to be used for a longer period of time, it should be cleaned and the chains should be
lubricated. It is also recommended to spray the machine with an anti-corrosion oil. Store the machine in a dry
and dust-free environment.
It is strongly recommended to use original spare parts. Repairs should be performed by the manufacturer.
Errors and damage caused by unauthorized use and changes or adjustment of the machine are not covered by
warranty.
Machine service is required annually.
10.1. CHAIN MAINTENANCE AND ADJUSTMENT
Keep the chains well adjusted and clean from dust and dirt. Lubricate regularly with a waterproof chain oil
spray.
Please follow below instructions on both chains.
Tighten the chains
Remove the chain covers
Loosen the two Allen screws
Turn the Allen screw to tighten the
chains
Tighten the two Allen screws
A
NB: To maintain your 36-months warranty, you
have to meet the given service requirements.

Page | 12 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
Check Chain Tension
•The chains should be tightened to an
extent that they can be lifted only 3-5
mm from the chain support rail
•Chain tension can vary on different
positions on the chain
•Rotate chain and check in several
positions
B
A
Lubricate the Chain
•Use a good quality water resistant chain
oil spray
•Remove the chain cover
•Turn on the machine and let it run
slowly without load
•Spray between the chain and the chain
support rail
•Be careful not to spray oil onto the
chain rubber surface
C

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
11. MACHINE OVERVIEW
Digital counter
(speed and distance)
Pushing Power
Indicator (PPI)
Air valve
Connections for
hydraulics and
compressed air
Inlet guide (2 sets)
Adaptor plates
Air flow
regulator
Hand wheel for
chain adjustment
Air pressure
manometer

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
12. OPERATION
Before Operation
Is the chain support rail worn in a way that geometry is
odd?
•Change wear parts, if necessary
Does the diameter of the nylon inlet guide bush fit the
actual fiber cable, ensuring fiber cable entry in the middle
of the chain groove?
•Size can be wrong
•Extensive wear can make the hole oval
•Chain tension can vary on different positions on the
chain. Please rotate chain and check in several positions.
Is chain tension correct? Chains should be tightened to
an extent that they can be lifted only 3-5 mm from the
chain support rail.

Page | 15 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
12.1. PREPARING OPERATION
The microduct that the cable is blown into, should be without sharp corners or bends. Before blowing it is
recommended to blow a sponge through the duct. This ensures that the fiber cable can get all the way through
the duct without getting stuck.
Cleaning the duct
1. Apply one or multiple sponges in the duct.
2. Add air pressure and blow sponge.
3. Make sure the ponge arrives at the other end of
the duct.
4. Check that the sponge looks clean after it arrives
at the other end - or repeat with new sponges
until its clean.
Lubricating the duct
1. Remember to clean the duct prior to lubricating
it.
2. Apply one sponge at the desired depth (See
guideline on FlowLUB).
3. Add desired amout of FlowLUB
4. Apply one more sponge (creating three layers
with sponges and lubrication)
5. Add air pressure pushing sponges and FlowLUB all
the way through to the end.
Activate the joystick in
forward direction.
Increase the pressure,
until the machine starts
to run.
Increase hydraulic
pressure a bit more to
ensure continuous
running.
If the fiber cable meets
extensive resistance,
the machine will stop
and prevent wheel-spin
and damage to fiber
cable and chains.
Reduce the oil flow
(=machine speed) on
the upper valve handle
and activate the
joystick.
Check, that the chains
operate
with moderate speed.
Speed can be adjusted
later during operation.
Reduce the hydraulic
pressure
(=machine pushing
power) on the lower
valve handle.

Page | 16 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
Lubricate chains
regularly
Check for rubber
particles in this area
12.2. DURING OPERATION
The chain pressure on the fiber cable should be
sufficient to create enough friction.
•Too low pressure can cause “wheel-spin”,
damaging fiber cable and chains.
•Too high pressure can deform the fiber cable
and rubber on chains.
Check the chain pressure on the fiber cable
regularly.
Lubricate the chains regularly. Use a chain oil spray
of good quality. Spray the chains with oil through
the holes in the chain covers. Be careful not to add
too much, since lubricant on the chain rubber
profile decreases friction between chain and fiber
cable dramatically.
Many rubber particles on the machine surface can
be a sign of excessive wear.
Check the air pressure regularly. Use the airflow
regulator to adjust pressure, if necessary.
In general, it is recommended to adjust the
hydraulic pressure and thereby the pushing power
to the lowest level possible, with just enough
power to draw the fiber from the drum.
The main work to get the fiber cable through the
duct should be done by the compressed air flow.
12.3. AFTER OPERATION
When the fiber cable is through the duct, turn off the hydraulic power.
The air pressure inside the duct is released by turning the air valve to
the left.

Page | 17 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
13. ADJUSTMENT OF PUSHING POWER INDICATOR
(PPI)
The offset point of the PPI indicator can be adjusted. This can be necessary when the machine has been in
operation for some time.
•Use a 5 mm hex key to adjust the Allen screw placed behind the hole above the lifting handle
•Adjust until the indicator is placed at the start of the scale
•Push the blowing junction block in direction away from chains
•Let the blowing junction block return to unloaded position
•Re-adjust, if necessary

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
14. CHANGING ADAPTOR PLATES
•The brass adaptor plates can be changed
without the use of tools
•Click the adaptor plates into position
Ball
lock top
Ball
lock
bottom
•The adaptor plates are locked at the
top and bottom by a spring loaded ball
lock
•Check that the groove in the adaptor
plate is aligned with the ball lock

Page | 19 of 27
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
15. CHANGING CHAINS AND CHAIN SUPPORT RAILS
•Remove the chain support rail
•Check for wear and replace, if necessary
•Remove the chain wheel from its position
•Remove the chain covers
•Remove the upper part by unscrewing the two
Allen screws
•Unscrew the Allen screw in the middle of the
chain wheel
•Replace the chain
•Revert all operations
•Follow the instructions in
Chain Maintenance and Adjustment

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
16. INITIAL ADJUSTMENT OF JOYSTICK
16.1. PREPARATION
•Connect the hydraulic MultiPower Pack to
the control valve
•Connect the control valve to the machine
•Start the hydraulic power unit according to
operating instructions
•Check that there is no fiber cable in the
blowing machine
•Check that the chains are not in contact
with each other