Fremco PowerFlow RAPID User manual

Valid from 01.07.2021 | Rev. 1.1
From Serial No. 9328.3649 & 9328.3748
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: PowerFlow RAPID & MultiFlow RAPID
This is the original operating manual for PowerFlow RAPID and MultiFlow RAPID from Fremco.
PowerFlow RAPID MultiFlow RAPID
For single cable For both single cable and relining

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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. POWERFLOW RAPID...................................................................................................................9
3.2. MULTIFLOW RAPID....................................................................................................................10
3.3. HYDRAULIC CONTROL UNIT....................................................................................................11
4. SAFETY AND RESIDUAL RISKS ..............................................................................................13
4.1. BUILT-IN SAFETY MEASURES .................................................................................................13
4.1.1. SAFETY FUNCTIONS.................................................................................................................13
4.2. WARNING - FORESEEABLE MISUSE.......................................................................................14
4.3. SAFETY MEASURES, TO BE TAKEN BY THE USER ..............................................................14
4.3.1. CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE) ...........................................14
4.3.2. HANDLING OF DANGEROUS SUBSTANCES AND MATERIALS............................................15
4.3.3. RESIDUAL RISKS.......................................................................................................................15
4.3.4. WORK PROCEDURES...............................................................................................................16
4.3.5. IN CASE OF EMERGENCY........................................................................................................16
4.3.6. VIOLATION OF SAFETY REGULATIONS..................................................................................16
5. OVERVIEW AND APPLICATION...............................................................................................17
5.1. GENERAL DESCRIPTION..........................................................................................................17
5.2. THE MACHINE’S PURPOSE AND INTENDED USE .................................................................17
5.3. OPERATING POSITIONS, LOCATION AND ARRANGEMENT.................................................18
5.4. USER INTERFACE .....................................................................................................................19
5.5. MACHINE ASSEMBLY AND ADJUSTMENT..............................................................................21
6. TRAINING ...................................................................................................................................24
6.1. OPERATORS ..............................................................................................................................24
6.2. MAINTENANCE PERSONNEL ...................................................................................................24

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
7. OPERATION ...............................................................................................................................25
7.1. TRANSPORTING THE MACHINE ..............................................................................................25
7.2. START/STOP ..............................................................................................................................25
7.3. ENERGY SUPPLY CONNECTION/DISCONNECTION..............................................................25
7.4. FEEDING/REMOVING PRODUCTS...........................................................................................27
7.5. AIR/WATER SUPPLY..................................................................................................................27
8. MAINTENANCE, TROUBLESHOOTING AND REPAIR............................................................28
8.1. QUICK GUIDE TO MAINTENANCE, TROUBLESHOOTING AND REPAIR..............................28
8.2. PREPARATION FOR MAINTENANCE AND REPAIR................................................................28
8.2.1. CLEANING ..................................................................................................................................28
8.2.2. CORRECTIVE MAINTENANCE..................................................................................................28
8.2.3. REPAIR........................................................................................................................................29
8.3. SERVICE AND REPAIR ADDRESS ...........................................................................................29
8.4. DISCONNECTION AND DEPRESSURIZATION OF ENERGY SOURCES...............................29
8.5. MAINTENANCE SCHEDULE......................................................................................................30
8.5.1. VISUAL INSPECTION.................................................................................................................32
8.5.2. CHAIN SUPPORT RAIL..............................................................................................................32
8.5.3. LUBRICATION OF THE CHAINS AND CHAIN SUPPORT RAIL ...............................................33
8.5.4. CHAIN ADJUSTMENT ................................................................................................................33
8.5.5. CHAINS AND SPROCKET WEAR..............................................................................................34
8.5.6. SPINDLE LUBRICATION............................................................................................................35
8.6. WEAR AND TEAR PARTS..........................................................................................................35
9. BLOWING TECHNIQUE.............................................................................................................37
9.1. BEFORE FIBER BLOWING ........................................................................................................37
9.2. PREPARING THE DUCTS FOR FIBER BLOWING ...................................................................37
9.3. INITIATING FIBER BLOWING ....................................................................................................38
10. CESSATION OF USE .................................................................................................................39
10.1. DISMANTLING ............................................................................................................................39
10.2. SCRAPPING................................................................................................................................39
11. EC DECLARATION OF CONFORMITY .....................................................................................40
12. UKCA DECLARATION OF CONFORMITY................................................................................41

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
13. APPENDIXES..............................................................................................................................42
13.1. HYDRAULICS SCHEMATICS.....................................................................................................42
13.2. PNEUMATICS SCHEMATICS ....................................................................................................43
13.3. DRAWINGS OF MECHANICAL CONSTRUCTION....................................................................44

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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!

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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 PowerFlow RAPID and/or
MultiFlow 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 9328.3649 (PowerFlow RAPID) &
9328.3748 (MultiFlow RAPID).
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.

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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 PowerFlow RAPID or MultiFlow RAPID.
2.3. MACHINE PLATE
The machine plate is situated on the front of the machine:
Figure 1: Location of machine plate
Figure 2: Location of the UKCA
sticker is placed next to the 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
The machine is equipped with the following safety markings:
•Hand crush hazard symbol
•Max. air pressure on the Flex block RAPID

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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. POWERFLOW RAPID
Manufacturer Fremco A/S
Ellehammervej 14
9900 Frederikshavn
Denmark
Item No. .........................................................................................................................................................................................101-40001
Cable diameter1............................................................................................................................................................................5.5-25 mm
Duct diameter2...............................................................................................................................................................................10-63 mm
Blowing distance3.............................................................................................................................................Up to 5,000 m (16404 ft)
Floating distance3........................................................................................................................................... Up to 10,000 m (32808 ft)
Blowing speed3...................................................................................................................................................Up to 80 m/min. (262 ft)
Pushing force .............................................................................................................................................................. 0-125 kg (0-275 Ibs)
Max. pressure and airflow4: .....................................................................16 bar (232 psi), 8,000-12,000 l/min. (282.5-423.7 cfm)
Max. hydraulic pressure................................................................................................................................................110 bar (1595 psi)
Weight ...................................................................................................................................................................................... 45 kg (99 Ibs)
Length........................................................................................................................................................................................950 mm (38”)
Width ........................................................................................................................................................................................400 mm (16”)
Height........................................................................................................................................................................................500 mm (20”)
1Two sets of chains needed (5.5-8 mm/8-16 mm/14-25 mm).
2Standard duct OD: 14 - 60 mm, Custom made duct OD: 10-13 mm & 61 -63 mm
3Depending on type and quality of fiber cable and microduct
4Air must be filtered, cooled and dried

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3.2. MULTIFLOW RAPID
Manufacturer Fremco A/S
Ellehammervej 14
9900 Frederikshavn
Denmark
Item No. ...................................................................................................................101-40021 (Single cable) & 101-40002 (Relining)
Cable diameter1............................................................................................................................................................................5.5-32 mm
Duct diameter2...............................................................................................................................................................................10-63 mm
Blowing distance3.............................................................................................................................................Up to 5,000 m (16404 ft)
Floating distance3........................................................................................................................................... Up to 10,000 m (32808 ft)
Blowing speed3...................................................................................................................................................Up to 80 m/min. (262 ft)
Pushing force ...........................................................................................................................................................0-200 kg (0-440.9 Ibs)
Max. pressure and airflow4: ........................................................ 8-12 bar (116-174 psi), 8,000-12,000 l/min. (282.5-423.7 cfm)
Max. hydraulic pressure................................................................................................................................................110 bar (1595 psi)
Weight ....................................................................................................................................................................................51 kg (112 Ibs)
Length..................................................................................................................................................................................... 1050 mm (41”)
Width ........................................................................................................................................................................................400 mm (16”)
Height........................................................................................................................................................................................500 mm (20”)
1Two sets of chains needed (5.5-8 mm/8-16 mm/14-32 mm).
2Standard duct OD: 14 - 60 mm, Custom made duct OD: 10-13 mm & 61-63 mm
3Depending on type and quality of fiber cable and microduct
4Air must be filtered, cooled and dried