Fremco PowerFlow RAPID User manual

Valid from 12.01.2021
Rev. 1.0
FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
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. OVERVIEW AND APPLICATION.................................................................................9
3.1. GENERAL DESCRIPTION ...........................................................................................9
3.2. THE MACHINE’S PURPOSE AND INTENDED USE ....................................................9
3.3. WARNING - FORESEEABLE MISUSE.......................................................................10
3.4. TECHNICAL SPECIFICATIONS.................................................................................10
3.4.1. PHYSICAL DIMENSIONS IN METRIC UNITS............................................................11
3.4.2. PHYSICAL DIMENSIONS IN IMPERIAL UNITS.........................................................11
3.4.3. PNEUMATICS ............................................................................................................11
3.4.4. HYDRAULICS.............................................................................................................12
3.4.5. NOISE ........................................................................................................................12
3.5. OPERATING POSITIONS, LOCATION AND ARRANGEMENT..................................12
3.6. USER INTERFACE.....................................................................................................13
3.7. MACHINE ASSEMBLY AND ADJUSTMENT..............................................................15
4. SAFETY AND RESIDUAL RISKS..............................................................................18
4.1. BUILT-IN SAFETY MEASURES .................................................................................18
4.1.1. SAFETY FUNCTIONS................................................................................................18
4.2. SAFETY MEASURES, TO BE TAKEN BY THE USER...............................................19
4.2.1. CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE).............................19
4.2.2. HANDLING OF DANGEROUS SUBSTANCES AND MATERIALS .............................20
4.2.3. RESIDUAL RISKS......................................................................................................20
4.2.4. WORK PROCEDURES...............................................................................................20
4.2.5. IN CASE OF EMERGENCY........................................................................................21
4.2.6. VIOLATION OF SAFETY REGULATIONS..................................................................21
5. TRAINING ..................................................................................................................22
5.1. OPERATORS.............................................................................................................22

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
5.2. MAINTENANCE PERSONNEL...................................................................................22
6. OPERATION ..............................................................................................................23
6.1. TRANSPORTING THE MACHINE..............................................................................23
6.2. START/STOP .............................................................................................................23
6.3. ENERGY SUPPLY CONNECTION/DISCONNECTION ..............................................23
6.4. FEEDING/REMOVING PRODUCTS...........................................................................25
6.5. AIR/WATER SUPPLY.................................................................................................25
7. MAINTENANCE, TROUBLESHOOTING AND REPAIR.............................................26
7.1. QUICK GUIDE TO MAINTENANCE, TROUBLESHOOTING AND REPAIR................26
7.2. PREPARATION FOR MAINTENANCE AND REPAIR.................................................26
7.2.1. CLEANING AND ORDER ...........................................................................................26
7.2.2. CORRECTIVE MAINTENANCE..................................................................................27
7.2.3. REPAIR ......................................................................................................................27
7.3. SERVICE AND REPAIR ADDRESS ...........................................................................27
7.4. DISCONNECTION AND DEPRESSURIZATION OF ENERGY SOURCES ................28
7.5. MAINTENANCE SCHEDULE......................................................................................29
7.5.1. VISUAL INSPECTION ................................................................................................30
7.5.2. CHAIN SUPPORT RAIL..............................................................................................31
7.5.3. LUBRICATION OF THE CHAINS AND CHAIN SUPPORT RAIL ................................31
7.5.4. CHAIN ADJUSTMENT................................................................................................31
7.5.5. CHAINS AND SPROCKET WEAR..............................................................................32
7.5.6. SPINDLE LUBRICATION............................................................................................33
7.6. SPARE PARTS...........................................................................................................34
8. BLOWING TECHIQUE...............................................................................................36
8.1. BEFORE FIBER BLOWING........................................................................................36
8.2. PREPARING THE DUCTS FOR FIBER BLOWING....................................................36
8.3. INITIATING FIBER BLOWING....................................................................................37
8.4. USE OF COMPRESSED AIR FOR FIBER BLOWING................................................38
8.5. USE OF WATER FOR FIBER FLOATING..................................................................38
9. CESSATION OF USE.................................................................................................39
9.1. DISMANTLING ...........................................................................................................39
9.2. SCRAPPING...............................................................................................................39

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
10. EC DECLARATION OF CONFORMITY .....................................................................40
11. APPENDIXES.............................................................................................................41
11.1. HYDRAULICS SCHEMATICS.....................................................................................41
11.2. PNEUMATICS SCHEMATICS....................................................................................42
11.3. DRAWINGS OF MECHANICAL CONSTRUCTION.....................................................43

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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.
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

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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. OVERVIEW AND APPLICATION
3.1. GENERAL DESCRIPTION
The machine consists of:
•Hydraulic control valve unit
•PowerFlow RAPID/MultiFlow RAPID unit:
oInlet with digital counter
oChain drive unit
oFlex block RAPID
3.2. THE MACHINE’S PURPOSE AND INTENDED USE
The machine is constructed for blowing fiber optic cables into microducts. MultiFlow RAPID can
also be used to reline multiple microducts. The machine may only be used for these exact
purposes.
PowerFlow RAPID has a fiber/cable OD of 5.5-25 mm and a duct size OD of 10-63 mm*.
MultiFlow RAPID has a fiber/cable OD of 5.5-32 mm and a duct size OD of 10-63 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.
Inlet
Chain drive unit
Flex block RAPID
Control valve unit

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
Only suitable CE-marked equipment (hydraulic and pneumatic compressor) may be connected to
the machine.
The machine is not to be used for any other purpose than those provided above
*Standard duct size OD for PowerFlow RAPID and MultiFlow RAPID: 14-60 mm.
Custom duct size OD for PowerFlow RAPID and MultiFlow RAPID: 10-13 mm & 61-63 mm.
3.3. WARNING - FORESEEABLE MISUSE
Before using the machine, operators must ensure that:
•The guarding is intact
•The operator is able to monitor all machine movements
•The hydraulic and pneumatic hoses are undamaged
•There is no damage to any pressure caring component
•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
The operator must NOT under any circumstances:
•Reach into/touch the chain drive while the machine is in operation
•Exceed the maximum supply pressure of hydraulic control unit, water and air.
Machine surfaces must be kept clear of clutter and must not be used as work surfaces.
3.4. TECHNICAL SPECIFICATIONS
Service life expectancy
The machine gas a minimum service life expectancy of 20 years.
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 components.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3.4.1. PHYSICAL DIMENSIONS IN METRIC UNITS
Machine: Hydraulic control unit:
PowerFlow RAPID:
MultiFlow RAPID:
Length: 950 mm
Length: 1050 mm
Width: 400 mm
Width: 400 mm
Height: 500 mm
Height: 500 mm
Weight: 45 kg
Weight: 51 kg
3.4.2. PHYSICAL DIMENSIONS IN IMPERIAL UNITS
Machine: Hydraulic control unit:
PowerFlow RAPID:
MultiFlow RAPID:
Length: 38”
Length: 41”
Width: 16”
Width: 16”
Height: 20”
Height: 20”
Weight: 99Ibs
Weight: 112Ibs
3.4.3. PNEUMATICS
Air consumption: up to 10 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.
Control unit
Length: 260 mm
Width: 230 mm
Height: 300 mm
Weight: 12 kg
Hose length: 1500 mm
Control unit
Length: 10”
Width: 9”
Height: 12”
Weight: 26Ibs
Hose length: 60”

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3.4.4. HYDRAULICS
Oil consumption: 18 l oil per minute at max. 110 bar
Filtrated to below 25 μm
3.4.5. NOISE
Airborne noise emitted by the machine:
Measured sound pressure level: 85 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 hydraulic
pump).
3.5. OPERATING POSITIONS, LOCATION AND ARRANGEMENT
The operator’s workstation is located the front of the machine, next to the control unit.
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

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
3.6. USER INTERFACE
Below, you will find all operating handles and a short description of their use:
Handle for control valve
•Provides Manometer readout of max.
hydraulic oil pressure (110 BAR/1595 PSI)
•Enables speed and torque adjustment
•Handle moves forward/backwards
•Attach the end of the hose with the yellow
markers to the hydraulic unit.
Air valve
•Controls the amount of air entering the
blowing chamber.
•Picture shows the OPEN position.
•Turn clockwise to close, turn
anticlockwise to open.
Vent valve
•Releases air pressure from the duct and
blowing chamber before opening the Flex
block.
•Picture shows the OPEN position, turn
anticlockwise to close.

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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/water)
•Connects to the EU/US claw coupling for
the airhose.
•The EU (DIN 3238) claw coupling is
mounted by default.
•The US claw can be found in the box.
Safety valve
•Air over pressure relief valve. Set to
release pressure above 16 BAR/230 PSI.
Handle for spindle.
•Rotate clockwise to move top chain down
towards bottom chain.
•Rotate anticlockwise to move top chain up
and away from bottom chain.
Manometer
•Provides readout of currentl pressure in
flex block RAPID.
•Maximum pressure 16BAR/230 PSI.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
Digital distance and speed counter
•Readout 1 shows the total length of fiber
passing the counter.
•Readout 2 shows the speed of fiber
passing the counter.
•Blue button resets total meter counter.
3.7. MACHINE ASSEMBLY AND ADJUSTMENT
Parts in the Flex block
RAPID
Duct holder inserts and adaptors
are chosen according to the duct
size.
The same goes for choosing nylon
sealing and cable sealings.
The O-ring should be adjusted
depending on the adaptor and duct
size.
Nylon seals
Adaptor (top)
Duct holder
insert
Cable sealings x3
Adaptor (bottom)
O-ring
Duct holder
insert
Duct holder

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
1.
2. Not mounted 3. Mounted
Mounting the Flex block
RAPID
Mounting the Flex block RAPID to
the machine involves sliding the
bottom part of the Flex block
RAPID onto the steel bracket bars
(Picture 1).
Slide the block onto the bars until it
clicks into place, and tighten the
hand knob (Picture 3).
If you have not mounted the Flex
block RAPID properly, you will not
be able to see the locking
mechanism (Picture 2).
However, when the Flex block
RAPID is mounted properly, the
lock mechanism will be shown
(Picture 3).
To dismount the Flex block RAPID,
repeat the process backwards.
1. 2.
3. 4.
Adjusting the Flex block
RAPID
Before any fiber blowing job, ensure
that the flex block RAPID is
adjusted to the machine. You can
adjust the height and length.
Adjusting the height
Find the hand knob beneath the
Flex block RAPID (Picture 1) and
turn to adjust the height of the flex
block RAPID until the nylon guides
aligns with chains on the machine
(Picture 2).
Adjusting the length
Find the hand knob at the end of
the steel bracket bars (Picture 3)
and turn to adjust the length until
the gap between the nylon seal and
chain is as small as possible
(approximately 2 mm). Make sure
that the nylon guides do NOT
touch the chains.
Steel bracket bars
Hand knob

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
1. 2.
3. 4.
5.
Opening and closing the
Flex block RAPID
To open the Flex block RAPID,
unscrew four hand knobs (Picture
1). The two hand knobs on the
operational side can now be
loosened/moved away. Pull the
round hand knob on top of the flex
block RAPID upwards and and pull
away from the operational side to
open the flex block RAPID (Picture
2).
Now continue with the duct
holder, as shown in pictures 3, 4 &
5.
To close the Flex block RAPID,
repeat the process backwards.
1. Inlet for single cable 2. Inlet for relining
Parts in the inlet
•Adjust the rollers to
centre the cable or
multiple ducts.
•The digital distance and
speed counter is pre-
mounted on the inlet.
Rollers
Nylon guides for
microduct

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
4. SAFETY 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 fixed guards for the safety of personnel/operators.
To prevent over pressurising the pneumatic system, the machine is equipped with an over
pressure relief valve.
4.1.1. SAFETY FUNCTIONS
Safety Function 1
Safety function
Description
Hold-to-run system for forward and
backward operation of the chain drive.
The operation of the machine is implemented as a
hold-to-run system. This means that the operator must
perform a continuous actuation on the joystick on the
hydraulic control unit in order for the machine to
produce movement.
If the actuation ceases, the joystick will return to
neutral and all machine movement stops immediately.
Over pressure relief valve for the
pneumatic system
The machine is equipped with an over pressure relief
valve, to prevent over pressurising the pneumatic
system.
These safety features must always be active and must not be overridden.
Shut-off valve:
The machine is equipped with a quick coupling to enable the quick release of the hydraulic and
pneumatics systems.
Test intervals:
If the below test limits are exceeded, consider the safety features to invalid and unable to protect
operators from the hazards of the machine. Safety features must be tested several times a year.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
4.2. SAFETY MEASURES, TO BE TAKEN BY THE USER
4.2.1. 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 safety glasses and safety shoes must be used during daily operation of
the machine.
Do NOT wear any loose clothing, jewellery, scarves, etc. while operating the machine.
During maintenance and repair:
Appropriate PPE must be used for repair and maintenance work. The area around the machine
must be cleaned of spills and other items.
The manufacturer's instructions must be followed when replacing a machine component.
•PPE in the form of work gloves, safety 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.

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FREMCO A/S
ELLEHAMMERVEJ 14 |DK9900 FREDERIKSHAVN, DENMARK |VAT NO.: DK30815416
TELEPHONE [phone] |[email protected] |WWW.FREMCO.DK
4.2.2. HANDLING OF DANGEROUS SUBSTANCES AND MATERIALS
Chemicals and hydraulic fluids:
PPE must be used in accordance with the individual product’s safety data sheets when:
•Handling/using hydraulic fluids
•Installing of liquid-filled components
•Maintaining liquid-filled components
•Handling hoses/couplings containing liquid, etc.
Disposal of products and other waste must be done in accordance with the guidelines for the
materials in question.
4.2.3. RESIDUAL RISKS
Consider the following residual risks during maintenance and repair:
•Accumulated energy in pneumatics or hydraulics
•Contact with hydraulic oil and/or lubricants
Before service and repair or maintenance, ensure the following:
•The machine has been disconnected from its energy supply
•Accumulated energy has been relieved
•The proper PPE is being used.
4.2.4. WORK PROCEDURES
Before operating the machine, the following must to be ensured:
•The site of operation suitable or has been made safe for operation
•Weather conditions allow for safe operation of the machine
•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 unwanted personnel
•There is adequate lighting to safely operate the machine
•The safety glasses and gloves are worn when connecting and disconnecting hydraulic
components
•Protective glasses and protective gloves are worn when servicing hydraulic components.
•All machine components and energy supplies have been correctly installed.