Beruflich Dokumente
Kultur Dokumente
Premier LW Blower
CONDUX
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
ADVERTENCIA:
Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si
Ud. no comprende las instrucciones favor de consultarle a su jefe.
READ MANUAL
FIRST
CALL 1-800-533-2077
CONDUX
2
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Condition of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Air Compression Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
D. Operational Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Battery Counter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G. Acoustic Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
H. Caterpillar Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
I. Conduit Coupling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Safe Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Work Area Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B. Hydraulic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
C. Pneumatic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Unpacking the Premier LW Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. Blower Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Set Up the Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. Remove Blower from Shipping Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Cable Crash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Pressure Test Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Prepare Conduit for Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9 Prepare Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 Final Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A. Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11 Blower Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
A. Observer at Exit Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
B. Connect Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
C. Set up the Electronic Counter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
D. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12 Tear Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A. Remove Power from Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B. Remove Cable from Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
C. Separate Unit from Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A. Track Cleaning & Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
B. Replacement of Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C. Torque Specifications for Capscrews into Various Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
14 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
15 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
A. Re-Program the Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
B. Upper Drive Shaft Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
C. Lower Drive Shaft Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
D. Hydraulic Motor Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
E. Idler Bracket Bushing & Idler Bracket Screw Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 41
F. Air Block Assembly Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
G. Counter Clamp Roller & Cable Guide Replacement Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
H. Timing & Takeup Roller & Idler Roller Replacement Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
I. Hydraulic Coupler (Male) Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
J. Hydraulic Coupler (Female) Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
K. Clamp Adjustment Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
L. Lower Counter Roller Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
M. RH Cable Guide Roller Replacement Kit & Rear Cable Guide Replacement Kit . . . . . . . . . . . . . . 50
N. LH Cable Guide Roller Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
O. Meter Box Replacement Kit & Counter Spring Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 52
P. Base Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Q. Suggested Hydraulic Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
R. Possible Wear & Replacement Parts & Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
S. Pneumatic Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
T. Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
16 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
General Information
The operating instructions contain a full description of the Premier LW Blowing
1.
machine, which has been designed for the purpose of feeding fiber optic cable
through round conduits of uniform cross section. The conduit must previously have
been installed underground or overhead to receive the fiber optic cable and must be
of sufficient length on exit to be received by the machine. The conduit must be made
of material with sufficient compression strength for it to be adequately sealed in the
exit of a machine. The conduit must be airtight up to a pressure of 175 psi (12 bar).
For this purpose, connectors of screw, compression or fusion type must be used.
Conduits from 1" (25.00 mm) to 1.97" (50.00 mm) and fiber optic cables from 1/4"
(6 mm) to 1.13" (28.7 mm) diameter can be accepted by the machine.
Fiber optic cable is fed into the conduit by combining pulling and pushing forces,
which draw the fiber optic cable through the conduit. The pulling force is achieved
by connecting the leading end of the fiber optic cable to a piston or carrier, which
fits exactly into the conduit to make an airtight seal. Air under pressure is fed in
behind the carrier causing it to be forced through the conduit. As the carrier moves
through the conduit, it pulls the fiber optic cable behind it. The fiber optic cable is
continuously pushed into the conduit by a tractor drive. This consists of two
caterpillar tracks, which grip the top and bottom of the fiber optic cable moving it into
the conduit. This ensures the fiber optic cable is always free as it moves into the
conduit and reduces the magnitude of the pulling forces needed to carry the leading
end through. Special lubricants are used to make it easier for the carrier to pass
through the conduit.
The exit of the machine consists of an air box that is made in two halves that clamp
together. The air box contains special removable seals on entry and exit, which
clamp around either the end of the conduit or the fiber optic cable to be fed into the
conduit. The seals can be changed to accommodate different conduit and fiber optic
cable sizes. The conduit is clamped between a pair of seals at the entrance to the
air block. A clamp located in front of the entrance to the air block holds the conduit
mechanically to prevent it from moving axially. The fiber optic cable enters through
two seals located in an aluminum nozzle that splits in half. The aluminum nozzle is
located in the entrance to the air box and is shaped to ensure an airtight seal around
the fiber optic cable. When the two halves of the air box are closed, air pressure is
admitted into the space between the seals on entry and exit.
The use of the Condux Premier LW Fiber Optic Blower for operations different from
those discussed in this manual are considered extremely dangerous and thus
forbidden. The non-respect for the prescribed restraints of the machine causes a
situation of improper use and relieves the manufacturer from any responsibility, civil
or penal. The manufacturer’s responsibility declines even when one of the following
happens:
a. The consequences caused by tampering and/or modifications carried out
without the manufacturer’s written acceptance.
b. The use of imitative spare parts.
c. Bad maintenance.
d. Use with disconnected safety devices.
e. The connection to machine and/or parts not produced and not directly
authorized by the manufacturer in a written acceptance.
4
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
The Condux Premier LW Blower is a unique device for inserting fiber optic cable
directly into conduit. The Premier LW Blower is comprised of an air block and a
tractor drive that, when combined with an air compressor and a hydraulic power unit,
will propel fiber optic cable measuring from 1/4" to 1.13" (6 mm to 28.7 mm) into an
unobstructed, unoccupied, airtight conduit run at speeds of 0 to 300 feet per minute
(0-91 m/min). A cable carrier must be placed at the front end of the cable.
The blower comes standard in a shipping case, hydraulic & pneumatic hoses with
couplings, digital LCD speed and distance displays, and adjustable control values for
speed adjustment.
OPERATOR QUALIFICATIONS
a. Operator must know the required safety directives to run the machine that are
pertinent to the country where it is being used.
b. Operator in charge of the machine and installation project must be appropriately
dressed, avoiding large clothes, hanging jewelry or whatever might become
entangled in the moving parts.
c. Operator must also wear the necessary protective equipment such as gloves,
boots, helmet, etc.
d. Operator must carefully follow all advisements contained in the instruction
manual or on the machine.
e. Operator must have work area kept clean of obstacles that might inhibit a safe
working area.
MAINTENANCE QUALIFICATION
a. All of the machine maintenance must be carried out with the machine on a level
surface and not attached to any form of power source: pneumatic, nor hydraulic.
b. Authorized and trained personnel must do all maintenance operations. Trained
personnel are defined as people who have received qualified training from the
using company or from the manufacturer.
5
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Technical Information
A. HYDRAULIC SYSTEM REQUIREMENTS
2.
• Hydraulic Operating Pressure: 1500 psi (103 bar) maximum
• Hydraulic Flow: 5.5 gpm (20.8 l/m) maximum
• Hydraulic Circuit Type: Open Center
• 5 micron filtration
• Fitted with BHTMA standard 1/2" flat faced quick release couplings
• Proper sized power unit should be used to run the blower machine to
prevent overheating
IMPORTANT: Operators must take any precautions that may have been
recommended by the suppliers of lubricants or hydraulic fluids. This applies
to the use and disposal of lubricants and hydraulic fluids including the
lubricant used to ease the passage of fiber optic cables through conduits.
B. CONDITION OF USE
Temperature from 21° F ( -6° C) to 110° F (+43° C)
Humidity from 30% to 90% +/- 5%
Weather conditions relevant to working conditions
Natural and/or artificial lighting of the work site, minimum 200 lux
The following charts help to determine the compressor size requirement based on
testing the conduit system (Figures 1-3).
6
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
CFM
700-750
650-700
2 in. 600-650
550-600
1.5 in. 500-550
Conduit Inner 450-500
Diameter 400-450
1.25 in.
350-400
300-350
1 in. 250-300
0.1 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 200-250
(Pstart-Pend)/time, (psi/second) 150-200
100-150
50-100
CFM
700-750
650-700
2 in. 600-650
OUT OF RANGE 550-600
1.5 in. 500-550
Conduit Inner 450-500
Diameter
1.25 in. 400-450
350-400
300-350
1 in.
250-300
0.1 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4
200-250
(Pstart-Pend)/time, (psi/second) 150-200
100-150
50-100
Figure 2. Compressor Sizing for 4,921 ft (1,500 m) of Conduit Run
CFM
2 in. 700-750
650-700
OUT OF RANGE
600-650
550-600
1.5 in. 500-550
Conduit Inner 450-500
Diameter 400-450
1.25 in. 350-400
300-350
250-300
1 in. 200-250
0.1 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 150-200
(Pstart-Pend)/time, (psi/second) 100-150
50-100
D. OPERATIONAL CAPACITIES
• Pushing Force: 175 lbs (778 N) maximum
• Pushing Speed: 300 ft/min (91 m/min) maximum
• Cable Sizes: .25" to 1.13" (6 mm to 28.7 mm)
• Conduit Sizes: 1", 1-1/4" TRUE, 1-1/4", 1-1/2" SDR 11 & 13.5 and
metric O.D. conduit; 25 mm, 32 mm, 36 mm, 37 mm, 40 mm, 42 mm,
44 mm, 46 mm and 50 mm
G. ACOUSTIC EMISSION
• Level of max. sound pressure to the operator seat (ISO 11202) Lep=85 dB(A)
8
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
3.
Premier LW Blower. Observe all safety information on this page and note specific
safety requirements as explained by procedures called out in this manual. Failure to
follow these instructions could result in serious personal injury, property damage or
death.
2. The safe operation of this equipment requires that the operators be on stable
footing.
6. Use the blower only for its intended purpose. Do not use the tractor drive
without the air block to push or pull cable.
7. Do not place cable reel too close to unit. Place the reel far enough away from
the unit to ensure proper control.
9. Place cable grip on end of conduit to catch cable carrier and cable.
10. Keep hands away from tractor drive while blower is in operation.
B. HYDRAULIC DEVICES
Escaping fluids under pressure can penetrate the skin and cause serious personal
injury. Observe the following precautions to avoid hydraulic hazards:
2. Check for leaks with a piece of cardboard. Do not use your hands!
C. PNEUMATIC DEVICES
The Condux Premier LW Blower is a pneumatic device, using pressurized air to
project cable at high velocities. Please observe the following precautions when
operating the blower:
1. Forced air creates flying debris. Always wear personal protective equipment.
Severe personal injury could result.
2. Ensure no personnel are in the destination access vault during the blowing
operation. Severe personal injury could result.
9
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
4.
Each Condux Premier LW Blower Package contains the following items.
• Hydraulic hose from hydraulic control assembly to hydraulic power unit
• Shipping Case
• Allen Wrench (3/32")
• Allen Wrench (2.5 mm)
• Allen Wrench (5 mm)
• Flat face - pin style spanner wrench 1.00" dia. hole pattern w/ .187" dia. pins
• 5/8" x 600 lb. Swivel
• Venturi Air Plug
• Plastic Divided Case w/Parts Label
• User's Guide and Safety Manual
• Capscrew Set (10) (M04-0.7’s )
• O-Ring Seal Kit
NOTE: If any parts are missing: please contact your Condux representative or call
Condux International at 1-800-533-2077 (USA or CANADA), or 1-507-387-6576.
10
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
5.
Blower.
IMPORTANT: The Premier LW Blower must not be located below overhead gantries,
power lines or walkways where there might be a risk of falling objects. The operator
must be wearing recommended protective gear before operating the blower.
Operating light levels should be at least 200 lux of light intensity.
11
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
6.
the installation of cable with the Condux Premier LW Blower. This test is necessary
to set the hydraulic motor pressure of the blower below the point that it may cause
cable damage as a result of over pushing or encountering an obstruction in the
sub-duct system.
Every cable has different pushing values and these values vary depending on
duct I.D. Example: A cable with a crash test value of 75 bar in 33 mm I.D. duct,
may have a crash value of only 60 bar in a 40 mm I.D. duct. This is because the
area of lateral movement is larger as the duct size increases.
NOTE: The hydraulic motor pressure adjustment will have no effect on the
installation speed of the blowing unit. This is not a flow adjustment. This is a
pressure adjustment to prevent damage to the cable that can be caused by excessive
pushing force.
IMPORTANT: For the Crash Test to work properly use the same size cable and duct
that will be used for the job.
Set the hydraulic motor pressure on your Condux Premier LW Blower using the
following procedure:
2. Install Conduit Pulling Eye on the receiving end of the duct (Figure 7).
3. Cut a piece of fiber optic cable 15' (5 m) long. This is your test piece of cable.
12
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
4. Attach the correct size Venturi to fit the cable being installed (Figure 8).
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
OPERATOR
AIR HOSE
AIR
COMPRESSOR
B. Start the hydraulic power unit and check all connections for leaks with a
piece of cardboard. In cold weather, run hydraulic power supply until
hydraulic oil warms up.
WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Observe the following precautions to
avoid hydraulic hazards:
C. Run the blower for approximately 1 minute to remove any trapped air and
then stop the blower and hydraulic power source.
13
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
6. Remove the Cap/Cover from the stem of the Relief Valve (Figure 11).
9. Place Cable in Blower from Rear Rollers through Tractor Drive. Push cable
through the duct until it stops against the Pulling Eye (Figure 14).
14
Figure 15. Mark the Cable
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
11. Install top Venturi (Figure 16). Close Air Block and tighten (Figure 17).
Figure 16. Install Top Venturi Figure 17. Close Air Block
and tighten
12. From the Rear Rollers, pull out approximately 8' (2.4 m) of cable from the
blower.
13. Set the Hydraulic Flow Control to the highest speed by rotating the flow
control knob counter-clockwise.
14. Lower the Tractor Drive Cover, and tighten until it stops on the
Stopper- Bushing.
15. Turn on Hydraulic Power. If cable does not move, turn off Hydraulic
Power and go on to step 16. If cable moves, allow it to move until it stops.
Note pressure. Turn off Hydraulic Power and go on to step 17.
15
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
22. Remove folded fiber and test again at current Relief Valve settings to ensure
no fiber fold over or damage occurs.
Figure 19. Cable folds over Figure 20. Tighten Jamb Nut
16
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
7.
be free of leaks. A Conduit Pressure Test Kit, part number 08761457, is available to
perform this test. Conduit may also be tested for pressure using the Premier LW
Blower, follow the steps below.
1. Loosen the 6 spanner nuts on the Air Block assembly using the spanner
wrench (Figure 21). Open the Conduit Clamp Cover and Air Block Cover
(Figure 22).
Figure 21. Loosen Air Block Figure 22. Open Conduit Clamp
Assembly Cover & Air Block Cover
2. Select the correct Conduit and Cable Components according to conduit and
cable size. Refer to the Conduit and Cable Pack selection charts
(Tables 1 and 2, page 18).
3. Choose the correct Conduit Seal and install both halves securely. Use the
provided 2.5 mm hex wrench (Figure 23).
4. Choose the correct Conduit Clamp and install both halves (same color as the
conduit seal). Use the provided 2.5 mm hex wrench (Figure 24).
Figure 23. Install Conduit Seal Figure 24. Install Conduit Clamp
17
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
0.35-0.42 08761424
0.35-0.48 08780282 (8.9-10.7) 0.32-0.48 08643755
(8.9-12.2) Blue 0.43-0.48 08761425 (8.1-12.2) 033-29-1195
2 0.35-0.60
(8.9-15.2)
08780394
Pack #2
(10.8-12.2)
0.49-0.55 08761426
0.49-0.60 08780283 (12.3-14.0) 0.42-0.61 08643756
(12.3-15.2) Green 0.56-0.60 08761427 (10.7-15.5) 033-29-1196
(14.1-15.2)
0.61-0.67 08761428
0.61-0.73 08780284 (15.3-17.0) 0.53-0.74 08643757
(15.3-18.5) Red 0.68-0.73 08761429 (13.5-18.8) 033-29-1197
0.61-0.85 08780395 (17.1-18.5)
3 (15.3-21.6) Pack #3
0.74-0.85 08780285
0.74-0.79
(18.6-20.1)
08761430
0.64-0.87 08643758
(18.6-21.6) Gold 0.80-0.85 08761431 (16.3-22.1) 033-29-1198
(20.2-21.6)
0.86-0.92 08761432
0.86-0.97 08780286 (21.7-23.4) 0.75-1.00 08643759
(21.7-24.6) Clear Alum. 0.93-0.97 08761433 (19.1-25.4) 033-29-1199
0.86-1.13 08780396 (23.5-24.6)
4 (21.7-28.7) Pack #4
0.98-1.13 08780446
0.98-1.04
(24.7-26.4)
08761434
1.00-1.24 08643137
(24.7-28.7) Black 1.05-1.13 08761435 (25.4-31.5) 033-03-013
(26.5-28.7)
0.45-0.49 08780116
5 0.43-0.55
(11.0-14.0)
08780245
Pack #5
0.43-0.55
(11.0-14.0)
08780111
Orange
(11.4-12.4)
0.50-0.55
(12.7-14.0)
08780117
0.42-0.61
(10.7-15.5)
08643756
033-29-1196
6 All of the Above Pack #6 All of the above, available only on initial Premier LW Blower order
1 1"
SDR 11/13.5
08780386
Pack #1
1.315
(33.4)
08780369
Blue
1.315
(33.4)
08780307
Blue
1.121
(28.5)
08761250 1.25
(31.8)
08761439 1.00-1.24 08643137
(25.4-31.5) 033-03-013
1.10-1.50
(27.9-38.1)
2 1.25"
SDR 11/13.5
08780392
Pack #2
1.660
(42.2)
08780375
Green
1.660
(42.2)
08780051
Green
1.414
(35.9)
08761255 1.50
(38.1)
08761440 1.50-1.99 08643149
(38.1-50.5) 033-03-016
1.10-1.50
(27.9-38.1)
3 1.5"
SDR 11/13.5
08780397
Pack #3
1.900
(48.3)
08780404
Red
1.900
(48.3)
08780398
Red
1.618
(41.1)
08761260 1.75
(44.5)
08761441 1.50-1.99 08643149
(38.1-50.5) 033-03-016
1.34-1.74
(34.0-44.1)
4 All of the
Above
Pack #4 All of the above, available only on initial Premier LW Blower order
5 25 mm 08780240
Pack #5
0.984
(25.0)
08780099
Orange
0.984
(25.0)
08780134
Orange
0.787
(20.0)
08780230 1.25
(31.8)
08761439 1.00-1.24 08643137
(25.4-31.5) 033-03-013
0.63-1.00
(16.0-25.4)
6 32 mm 08780385
Pack #6
1.260
(32.0)
08780368
Gold
1.260
(32.0)
08780306
Gold
1.063
(27.0)
08761560 1.25
(31.8)
08761439 1.25-1.49 08643143
(31.8-37.8) 033-03-015
0.80-1.25
(20.3-31.7)
7 36 mm 08780387
Pack #7
1.417
(36.0)
08780370
Red
1.417
(36.0)
08780308
Red
1.181 (30.0)
1.220 (31.0)
08761643
08761555
1.25
(31.8)
08761439 1.25-1.49 08643143
(31.8-37.8) 033-03-015
1.10-1.50
(27.9-38.1)
37 mm 08780388 1.457 08780371 1.457 08780309 1.220 08761555 1.25 08761439 1.25-1.49 08643143 1.10-1.50
8 Pack #8 (37.0) Blue-Gray (37.0) Blue-Gray (31.0) (31.8) (31.8-37.8) 033-03-015 (27.9-38.1)
1.25" TRUE 08780389 1.500 08780372 1.500 08780333 1.250 08761670 1.50 08761440 1.25-1.49 08643143 1.10-1.50
9 Pack #9 (38.1) Clear Alum. (38.1) Clear Alum. (31.7) (38.1) (31.8-37.8) 033-03-015 (27.9-38.1)
40 mm 08780390 1.575 08780373 1.575 08780334 1.299 08761525 1.50 08761440 1.50-1.99 08643149 1.10-1.50
10 Pack #10 (40.0) Black (40.0) Black (33.0) (38.1) (38.1-50.5) 033-03-016 (27.9-38.1)
11 42 mm 08780391
Pack #11
1.653
(42.0)
08780374
Blue-Gray
1.653
(42.0)
08780335
Blue-Gray
1.378
(35.0)
08761660 1.50
(38.1)
08761440 1.50-1.99 08643149
(38.1-50.5) 033-03-016
1.10-1.50
(27.9-38.1)
12 44 mm 08780545
Pack #12
1.732
(44.0)
08780546
Gold
1.732
(44.0)
08780547
Gold
1.496
(38.0)
08761786 1.50
(38.1)
08761440 1.50-1.99 08643149
(38.1-50.5) 033-03-016
1.10-1.50
(27.9-38.1)
13 46 mm 08780460
Pack #13
1.811
(46.0)
08780466
Blue
1.811
(46.0)
08780461
Blue
1.299
(33.0)
08761525 1.50
(38.1)
08761440 1.50-1.99 08643149
(38.1-50.5) 033-03-016
1.10-1.50
(27.9-38.1)
14 50 mm 08780575
Pack #14
1.969
(50.0)
08780435
Blue
1.969
(50.0)
08780431
Blue
1.606
(40.0)
08761579 2.00
(50.8)
08761442 1.50-1.99 08643149
(38.1-50.5) 033-03-016
1.34-1.74
(34.0-44.1)
5. Choose the correct Venturi to fit the cable being installed. Do not install at
this time!
6. Place conduit in the Conduit Seal and Conduit Clamp. Note placement up
to ridge on Conduit Seal (Figure 25).
9. Close Air Block Cover and secure (Figure 28). Tighten spanner nuts
securely, but do not over tighten. Use a cross-tightening procedure.
Figure 27. Installing Seal Disk Figure 28. Tighten Air Block
Cover
19
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
10. Plug receiving end of Conduit with a properly sized Conduit Pulling Eye
(Figure 29) (Appendix R pg. 58).
11. Choose the correct Pulling Grip & install on receiving end of Conduit
(Figure 30).
b. Attach the hose supplied with the air compressor to the air compressor
coupling. The blower air valve assembly is equipped with a claw type
connector. Use safety clips on all pneumatic hose connections (Figure 32).
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
OPERATOR
AIR HOSE
AIR
COMPRESSOR
Figure 31. Typical Connections Figure 32. Installing Air Hose with
Safety Clips
20
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
13. Slowly open Air Control Valve. Pressurize conduit to 80-100 psi (5.5-6.9 bar)
(Figure 33).
Figure 33. Open Air Control Valve Figure 34. Close Air Control Valve
b. Conduit must not lose more than 20 psi (1.38 bar) over a 2-minute period.
c. After 2 minutes, relieve air pressure. Open air pressure relief valve
(Figure 35).
d. If conduit fails to hold required pressure, check entire conduit run for leaks
and repair them.
e. Repeat the pressure test until all leaks are found and repaired.
21
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Figure 36. Install Pulling Grip on Figure 37. Open Air Block Cover
Conduit
Figure 38. Loosen Handle to Tilt Figure 39. Pour Lube into
Blower Conduit
6. Insert Seal Disk in venturi slot if not already in place. (Figure 41).
22
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Figure 40. Insert Foam Carrier Figure 41. Insert Seal Disk
7. Close the Air Block Cover. Tighten spanner nuts securely, but do not over
tighten (Figure 42). Use cross tightening procedure with the spanner wrench to
secure completely.
a. Re-connect the air hose to the fiber blower and attach all safety clips.
b. Turn the Air Control Valve and turn on the air from the compressor
(Figure 43).
d. Blow Foam Carrier through conduit to spread lubricant and check for
blockage. Follow all safety precautions.
NOTE: Foam Carrier must exit in a reasonable time, allow for approximately
10 seconds per 1,000 feet (300 m) or conduit may be contaminated or blocked.
23
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
10. Remove Seal Disk and install Venturi (Figure 45). Use the provided 2.5 mm
hex wrench.
24
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Prepare Cable
The Premier LW Blower is designed so cable may be installed from the side. Follow
9.
these steps so cable is properly positioned to begin operation.
1. Choose the correct Cable Grip and install on fiber optic cable (Figure 47)
(See Tables 1 & 2, on page 18).
2. Install 5/8" (16 mm) Swivel on Cable Grip using the 3/32" hex wrench. Grip
must be firmly secured to cable (Figure 48). The eye on the grip can be
compressed to fit smaller diameter conduits. The eye of a new grip can be
taped with electrical tape in order to make it narrower and travel more easily
through the conduit.
4. Raise upper Tractor Drive Cover with turn crank (Figure 50). Open the rear
cable guide roller by pulling out spring plunger and rotating the roller out
(Figure 51).
7. Feed Cable Assembly through the counter rollers by lifting the Counter Roller
Bracket. Feed the cable through the Tractor Feed. (Figure 54). Lock the
Rear Cable Guide Roller into place, and tighten so they are closer to the
cable diameter (Figure 54B).
Figure 53. Add Lubricant before Figure 54. Feed Cable Assembly
Cable Assembly Through Blower
Figure 54B. Tighten Rear Roller Figure 55. Add Lubricant Behind
Adjustment Cable Assembly
26
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
10. Choose the correct Cable Seals and install on cable. Grooved side of Cable
Seal faces conduit. Place Cable Seals into Venturi, split side down
(Figure 56).
11. Close Air Block Cover (Figure 57). Tighten spanner nuts securely, but
do not over tighten. Use cross tightening procedure with the spanner wrench
to completely secure.
Figure 56. Install Cable Seals Figure 57. Close Air Block Cover
Final Set-Up
1. Lower Tractor Drive Cover with turn crank until the cover reaches the stopper-
10.
bushing. The stopper-bushing will prevent the tractor cover from being clamped
too tightly on the cable (Figure 58).
2. Level the height of Air Block’s Venturi Tube with Tractor Drive and the
approximate center line of the cable (Figure 59). After adjustments are made
tighten slide cap screws using 5 mm allen wrench (Figure 60).
Figure 58. Lower Tractor Drive Figure 59. Level Air Block With
Cover With Turn Crank Tractor Drive
27
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
A. FINAL INSPECTION
!CAUTION: Before placing the
blower into operation, always per
form a final inspection of all Figure 60. Tighten Slide
components used. Cap Screws
1. Check that the Cable Grip is attached to conduit on receiving end.
2. Notify crew that preparations are complete and cable blowing is to begin.
11.
Station an observer with a 2-way communication device, at the far end of the
Conduit, where the Cable Carrier will exit.
1. Attach the quick-disconnect couplings to the hydraulic power supply (Figure 62).
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
OPERATOR
AIR HOSE
AIR
COMPRESSOR
2. Start the hydraulic power unit and check all connections for leaks with a piece
of cardboard. In cold weather, run hydraulic power supply until hydraulic oil
warms up.
WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Observe the following precautions to
avoid hydraulic hazards:
3. Run the blower for approximately 1 minute to remove any trapped air and then
stop the blower and hydraulic power source.
Figure 63. Install Counter Box Figure 64. Attach Sensor Cord
A description of each of the switches and displays for the Condux Premier LW
Blower Counter Box appears below.
29
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Figure 65. Toggle Between Speed Figure 66. Reset Distance to Zero
and Distance Display
D. OPERATION
1. Re-connect hose from air compressor and attach all safety clips. Start the Air
Compressor and Hydraulic Power Supply. Refer to respective manufacturers
operating instructions for these units.
2. Turn the hydraulics to the “on” position (Figure 67). Slowly rotate the flow
control knob, counterclockwise to engage tractor drive and increase speed
(Figure 68). Push cable 50 to 100 feet (15 to 30 m) into Conduit.
3. Slowly open the Air Control Valve to allow air flow to the Air Block (Figure 69).
!WARNING: Never wrap line around your hand, arm, foot, or leg. Severe
personal injury or death could result from entanglement.
30
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
5. Turn Tractor Drive off immediately when the observer indicates the Cable
Carrier has exited the Conduit (air pressure will decrease sharply).
6. Turn off compressed air flow to the Air Block (Figure 70).
8. If cable blower stops before Cable Carrier exits, restart blower, slowly and
check for duct obstructions. Also see Troubleshooting Guide.
12.
is operated. Opening Air Block while under pressure may cause serious
personal injury. Ensure blower is depressurized before removing Air
Block cover.
31
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Figure 71. Turn Off Air at the Figure 72. Decompress Air Block
Air Block Hose
3. Turn off Hydraulic Power Supply and disconnect hydraulic hoses (Figure 74).
Keep all connections free of dirt and particles. Use hose end caps (supplied).
Figure 72. Raise Tractor Drive Figure 74. Turn Off Hydraulic
Cover Power
!WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Release pressure before disconnecting
hoses.
32
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
2. Pull the Guide Roller Knob and move Rear Guide Roller into open position.
Lift Counter Roller Knobs so rollers are clear of cable (Figure 76). Pull cable
out from side of unit.
Maintenance
13.
Procedure Daily Weekly Monthly 60 Days 90 Days
Clean all assemblies and
X X X X X
components thoroughly.
1. Remove the 2 capscrews which hold the sled in place with a 3 mm T-handled
allen wrench. This should allow the sled to rotate up.
3. On the bottom drive, remove the 3 capscrews from the prox cover with a 2 mm
allen wrench.
4. The bearing cap can be removed from both the top and bottom assembly using
a 5 mm allen wrench.
5. At this point, the drive pulley can be removed straight out the same hole as the
bearing cap and the belt can be removed. This sequence is reversed for the
reassembly of the new belt with a key note, the dampening bushing must be
rotated back to the smaller lobe position on the pivot shaft.
NOTE: Become familiar with the Replacement and Wear Parts associated with
the Premier LW Blower, they are listed in Appendix R pg. 55.
34
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
35
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Troubleshooting Guide
14. Problem
Tractor Feed does not pull the cable Assist the reel by pushing it, and/or by
off the reel. pulling the cable off the reel.
The cable run is hard to restart after Put air to the system with the track
having stopped. down. The tractor feed can be restarted
after the air pressure has increased
and stabilized.
36
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
2) Press and hold the “T/R<” key while repeatedly pressing the “RST^” key to advance to
successive screens.
A.
APPENDIX
3) The “RST^” key will scroll until reaching the desired digit value.
4) The “T/R<” key will move the flashing digit one place to the left
a. “00.5266” - {Count Scale Factor}
b. “000000” - {Totalizer Decimal Point}
c. “31.59” - {Rate Scale Factor} when the lower case “d” appears on the right of the
display, the decimal point can be moved to the correct location by pressing “RST^”
d. “0000” - {Ratemeter Decimal Point}
e. “1” - {Rate x1/x10} Press the “RST^” to select 1 or 10
f. “R” - {Reset Key Enable/Disable}
To exit the program mode, remove the jumper between terminal #1 and #5.
2) Press and hold the “T/R<” key while repeatedly pressing the “RST^” key to advance to
successive screens.
3) The “RST^” key will scroll until reaching the desired digit value.
4) The “T/R<” key will move the flashing digit one place to the left
a. “00.1605” - {Count Scale Factor}
b. “000000.” - {Totalizer Decimal Point}
c. “9.628” - {Rate Scale Factor} when the lower case “d” appears on the right of the dis
play, the decimal point can be moved to the correct location by pressing “RST^”
d. “0000.” - {Ratemeter Decimal Point}
e. “1” - {Rate x1/x10} Press the “RST^” to select 1 or 10
f. “R” - {Reset Key Enable/Disable}
To exit the program mode, remove the jumper between terminal #1 and #5.
37
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
B.
APPENDIX
C.
APPENDIX
D.
APPENDIX
40
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
E.
APPENDIX
F.
APPENDIX
G.
APPENDIX
H.
APPENDIX
I.
APPENDIX
46
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
J.
APPENDIX
47
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
K.
APPENDIX
L.
APPENDIX
49
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
M.
APPENDIX
N.
APPENDIX
51
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
O.
APPENDIX
Base Mount
P.
APPENDIX
53
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Q.
APPENDIX
use of lubricants not in conformity with the technical specifications indicated in the
present manual could seriously damage the machine components and consequently
the warranty conditions are not valid. Life expectancy of the machine can only be
assured if the recommended lubricants are used.
54
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Description
Belt, Cable 50MM X 260MM Center
Cable seals
Part Number
08780904
See Table 1, pg 18 for correct cable seal size
R.
APPENDIX
Kit, Seal Replacement-LW Blower 08780126
Machine Screws,M04-0.7X16 (10) 08780424
Pad,guide-rear cable entry 08780135
Guide,cable-upper entrance 08780266
Rear Entry Rollers 08780135
Upper Counter Roller 08780091
Lower Counter Roller 08780022
Carrier Seals See Table 2, pg 18 for correct carrier size
PACKAGE ADD-ONS
08780393 CABLE PACK 0.23"-0.34" (5.8-8.6 mm) CABLE-LW
08780394 CABLE PACK 0.35"-0.60" (8.9-15.2 mm) CABLE-LW
08780395 CABLE PACK 0.61"-0.85" (15.3-21.6 mm) CABLE-LW
08780396 CABLE PACK 0.86"-1.05" (21.7-26.7 mm) CABLE-LW
08780240 DUCT PACK 1.00" DUCT OD SDR 13.5/ SDR 11
08780385 DUCT PACK 1.25" DUCT OD SDR 13.5/ SDR 11
08780389 DUCT PACK 1.50" DUCT OD SDR 13.5/ SDR 11
08780386 DUCT PACK 33.4MM (1.315) DUCT OD LW
08780387 DUCT PACK 36.0MM (1.417) DUCT OD LW
08780388 DUCT PACK 37.0MM (1.457) DUCT OD LW
08780389 DUCT PACK 38.1MM (1.500) DUCT OD LW
08780390 DUCT PACK 40.0MM (1.575) DUCT OD LW
08780391 DUCT PACK 42.0MM (1.653) DUCT OD LW
08780392 DUCT PACK 42.2MM (1.660) DUCT OD LW
08780460 DUCT PACK 46.0MM (1.811) DUCT OD LW
08780397 DUCT PACK 48.3MM (1.900) DUCT OD LW
08780545 DUCT PACK 44.0MM (1.732) DUCT OD LW
08780575 DUCT PACK 50.0MM (1.968) DUCT OD LW
BLOWING LUBRICANT
08230600 LUBRICANT,POLY PL2K 1 QT 12/C EA
08230601 LUBRICANT,POLY PL2K 1 GL 4/C EA
08230900 LUBRICANT,POLY WPL2K 1 QT 12/C EA
08230901 LUBRICANT,POLY WPL2K 1 GL 4/C EA
08230700 LUBRICANT,CABLE EASE 1 QT 12/C EA
MANUALS
08780992 MANUAL,PREMIER LW BLOWER
TOOLS
02288787 DRIVER, HEX BALL-POINT 2.5MM
02288662 WRENCH,SPANNER .187 PIN/1.00 D
02283800 DRIVER, HEX BALL 3/32 INCH
02289261 WRENCH, ALLEN 5MM
56
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
57
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
NOTE: To determine correct pulling eye size, obtain the actual innerduct inside
diameter (I.D.). The I.D. measurement must be greater than dimension A and
smaller than dimension B.
D A B C E
58
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
INNERDUCT SLITTER
The Innerduct Slitter is designed for fast, safe cutting of innerducts from 1" (25 mm) to
2" (51 mm) OD.
59
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
INNERDUCT COUPLINGS
ETCO Double “E-Loc”® Innerduct Couplings are designed to join
both smooth and ribbed HDPE innerduct, specifically for
pneumatic methods of cable placement where air and
water-tight integrity of the system is imperative, and where the
joint is unrestrained such as in a vault, manhole or hand hole.
The couplers are pressure tight to internal pressures above 200
psi when restrained or buried, and can maintain these pressures
unrestrained, and are reusable. There are no metal parts and
can be hand tightened with no special tools.
Coupling
Conduit Length
Part Nominal Conduit O.D. when tight
Number Conduit Size Type (in) (mm) (in) (mm)
08676510 1" IPS Smooth 1.315 33 6.25 159
1.34" O.D. Ribbed 1.340 34 6.25 159
08676511 1.42" O.D. Smooth 1.420 36 6.25 159
11⁄8" SIDR 9 Ribbed 1.460 37 6.25 159
08676512 1.50" O.D. SDR 11 Smooth 1.500 38 6.25 159
08676513 11⁄4" True 1.125 I.D. Smooth 1.530 39 6.25 159
11⁄4" O.D. Ribbed 1.575 40 6.25 159
08676514 1.60" O.D. Smooth 1.600 41 6.25 150
08676515 11⁄4" IPS Smooth 1.660 42 6.25 159
11⁄4" O.D. Ribbed 1.700 43 6.25 159
08676516 11⁄2" True SIDR 9 Ribbed 1.830 46 8.25 210
08676517 11⁄2" True SIDR 9 Smooth 1.830 46 8.25 210
08676518 11⁄2" IPS Smooth 1.900 48 8.25 210
08676520 2" IPS Smooth 2.375 60 8.50 216
60
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Pneumatic Circuit
S.
APPENDIX
Pneumatic Circuit
08780909
Hydraulic Circuit
REGULATOR, PRESSURE-COMPENSATED
HYRDA-FORCE PART NUMBER FR12-30F-0-N-5.5
T.
APPENDIX
CONSTANT DIFFERENTIAL PRESSURE OF 6.5 BAR
CAVITY: C12-3
MAX OPERATING PRESSURE: 3500 PSI
MAX FLOW RATE: 13.0 GPM
CHECK VALVE
HYDRA-FORCE PART NUMBER CV10-20-0-N-5
PARKER PART NUMBER CV101P
MAX OPERATING PRESSURE: 3500 PSI
MAX FLOW: 15 GPM
CAVITY: C10-2
NITRILE SEALS
Hydraulic Circuit
08780910
61
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
62
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Warranty Information
A. FACTORY ASSISTANCE
Condux International can provide further advice regarding any problems with the
installation, service, assembly, or disassembly of the Condux Premier LW Blower.
Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for
assistance. The Premier LW Blower can be returned to the factory at any time for
service or repair; however, a Return Material Authorization (RMA) must be obtained
from Condux before shipping. Condux will not accept returned items without an RMA.
16.
B. LIMITED WARRANTY
Condux International, Inc. extends the following warranty to the original purchaser of
these goods for use, subject to the qualifications indicated: Condux International,
Incorporated warrants to the original purchaser for use that the goods or any
component thereof manufactured by Condux International will be free from defects in
workmanship for the period of one year from the date of purchase. Provided such
goods are installed, maintained, and used in accordance with Condux’s written
instructions.
Lack of routine maintenance as specified in the maintenance section of the
User’s Guide will void the warranty.
Components not manufactured by Condux International but used within the assembly
provided by Condux International are subject to the warranty period as specified by
the individual manufacturer of said component, provided such goods are installed,
maintained, and used in accordance with Condux’s and the original manufacturer’s
written instructions.
Listed wear parts as called out in the User’s Guide are not covered under the
warranty.
Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under
this limited warranty, and for any and all claims arising from the purchase and use of
the goods, shall be limited to the repair and replacement of the goods that do not
conform to this warranty.
To obtain repair or replacement service under the limited warranty, the purchaser
must contact the factory for a Return Material Authorization (RMA). Once obtained,
send the RMA along with the defective part or goods, transportation prepaid, to:
Condux International, Inc.
145 Kingswood Road
Mankato, MN 56001 USA
63
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com