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GMP Air Stream 89300, Operation And Maintenance

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GMP Air Stream 89300 Operation And Maintenance Download Page 15

Page 15 of 41 

Connect the air supply to the machine. 

 

The air inlet to the machine is male via a crowfoot coupling on the back of the airbox. An on/off valve is fitted to 

the air box to provide control of the air supply to the operator and a pressure gauge is fitted to the air box to 

indicate air box pressure. Maximum safe working pressure is 15 Bar ( 210 psi). 

 

 

Connect the electrical supply to the 

machine. 

 

Note:

  Please refer to Section 4.0 Specification for details 

on power supply quality. General Machine Products (KT), 

LLC recommend the use of a Honda EU1000i generator. 

 

The transformer accepts voltages between 100-277 Vac 

50/60Hz automatically.  Adaptors are available to suit any 

required existing connector, speak to our sales department 

for full details and specification of connector. 

 

 

If the power supply lead supplied with the AirStream Cable Blowing Machine is unsuitable and requires to be 

changed refer to the safety instructions for further details. 

 

 

IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE CONNECTIONS MEETS THE 

ELECTRICAL REGULATIONS FOR THE RELEVANT COUNTRY. 

 

 

 

The machine is now ready to start the cable installation. 

 

 

 

 

Summary of Contents for Air Stream 89300

Page 1: ...pied reproduced or transmitted in any form whatso ever without the written permission of General Machine Products KT LLC General Machine Products KT LLC 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 WEB www gmptools com CABLE BLOWING MACHINE Manual P N 36287 Ver 6a 071717 AKK ...

Page 2: ...ay 19 11 Updated photos to newer design A Konschak 04 Nov 20 12 Update to reflect new design without remote A Konschak 05 April 09 13 Update grounding and belt replacement info Various corrections and spec updates A Konschak 05 1 Feb 28 14 Added location of long inserts A Konschak 06 Sept 20 16 Wording changes per engineering A Konschak ...

Page 3: ...ocedure for changing the air box infeed guide 12 Procedure for changing the cable drive belts 13 Procedure for tensioning the drive belts 14 Procedure for checking and replacing the motor drive belt 15 Monthly Service check list 16 Service History Record 17 Tube integrity and Lubrication 18 Recommended Spares List APPENDICES Appendix 1 Cable and tube insert selection chart Appendix 2 Recommended t...

Page 4: ... of safety barriers especially when used in public places observe all statutory requirements for working environments 10 Beware of pinch points involved with rotating components 11 Beware of hot surfaces machine uses compressed air 12 When operating machine always wear appropriate safety clothing ear defenders eye protection hard hat safety shoes and leather gloves machine operates with compressed...

Page 5: ...L INJURY AS THE CABLE COULD BE EJECTED FROM THE CABLE BLOWING MACHINE WITH HIGH FORCE AND VELOCITY If the connecting plug on the power lead to the generator or supply supplied with the Airstream machine is unsuitable and requires replacement the new plug must be correctly connected observing the color codes as below IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE CONNECTIONS MEET THE ELECT...

Page 6: ... the cable run Severe personal injury may result Never open the air chamber when pressurized Only authorized fully trained personnel should operate the air compressor GENERAL ELECTRICAL SAFETY INSTRUCTIONS The machine has electronic and electrical power and control circuits Electric shock hazards exist that could result in severe personal injury Observe the following precautions to avoid electrica...

Page 7: ...ND CONNECTING FITTINGS ARE SUITABLE FOR OPERATING AT 15 BAR AIR PRESSURE TUBE CLAMP SECURELY TIGHTENED COMPRESSOR CAPACITY 15 BAR AND SUITABLE FOR SIZE OF TUBE BEING USED CABLE DRUM MUST BE LOCATED DIRECTLY BEHIND AND IN LINE WITH THE BLOWING MACHINE AIR CHAMBER DRIVE BELTS AND PULLEYS CABLE GUIDES MUST BE CLEAN AND FREE FROM DEBRIS SLUDGE DIRT WATER AND LUBRICANT THE CABLE MUST BE HAND GUIDED INT...

Page 8: ... insure that the cable is protected during installation Due to the variety and different methods of cable manufacture the responsibility of checking the cable compatibility with the equipment lies with the operator Therefore General Machine Products cannot accept liability for any damage to the cable ...

Page 9: ... cable by the rollers can be adjusted to prevent the cable buckling and to prevent damage to the cable A full range of accessories is available to allow the machine to handle a wide range of cables and tubes This machine has the added function of high low torque selection this has been developed to give greater sensitivity when operating in the low torque region aiding the installation of small ca...

Page 10: ...ine Products KT LLC should you require further assistance Cable size 2 5 to 11 0 mm 0 118 to 0 433 Tube size OD 5 to 18 0 mm 0 197 to 0 708 Cable speed 0 80 m min 0 262 ft min Maximum pushing force 20 Kg 44 lb Maximum air pressure 15 bar 210 psi Power requirements 100 277Vac 50 60 Hz power supply input Weight 14 Kg approx 31 lbs approx Weight inc case 31 Kg approx 68 lbs approx Dimensions ht x len...

Page 11: ...etch below this shows a plan view of the recommended set up Ensure the machine is secure either on its own stand or a separate suitable stand Ensure the machine is fitted with the appropriate guides and collets to suit the cable being installed and tubes into which the cable is to be installed See Appendix 1 for details of interchangeable parts To set the machine up to install cable it will be nec...

Page 12: ...d tube the length of tube underground into which the cable is to be installed using a suitable connector Slide a suitable size O ring over the end of the tube Fit the tube into the end of the air box housing so that it protrudes approx half way into the housing position the O ring so that it sits against the seal face as shown in the illustration below Once the tube has been positioned the tube cl...

Page 13: ...propriate split cable seal see appendix 1 and position it in the groove in the seal housing Press Start and slowly turn the speed control clockwise until the belts are just moving Take the cable to be installed and pass it through the infeed guide so that the end is between the belts Close the close arm to the left gently until the cable is gripped there is no need to apply the full installation p...

Page 14: ...bly is free to move This thumb screw is attached to the clamp arm lever The clamp arm lever controls the position of the roller assembly As the clamp arm is moved around the quadrant the belts move together and apart When the clamp arm is furthest to the right the gap between the belts is at a maximum And vice versa When preparing the machine to insert the cable the clamp arm is positioned at its ...

Page 15: ...ower supply quality General Machine Products KT LLC recommend the use of a Honda EU1000i generator The transformer accepts voltages between 100 277 Vac 50 60Hz automatically Adaptors are available to suit any required existing connector speak to our sales department for full details and specification of connector If the power supply lead supplied with the AirStream Cable Blowing Machine is unsuita...

Page 16: ...nstallation The GMP Airstream machine is ideally suited to this type of operation it may be coupled with a second machine to increase the distance a single cable can be installed without joins The only difference between this set up and the set up for installing cable with the machine above ground is that there will be no drum stand carrying the cable drum The cable will be exiting from one side o...

Page 17: ...d preventing air pressure blowing the cable out of the machine Note It is possible to reset the distance to zero even if speed is being displayed on the screen Should it be necessary to replace the speed distance measuring device please contact GMP Products reversing of the machine while installing cable Speed Distance indicator This device will measure and display the distance travelled by the ca...

Page 18: ...ed before the settings will be available the torque control may be set at the previously determined position Set the torque control to the position determined above and turn the speed control The rollers will now start to turn and the cable will feed through the air box increase speed setting to max if required When the cable has travelled a reasonable distance say 300ft 100 meters turn on the air...

Page 19: ...arge static build ups this can cause the Airstream to reset and stop without apparent reason and in severe cases damage the machine If this is occurring ground the Airstream via the ground point on the air box via a suitable copper conductor to a ground at the power source or earth Grounding Point ...

Page 20: ... it is being used by the roadside It is convenient to consider each function of the machine in turn As a general rule every time an interchangeable part is removed and replaced by a part of a different size shape etc the part being removed should be thoroughly cleaned before being returned to its box Similarly the cavity from which it was re moved can also be cleaned prior to the assembly of the r...

Page 21: ...e 2 m2 5 fixing screws Do not lose these screws they will be needed for the replacement in sert Remove the insert Loosen the thumb nut rotate the swing bolt to open the air box Loosen and remove the m4 fixing screw Do not lose this screw it will be needed for the replacement insert Remove the insert Repeat the process for the insert in the other box half To fit the new inserts reverse the disassem...

Page 22: ...guides Unscrew knurled screws securing the upper guide housing Loosen and remove the M2 5 screw securing the guide into the housing Remove and replace the guide If both long and short inserts are used the long inserts are mounted in the housings at the machine inlet Long Insert ...

Page 23: ...f the cut sealing material Place the pre cut length in the groove glue surface down starting at the end with the retainer plate and aligning flush with the end of the groove Work your way around pressing the seal into the groove and allowing the excess material to hang over the oppo site side Repeat the procedure for the second groove Trim excess material flush with end of groove Spread adhesive a...

Page 24: ...stics This will allow the cable to be pushed with high torque while being compressed lightly Additionally smaller cables may require a belt with a smaller groove profile to gain the best grip possible If these types of belt are needed the General Machine Products sales office will be able to advise on part numbers etc To fit these belts it will be necessary to remove the standard belts the procedu...

Page 25: ... it onto the tensioning shaft Replace the tension nut and then tension as described in section 13 0 NOTE NEVER POWER THE MACHINE UP OR RUN WITH THE GUARDS REMOVED DOING SO MAY RESULT IN INJURY TO THE OPERATOR remove the belt guides loosen and remove the tension nuts loosen the tension screws remove the idler pulleys and the belts ...

Page 26: ...tension is reached tighten the tension nut Note tightening the nut will tighten the belt slightly please set the tension screw to compensate for this The tension belt should have approximately 1 4 6 mm of slack If necessary loosen the tension nut and re adjust the tension screw until the cor rect tension is achieved Check that the tension nut is tight upon completion Note the belt tension should b...

Page 27: ...base as shown below Turn the machine over revealing the motor drive belt Loosen the set screw retaining the idler pulley as indicated below The shaft retaining the pulley should now be free to remove Once removed the belt can easily be replaced Assembly is the reverse of disassembly Set screw Shaft 1 2 3 5 6 4 Belt Path ...

Page 28: ... are completed can be entered into the spaces provided in this table This will give the user a record of what service has been carried out and when 1 Check the tool box ensure all tools and interchangeable parts are present clean and ready for use 2 Remove the clear belt guards clean the outside of the machine and replace 3 Check the slide mechanism operates smoothly lubricate if necessary with a ...

Page 29: ...Page 29 of 41 16 0 SERVICE HISTORY RECORD Service no Date Carried out by Record of service repair ...

Page 30: ...al in place of the cable The tube can then be pressurized without running the belt drive CAUTION ANY OBJECT INADVERTENTLY LEFT IN THE TUBE DURING THE TUBE LAYING MAY BE EXPELLED FROM THE END OF THE TUBE WITH HIGH FORCE AND VELOCITY IT IS IMPERATIVE THAT NO PERSONNEL BE IN THE VICINITY OF THE END OF THE TUBE OR THAT A SUITABLE DEVICE IS FITTED TO THE END OF THE TUBE TO ARREST ANY EXPELLED OBJECT Th...

Page 31: ...s made to blow cable down the tube Once the tube integrity has been confirmed by the method outlined above The tube may be lubricated Open the air box and tube clamp assembly as shown in the sketch above withdraw the tube and raise it so that the lubricant will pour into it easily and not overflow from the top Add lubricant according to the lubricant manufacturers recommendations Insert a suitable...

Page 32: ...1 4 2 mm cord seal See Appendix 1 5 7 A Fuses P N 30936 6 315 mA Fuses P N 89593 7 Motor Drive Belt P N 34742 For spare parts always quote the machine type and serial number and contact General Machine Products KT LLC 3111 Old Lincoln Hwy Trevose Pa 19053 TEL 1 215 357 5500 FAX 1 215 357 6216 E MAIL info gmptools com Website www gmptools com ...

Page 33: ...EMBLY 6 4 TO 8 0 mm DIAMETER 89379 CABLE SEAL COLLET ASSEMBLY 8 0 TO 9 5 mm DIAMETER SPARE CABLE SEAL 89510 CABLE SEAL 2 5 TO 3 0 mm PACK OF 5 89511 CABLE SEAL 3 0 TO 3 8 mm PACK OF 5 89512 CABLE SEAL 3 8 TO 5 0 mm PACK OF 5 89513 CABLE SEAL 5 0 TO 6 4 mm PACK OF 5 89514 CABLE SEAL 6 4 TO 8 0 mm PACK OF 5 89516 CABLE SEAL 8 0 TO 9 5 mm PACK OF 5 DRIVE BELTS sold in pairs 30952 DRIVE BELT 3 11 mm D...

Page 34: ...m Zero The picture to the right shows the torque and speed control potentiometers set in the maximum clockwise position In this position both torque and speed will be maximum see specification for details The torque control setting will allow the cable to be installed efficiently and without damage It is of vital importance that the torque setting is made with great care a little time spent unders...

Page 35: ...ith high stiffness may be less stiff than a large cable with medium stiffness The table reflects this If there is any doubt in the first instance err on the low side i e select a lower U figure 2 Assess the coefficient of friction of the cable insulation the outer coating Is it low or high Once again this relies on the user having some experience with bundled optical fiber cables As a guide if the...

Page 36: ...ontrol potentiometer approximately one half of the way around its maximum travel etc There is an alternative way of arriving at the appropriate setting for the torque control potentiometer Do the following Select a sample of the cable to be used Pass the cable through the machine as described in the manual Feed the cable into the beginning of a length of sample tube say 5 meters long Seal the open...

Page 37: ...cable Eventually the belts will stop turning because the torque limit has been reached It is worth noting at this stage that this approach may result in a great deal of force being applied to the cable More than the cable can withstand without sustaining damage sometimes it may be that the cable may be protected from buckling by a combination of torque control setting and slip The main purpose of ...

Page 38: ... Use to move to next digit o Use to increment digit this instruction applies to all following number inputs Hold and press o diV Cnt is displayed Press Enter value 01 0000 Hold and press o dP Cnt is displayed Press until 0 is displayed Hold and press o rES Cnt is displayed Press until MAnrE is displayedat Hold and press o FAc tAc is displayed Press Enter value 00 0091 for metres 00 0299 for feet H...

Page 39: ...9 of 41 Press Enter value 01 0 Hold and press o EndPro is displayed Press un l YES is displayed Hold and press o Programming completed OR Press un l no is displayed Hold and press o Programming mode restarted ...

Page 40: ...age includes a 50 foot 3 4 diameter air hose for connection to the microfiber cable blowing machine Micro Cable Fleeter P N 89002 The Micro Cable Fleeter replaces the manual method of figure eighting cable and pro vides protection and security for the cable It has a nominal capacity to store 6500 ft 2000 meters of 8 5 mm diameter cable BLOWING ACCESSORIES Engine Honda 21 hp Width 31 800mm Fuel Cap...

Page 41: ...Page 41 of 41 GMP 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 WEB www gmptools com ...

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