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GMP Breeze 89010, Operation & Maintenance Manual

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GMP Breeze 89010 Operation & Maintenance Manual Download Page 3

Page 3 of 42 

General Machine Products (KT), LLC 

 

CONTENTS 

 

1.  Safety Instructions 

 

2.  Critical Points 
3.  General Description 
4.  Specification 
5.  Operating procedures 
6.  Maintenance 
7.  Procedure for changing inserts in the tube clamp 
8.  Procedure for changing inserts in the air box 
9.  Procedure for changing inserts in the infeed guide 
10.  Procedure for re-positioning the measuring system fixed roller 
11.  Procedure for replacing the air box housing seal 
12.  Procedure for changing the air box infeed guide 
13.  Procedure for changing the drive rollers 
14.  Procedure for conversion to blow 12 count (1.6) fiber 
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 torque control potentiometer settings 

Appendix 3   

Programming the speed/distance measuring device. 

 

GMP Limited Warranty

 

Summary of Contents for Breeze 89010

Page 1: ...hatsoever without the written permission of General Machine Products KT LLC BREEZE MICRO CABLE BLOWING MACHINE OPERATION MAINTENANCE GMP 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 EMAIL info gmptools com September 18 2017 USA Ver 14a QC Final Inspection by _________________________ Date __________________ Unit Serial Number __________________ Build Date _______...

Page 2: ... 03 29 11 US Version 7 update blown fiber page 24 A Konschak 09 05 18 11 US Version 8 add guide positioning warning A Konschak 10 10 03 12 US Version 9 add 14 mm tube kit A Konschak 11 06 23 13 US Version 10 A Konschak 12 12 18 13 US Version 11 Various minor updates A Konschak 13 07 23 15 US Version 12 Photo updates A Konschak 14 10 20 16 US Version 13 Part number updates A Konschak 15 06 29 17 US...

Page 3: ... the measuring system fixed roller 11 Procedure for replacing the air box housing seal 12 Procedure for changing the air box infeed guide 13 Procedure for changing the drive rollers 14 Procedure for conversion to blow 12 count 1 6 fiber 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 se...

Page 4: ...ed while in use 9 Consider the use 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 hearing protection eye protection hard hat safety shoes and leather ...

Page 5: ...lowing Machine 22 Do not tamper with pressure relief valves or pressure reducing valves 23 The compressed air supply must not be allowed to enter the air chamber or tube before the drive rollers have been closed on to the cable Do not turn the air on until a reasonable length of cable 165 ft has been installed into the tube 24 Ensure the cable drum rotates freely on its stand the cable should leav...

Page 6: ...hole at the far end of the cable run Severe personal injury may result 3 Never open the air chamber when pressurized 4 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 prec...

Page 7: ...ed Tube connecting fittings are suitable for operating at 220 PSI air pressure Tube clamp securely tightened Compressor capacity 220 PSI 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 rollers cable guides must be clean and free from debris sludge dirt water and lubricant The cable must be hand guided into t...

Page 8: ...the design of its products to insure that the cable is protected during installation Due to the variety and differ ent methods of cable manufacture the responsibility of checking the cable compatibility with the equipment lies with the user Therefore GMP nor CBS Products Ltd can accept liability for any damage to the cable ...

Page 9: ...he cable being installed The rollers may be changed quickly us ing one simple tool The pressure the rollers apply to the cable is adjusta ble The torque applied to the cable by the rollers can be adjusted to help prevent cable buckling A full range of accessories is available to allow the ma chine to handle a wide range of cables and micro tubes As pictured the Breeze may be placed on the ground o...

Page 10: ...d 0 50m min 0 165 ft min Maximum pushing force 16 Kg 35 lbs Maximum air pressure 15 bar 220 psi Power requirements 115 220V ac 50 60 Hz Switchable Gripping force rollers onto cable 1 40 Kg 1 88 lb Weight 23Kg approx 50 lbs approx Dimensions ht x length x width 250mm x 390mm x 270mm 10 x 15 3 8 x 10 5 8 1 1 2 5 mm blown fiber available with add on kit ...

Page 11: ...ition the cable drum behind the machine and in line with the machine See sketch below this shows a plan view of the recommended set up 3 Ensure the machine is secure either on its own stand or a separate suitable stand 4 Ensure the machine is fitted with the appropriate guides and collets to suit the cable being installed and the tubes into which the cable is to be installed See appendix 1 for det...

Page 12: ...be closed Securely tighten clamp with swing bolt The tube is now secure Cut and split a short length of tube to use as an in feed guide this tube need only be split if blowing a cable mid span sometimes called series blowing This should be inserted in the in feed guide clamp In order to give the best support for the incoming cable it may be help ful if the end of the tube is cut off at an angle to...

Page 13: ...now possible to insert the cable in the machine Pass the cable through the tube in the in feed guide clamp on through the in feed guide as sembly and through the gap between the drive rollers Place the cable in the groove in the ca ble guide set Select the appropriate split cable seal see appendix 1 and position it around the cable Press the cable seal into the groove in the seal housing simultane...

Page 14: ...loosened The assembly is free to move This thumb nut is fixed to the clamp arm lever The clamp arm lever controls the position of the roller assembly As the clamp arm is moved to the left the rollers move together When the clamp arm is furthest to the right the gap between the rollers is at its widest Once the cable has been positioned in the machine the roll ers must be closed on the cable in ord...

Page 15: ...ical supply to the machine The machine is supplied complete with an electrical supply lead and a NEMA 5 15 plug The machine is now ready to start the cable installation The Breeze is designed to operate with either 115 volts or 220 volts AC The default setting for the Americas is 115 volts To change the voltage setting locate the voltage switch under the silver plug located to the left of the fuse...

Page 16: ...the main point of installation The GMP Breeze 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 with out splices 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 exit...

Page 17: ...e applied to the cable by the rollers Torque Range Switch Switches between normal torque range for blowing micro fiber cables and low torque range for finer torque adjustment when installing 1 1 6 mm blown fiber Speed control This knob controls the motor speed turn this clockwise to increase the speed of the rollers and the cable Turn counter clockwise to reduce the speed Emergency stop Pushing th...

Page 18: ...ximum counter clockwise and maximum clockwise position 4 Press start button The machine will try to push the cable with the torque control set to a minimum the rollers will not turn or only very slowly It is now necessary to set the torque control to a position appropriate to the stiffness of the cable and the characteristics of the cable insulation See appendix 2 for recommendations If the cable ...

Page 19: ...ocument supplied with the chemical must be observed Infeed guide assy this should be kept clean Build up of dirt etc on the faces will cause the cable to catch on the guide Clean with any work shop solvent Pay particular attention to the joint faces of the inserts and the hous ing Measuring system fixed roller this should be kept clean Build up of dirt etc on the faces will cause faulty readings o...

Page 20: ...be cleaned prior to the assembly of the replacement part Air box parts Keep clean A build up of moisture and dust will pre vent the joint faces from mating preventing the housing seal from sealing Use any traditional work shop cleaning agent Tube clamp inserts Keep clean A build up of moisture and dust partic ularly in the grooves will reduce the clamping ef fect Use any traditional workshop clean...

Page 21: ...screws Do not lose these screws they will be needed for the replacement insert 8 Procedure for changing inserts in air box Loosen the thumb nut rotate the swing bolt to open the air box Loosen and remove the mounting 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 ...

Page 22: ...emove the two screws securing the upper housing onto the lower housing Loosen and remove the screw se curing the insert into the upper housing Remove the insert Repeat the process for the insert in the other housing half To fit the new inserts reverse the disassembly procedure 10 Procedure for re positioning the measuring system fixed roller Loosen the screw holding the roller support bracket in p...

Page 23: ...ve to the top of 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 Sp...

Page 24: ...tion characteristics This will allow the cable to be pushed with high torque while being compressed lightly If this type of roller is needed the GMP sales office will be able to advise on part numbers etc To install this roller it will be necessary to re move the standard roller with the procedure as follows Loosen and remove the retaining screw and washer Remove the roller Repeat the procedure fo...

Page 25: ... ad justed so that just enough pressure is on the fiber to turn the measuring wheel with out deflecting it Set the tube in the air box as shown in photo to right This prevents possible buckling of the fiber in the air box Feed the fiber along the guides and into the tube making sure that the fiber is cen tered in the guides be fore you close the air box Ensure that the fiber feeds freely through t...

Page 26: ...heck the tool box insure all tools and interchangeable parts are present clean and ready for use 2 Clean the outside of the machine take care not to damage the rollers or springs 3 Check the measuring wheel insure it runs freely and that the speed distance functions respond when the wheel is rotated 4 Check the measuring wheel fixed roller make sure it rotates freely 5 Loosen the thumb nuts lockin...

Page 27: ...Page 27 of 42 General Machine Products KT LLC Service no Date Carried out by Record of service repair 16 SERVICE HISTORY RECORD ...

Page 28: ...then be pressur ized without running the roller drive The checks listed at 1 4 inclusive above may all be carried out at the same time using one check The procedure is outlined below Set up the air box and tube clamp as shown 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 im perative that no perso...

Page 29: ...In either case the fault should be corrected before any attempt is made to blow cable through the tube Once the tube integrity has been confirmed by the method outlined above The tube may be lubricated 1 Open the air box and tube clamp assembly withdraw the tube and raise it so that the lubri cant will pour into it easily and not overflow from the top 2 Pour lubricant available through GMP of reco...

Page 30: ... Highway Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 E MAIL info GMPtools com Website www GMPtools com Tube Seals see page 32 Cable Seals see page 32 Red Drive Rollers pair P N 89587 Lubricant six 8 oz bottles P N 89568 Seal Cord 3 ft P N 89691 5 A fuses 2 pk P N 89594 315 mA fuses 2 pk P N 89593 Hose assembly with Chicago fitting and gauge P N 89582 Electric Supply Cable P N 89583 ...

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Page 32: ...ponents Twelve count 1 6mm conversion is found on page 25 A D B E C F G NOT TO SCALE Tube O D P N 5 mm 89539 8 mm 89540 10 mm 89541 Tube Kits D E F G Included 12 mm 89542 12 7 mm 89543 16 mm 89544 14 mm 89538 18 mm 89536 8 5 mm 89537 Cable Size P N 2 5 3 0 mm 89530 3 0 3 8 mm 89531 3 8 5 0 mm 89532 5 0 6 4 mm 89533 6 4 8 0 mm 89534 Cable Kits A B C Included 8 0 8 5 mm 89535 Tube size O D Photo 5 0...

Page 33: ... before and whose characteristics are unknown The diagram to the left shows the torque and speed control knobs set in the maxi mum counter clockwise position In this position both torque and speed will be minimum Zero The diagram to the right shows the torque and speed control knobs set in the maximum clockwise position In this position both torque and speed will be maximum see speci fication for ...

Page 34: ...me familiarity with bundled optical fiber cables this will give the experience to assess whether the cable has low medium or high stiffness For instance a small diameter cable with high stiffness may be less stiff than a large cable with medium stiffness The table re flects 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 ...

Page 35: ...imum clockwise rotation of the torque control If this line is very close to the figure 0 5 marked on the y axis set the torque control 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 poten tiometer Do the following Select a sample of the cable to be used Pass the cable through th...

Page 36: ...llers apply to the cable Eventually the rollers 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...

Page 37: ...ocument a Press and hold SEL for 2 seconds to enter programming mode b Enter the Pro Code 111 a general code of 222 may also work c Press and Hold SEL for 2 seconds d Pro no should now be flashing press RST e Press RST to move through the various sections 1 input 2 rate etc f Press SEL to enter that section g To change the value of a parameter press RST h Press SEL to move to the next parameter i ...

Page 38: ...NO if correct press SEL Press RST Twice Rate Parameters 2 RATE RATE ENB YES if correct press SEL RATE DP 0 if correct press SEL RATE DSP 60 once correct press Hold SEL RATE INP 97 9 Metric m min or 29 8 Imperial ft min once correct press Hold SEL LO UDT 1 0 if correct press SEL HI UDT 2 0 if correct press SEL Press RST Three Times DISPLAY 3 DSPLAY SEL ENB YES if correct press SEL RST ENB YES if co...

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Page 42: ...Page 42 of 42 General Machine Products KT LLC GMP 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 EMAIL info gmptools com ...

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