C MICRO-DUCT TUBE BLOWING MACHINE

Transcription

1 OPERATOR MANUAL C MICRO-DUCT TUBE BLOWING MACHINE Copyright 2017 by CBS Products (KT) Ltd All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form whatsoever without the written permission of CBS Products (KT) Ltd. 1

2 REVISION HISTORY: Rev No. Date Details Author Original issue A. Miller Dimensional and various data modified A. Miller 2

3 CONTENTS 1. Safety Instructions 2. Critical Points 3. General Description 4. Specification 5. Operating Procedure 6. Maintenance 7. Procedure for Replacement of Chain Drives 8. Procedure for Replacement of Tube Collets 9. Procedure for Replacement of Sub-Duct Collets 10. Procedure for Adjusting the Air Chamber and collet type tube infeed guide assembly height 11. Alignment of Air Chamber to the Tube Pusher Unit 12. Monthly Service Check List 13. Service History Record 14. Sub-Duct Integrity and Lubrication 15. Troubleshooting Guide 16. Recommended Spares List 17. Battery Testing and charging 18. Battery Replacement APPENDICES Appendix 1 Appendix 2 Appendix 3 Appendix 4 Appendix 5 Appendix 6 Appendix 7 Appendix 8 Appendix 9 Appendix 10 Appendix 11 Layout of Tube Blowing Machine Drawing Tube Blowing Machine (CBS) Drawing Tube Blowing Pusher Unit (CBS) Tube Blowing Machine Service Connections Hydraulic & Electrical Panel Layout Air Chamber Components Collet and Chain List Chain Selection Guide Sub-Duct Clamp and Sub-Duct Seal Collet List Counter/Ratemeter Programming Instructions CE Certificate 3

4 Introduction CBS Products (KT) Ltd is a long established U.K company situated in rural Oakham, Rutland. From its 4-acre site, CBS design, manufacture, test and market a comprehensive range of quality products for the electricity, telecommunication and CATV industries. Products include overhead line and underground winches, cable drum trailers and stands, stringing equipment, in fact everything required for the installation or erection of conductors and cables. With a long history of designing standard and specialised equipment to meet the needs of customers worldwide, CBS has invested in the latest computer aided design and analysis systems and an integrated manufacturing plant. The CBS Products (KT) Ltd Design Facility is available to discuss specific customer requirements for any product / project, existing or new. Please contact CBS Products (KT) Ltd for further information. CBS Products (KT) Ltd operate stringent quality controls throughout the organisation and has a quality assurance system certificated to ISO 9001 : Our total commitment to providing quality products and service is reflected in the high standard of the finish, use and long life of all our products. There are certain controls and control functions, included in the Micro-Duct Tube Blowing Machine, which are critical to the safe operation of the Micro-Duct Tube Blowing Machine. These safety critical controls are clearly marked in the manual with the following symbol. It is imperative that these operating and maintenance procedures are followed exactly, to ensure safe operation. 4

5 1. SAFETY INSTRUCTIONS THIS EQUIPMENT MUST ONLY BE USED BY AUTHORISED PERSONNEL, WHO HAVE BEEN SUITABLY TRAINED AND COMPETENT TO DO SO. THESE INSTRUCTIONS ARE TO BE MADE AVAILABLE TO OPERATORS OF THIS EQUIPMENT AT ALL TIMES, FAILURE TO OBSERVE THESE SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY AND / OR PROPERTY DAMAGE. WORK AREA AND GENERAL SAFETY 1) Read and understand the operation and maintenance manual supplied with this equipment. Keep it in a convenient place for future reference. 2) Keep children and untrained personnel away from this equipment whilst in operation. 3) Keep all guards and safety devices in place. Do not operate this equipment with guards removed or damaged. 4) Keep hands, feet and loose clothing away from moving parts, especially at tube(s) entry points. 5) Always stop the machine and isolate, compressed air, electrical and hydraulic services to carry out lubrication and servicing. 6) Check machine before starting for worn or damaged parts. Check that all nuts and bolts are tight. 7) If machine is left unattended, ensure that unauthorised use is prevented. 8) Never leave the machine unattended whilst in use. 9) Use safety barriers to create an exclusion zone and prohibit access by any person(s) to the Tube Blowing Machine except the operator, this is especially important when used in public places. 10) Beware of pinch points involved with rotating components, e.g. screw operated tractor drive lifting mechanisms etc. 11) Beware of hot surfaces, machine uses compressed air and hydraulic services. 12) When operating or servicing machine always wear eye protection, hard hat, approved safety foot ware and leather work gloves, machine operates with compressed air at 5-8 Bar and hydraulic oil at 60 Bar. 13) Some component and assembly parts are in excess of 25kg (55lb). When lifting care must be taken, ensure sufficient man power/lifting gear is available, to prevent personal injury and damage to the machine. 5

6 14) Prior to installation ensure the sub-duct route is connected properly. 15) Beware of exposed electrical contacts. Do not touch, or allow metal objects to come into contact. 16) Waste hydraulic oils are to be disposed of via an environmentally acceptable method e.g.: passed on for re-cycling. 17) Wear ear defenders if noise levels are considered high to prevent ear damage. 18) Machine may cause additional fire hazard if involved in an existing fire due to compressed air and hydraulic oils. 19) No personnel are to be in manholes or ducts when the Tube Blowing Machine is being operated. 20) The machine must be operated on firm und in a level and stable condition. 21) Stay clear of tubes or lines under tension. 22) Stay clear of pressurised line and sub-duct. 23) Only use the machine for its intended purpose, do not use the tractor drive without the air chamber to push or pull tube(s). 24) Do not place tube(s) drum too close to the Tube Blowing Machine. 25) Do not tamper with pressure relief valves or pressure reducing valves. 26) The compressed air supply must not be allowed to enter the air chamber or sub-duct before the top tractor drive frame has been closed and the tube(s) inserted into the intake tube guide bracket assembly. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, AS THE TUBE(S) COULD BE EJECTED FROM THE TUBE BLOWING MACHINE WITH HIGH FORCE AND VELOCITY. 27) Do not open the air chamber until all the air has been exhausted and the air pressure gauge reads zero. 28) Never operate the blowing machine with the electronic control panel immersed in water. 29) To prevent damage to the hydraulic hoses and the emergency stop cable never leave them on the ground when not in use. 30) Do not allow the hoses to come in to contact with any harmful substances that may cause damage. 31) Do not use the Tube Blowing Machine if lighting levels are poor, such that make operation hazardous. 32) Do not use the Tube Blowing Machine with any component parts removed, missing or damaged. 6

7 33) Do not use or manoeuvre the Tube Blowing Machine on surfaces or in a position that is unstable and/or inclined that could result in the Tube Blowing Machine rolling, sliding or turning over. 34) Avoid using the Tube Blowing Machine in thunderstorm conditions and/or where there is a risk of lightning, snow / ice or high winds. 35) The Tube Blowing Machine must not be used in a potentially explosive atmosphere. 36) The operator must take care not to trip of fall when moving the Tube Blowing Machine. 37) The operator should monitor the Tube Blowing Machine for potential problems and hazards when the Tube Blowing Machine is in use, these may arise slowly, quickly or suddenly. 38) Only use the machine for its intended purpose. 39) Lift the Tube Blowing Machine with the lifting point provided adjacent to tube(s) clamping screw handle. 40) The tube drum(s) should be positioned directly behind and in line with the Tube Blowing Machine. 41) When not required for moving the Tube Blowing Machine, the frame mounted handles should be fully retraced and secured, (when in the extended position the handles may pose a potential tripping hazard). 42) The Tube Blowing Machine must not be operated until full training and compliance with the directives of this Operator Instruction Manual and the Operator Instruction Manual for any equipment to be used in conjunction with has been fully completed. 7

8 GENERAL HYDRAULICS SAFETY INSTRUCTIONS Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards:- 1) Ensure all hydraulic connections are securely tightened before operating the machine. 2) Check for leaks with a piece of cardboard. Do not use your hands! 3) Do not exceed working pressure of hydraulic hoses. 4) Visually inspect hoses regularly and replace if damaged. GENERAL PNEUMATIC SAFETY INSTRUCTIONS The CBS Tube Blowing Machine is a pneumatic device, using pressurised air to project tube(s) at high velocities. Please observe the following precautions when operating the Tube Blowing Machine:- 1) Compressed air can cause flying debris. This could cause personal injury. Always wear personal protective equipment. 2) Ensure no personnel are in the manhole at the far end of the tube(s) run. Severe personal injury may result. 3) Never open the air chamber when pressurised. 4) Only authorised, fully trained personnel should operate the air compressor. GENERAL ELECTRICAL SAFETY INSTRUCTIONS The electronic control assembly and power supply are electrical devices. Electric shock hazards exist that could result in severe personal injury. Observe the following precautions to avoid electrical hazards: 1) Do not operate in or near water. This includes setting the electronic control assembly on a wet surface or exposing them to rain. 2) Do not remove cover of electronic control assembly. There are no user serviceable parts inside. Refer servicing to qualified service personnel. 3) Check the condition of the emergency stop lead. Replace if worn or damaged. 4) Never run the tube blowing machine without the emergency stop cable being connected to the Tube Blowing Machine and Power Pack. 8

9 2. CRITICAL POINTS THAT DRAMATICALLY AFFECT THE OPERATION OF THE TUBE BLOWING MACHINE ½ - 1 TURN ON THE TUBE(S) CLAMPING SCREW TRACTOR DRIVE TO BE CLOSED AT ALL TIMES WHEN TUBE(S) IS/ARE INSTALLED INTO MACHINE. AIR CHAMBER HEIGHT ADJUSTMENT CORRECTLY SET. TUBE INFEED HEIGHT ADJUSTMENT CORRECTLY SET. CORD SEALS IN AIR CHAMBER CORRECTLY FITTED TO PROVIDE GOOD SEALING. SUB-DUCT FULLY CONNECTED AND PRESSURE-TESTED. SUB-DUCT TUBE(S) EXIT RETAINING DEVICE FITTED. COMPRESSOR CAPACITY 5-8 BAR AND SUITABLE FOR SIZE OF SUB-DUCT BEING USED. TUBE DRUM(S) MUST BE LOCATED DIRECTLY BEHIND AND IN LINE WITH THE BLOWING MACHINE. AIR CHAMBER, TRACTOR DRIVE BELTS/CHAINS, HOUSING FRAMES AND TUBE GUIDE INTAKE ASSEMBLY MUST BE CLEAN AND FREE FROM DEBRIS, SLUDGE, DIRT, WATER AND LUBRICANT. (EACH TIME THE BLOWING MACHINE IS USED). THE TUBE(S) MUST BE HAND GUIDED INTO THE BLOWING MACHINE THROUGH A DRY CLEAN CLOTH BY THE OPERATOR WEARING WORK GLOVES. THIS WILL REMOVE ANY DIRT, DEBRIS AND WATER ON THE TUBES. ENSURE THE COMPRESSED AIR SUPPLY IS NOT APPLIED TO THE TUBES UNTIL APPROXIMATELY 200 METRES OF TUBE HAVE BEEN INSTALLED OR THE HYDRAULIC PRESSURE BEGINS TO RISE. THE HYDRAULIC PRESSURE SHOULD BE BETWEEN BAR AT THE START OF A BLOWING INSTALLATION. IF GREATER DO NOT PROCEED. CHECK, TUBE CLAMPING SCREW SETTING, SUB-DUCT, TUBE, TUBE COLLETT SIZES, AIR CHAMBER / INFEED GUIDE HEIGHT SETTING. RECTIFY BEFORE RE-COMMENCING THE INSTALLATION. LUBRICATE THE DRIVE CHAINS BEFORE USE. DO NOT REPEATEDLY PRESS THE ON/OFF BUTTON ON THE LENGTH / SPEED READOUT, THIS MAY RESULT IN IRRELEVANT DIGITS BEING DISPLAYED OR MAY ALTER THE PROGRAMME. ALWAYS FIT THE HYDRAULIC HOSE DUST CAPS WHEN THE HOSE IS NOT IN USE, CLEAN AND CHECK THE QUICK RELEASE COUPLINGS BEFORE USE. 9

10 DISCLAIMER CBS Products (KT) Ltd take care in the design of its products to ensure that the tube(s) is/are protected during installation. Due to the variety and different methods of tube manufacture the responsibility of checking the tube compatibility with the equipment lies with the operator. Therefore, CBS Products (KT) Ltd cannot accept liability for any damage to the tube. 10

11 3. GENERAL DESCRIPTION TUBE BLOWING MACHINE The tube blowing machine comprising of an air box and tube pusher has been designed to provide an effective and safe method of micro-duct tube installation. The system installs microduct tube of various combinations from 5 12 mm overall diameter at up to 30m/min into preinstalled sub-ducts, employing the viscous drag compressed air principle. The machine is protected by preset pressure relief valve and preset pressure sensor. The compressed air is fed into the sub-duct via a Venturi principle, and the hydraulically powered tube feed system controls the micro-duct tube(s). The electronic control system provides read out of speed and distance and automatic protection against duct obstruction. The system comes mounted on an anti corrosion treated, sturdy, height adjustable, wheeled, tubular steel trolley unit for ease of site manoeuvrability, and is powered by a hydraulic supply system operating from a recommended supply of 60 Bar x 15 litres/min. The tube-blowing unit can be detached from the trolley unit and located in a trench or manhole (depending on the size of the manhole). The unit is supplied as standard with a quick release air hose coupling type1 ½ (female threaded plug coupling) JAYMAC A112 AU cam and groove coupling type. The air supply hose should be 32 mm (minimum) bore, (A 38 mm bore x 15 metre long compressor to blowing machine air hose with a termination suitable for fitting to a 1½ BSP female thread is supplied as standard by CBS). The unit is supplied with 2 x hydraulic hoses x 7 metres and an emergency stop lead x 8 metres long for connecting between the tube blowing machine and hydraulic power pack (or hydraulic power source). The unit is CE approved. 11

12 NOTE: The Tube Blowing Machine is normally powered by a petrol engine driven hydraulic power pack and has an emergency stop button fitted as standard. However if the power pack to be used is the CBS C D-01 diesel engine driven power pack then the emergency stop circuit cannot be connected and pressure switch inactive therefore any reference in this manual to these should be ignored. 12

13 FEATURES Fully labelled control panel containing: Power ON/OFF button (silver) Emergency Stop Button (red) Blowing speed read out in M/min Length counter recording in metres Hydraulic pressure read out dial Air pressure read out dial Air pressure control valve Hydraulic on/off control valve Emergency stop connection socket Adjustable speed control for drive belts Battery charger / charge level connection socket Control panels are anti corrosion treated and may be removed independently for repair work. CHASSIS AIRBOX TUBE FEEDER Front mounted wheel s for ease of manoeuvrability Light anti corrosion treated tubular steel frame Adjustable frame allowing unit to be tilted at 20º to manhole Adjustable rear legs for uneven terrain Detachable tube blowing unit for trench / manhole location Manufactured from aluminium Range taking of tubes from 5 12 mm diameter by means of interchangeable collets. Sub-duct sealing at mouth of airbox Sub-duct gripping facility with non-duct crush and distortion design. All seals are one size cord seals Upper section of airbox is retained Airbox alignment is adjustable for varying tube diameters Tools are not required to split box for insertion of tube and sub-duct. On/off air control valve Manufactured from cast aluminium Hydraulically powered Unit lifts and splits to allow insertion of tube(s) between drive belts Drive belts are polyurethane and moulded to unit ensuring long life between replacement. Lifting facility, to allow unit level lift. Belt tension can be set by means of adjustable chain drive tensioners fitted to side of unit System relief valve fitted as standard to operate at 80 Bar. 13

14 4. SPECIFICATION SERIAL NO: 771 OPERATING CAPACITIES Pushing Force: Pushing Speed: Tube Size: Sub Duct Size: 0 60 kg 0 45 M/min 5 12 mm OD (Outside Diameter) 10 63mm OD HYDRAULIC DRIVE SYSTEM Operating Pressure: Flow: 100 Bar (Max) 15 litres/min (recommended) Pressure Switch Setting: 80 Bar 5-12 OD tubes Relief Valve Setting: 110 Bar 5-12 OD tubes Initial starting pressure: Bar (if greater the set-up needs checking) PNEUMATIC SYSTEM Air Hose Bore (min): Operating Pressure: Max Tube Inflation Pressure: Flow: 32 mm (1¼ ) 5-8 Bar 5 Bar (or as specified by tube manufacturer) The air supply should ideally be filtered and de-humidified) For Ducts with an Inner Diameter of: Minimum Flow Acceptable 0 up to 25mm : 4m³/min 150CFM 26 up to 30mm : 5 m³/min 185CFM 31 up to 35mm : 7 m³/min 250CFM 36 up to 40mm : 10 m³/min 375CFM 41 up to 44mm : 12 m³/min 450CFM ELECTRONIC CONTROL SYSTEM 14

15 Power Requirements: Fuse Rating: Battery Charging: 12 Volts DC 3.15 amp (Anti-Surge) 12V d.c., 300mA max., 8 hours max. DIMENSION AND WEIGHTS Height: Length: Width: Weight: Tyre Size: Tyre Pressure: 1090mm 980mm (Mounting (frame handles retracted) 1400mm (Mounting frame handles extended) 700mm 70kg / 260 x 85 (puncture proof & pneumatic) 25 P.S.I. (If pneumatic tyres fitted) Drive Chain Lubrication: Metaflux Chain Spray INSTALLATION PRINCIPLE Basic standard: Optional: Viscous Drag Method Missile System 15

16 5. OPERATING PROCEDURE IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS TUBE BLOWING MACHINE BE FULLY TRAINED, COMPETENT AND AUTHORISED TO DO SO AND HAVE READ THE ENTIRE OPERATING MANUAL. CBS Products (KT) Ltd, CANNOT BE HELD RESPONSIBLE FOR MIS-USE OF THIS EQUIPMENT. 1) Position the Tube Blowing Machine in a suitable position in line with the proposed sub-duct. 2) Adjust the mounting frame to the desired height and angle by means of the front frame supports. Withdraw the front R clip and retaining pin while supporting the weight of the tube-blowing unit. Raise or lower the blowing unit and locate onto the support bar for the desired position. Refit the retaining pin and R clip. Alternatively the blowing unit may be detached from the trolley frame by withdrawing both R clips and retaining pins, while supporting the weight of the blowing unit. The blowing unit can then be located in a trench, manhole (depending on size) or at ground level. Ensure the blowing unit is stable and the electronic panel is not immersed in water. 3) If trolley mounted, stabilise the frame on uneven ground by adjusting the height on the pivoting feet at the rear of the unit and locking in position. NOTE: CARE SHOULD BE TAKEN WHEN WHEELING THE TROLLEY AROUND NOT TO CATCH THE ADJUSTABLE FEET PADS ON KERBS OR BOULDERS, THIS MAY DAMAGE THE PIVOTING FOOT. 4) POSITION THE TUBE DRUM(S) SOME 6-8 METRES DIRECTLY BEHIND AND IN LINE WITH THE TUBE BLOWING MACHINE. (TUBE CARRYING DEVICE TO BE SUITABLY LEVELLED AND RESTRAINED). 5) Ensure the service battery and spare battery are fully charged before commencement of installation. The battery is not charged by the power pack. Releasing the battery holder located in the underside of the electronic control panel accesses the battery. ENSURE THE CORRECT TRACTOR DRIVE CHAINS ARE FITTED, REFER TO SECTION 7. 6) Open tractor drive and unscrew retaining knobs on the air chamber. 7) Open the air chamber lid on the pivot bolts. CLEAN ANY DEBRIS, SLUDGE, DIRT, WATER, LUBRICANT, ETC. FROM THE AIR CHAMBER, FRAME HOUSINGS AND TUBE INTAKE GUIDE BRACKET ASSEMBLY EACH TIME BEFORE USE. LUBRICATE BOTH CHAINS BEFORE USE. CLEAN BOTH TRACTOR DRIVE BELTS BEFORE USE. 16

17 8) Unscrew the sub-duct clamp retaining bolts. Refer to the Section 4 SPECIFICATION for the correct pressure settings for the relief valve and pressure switch. NOTE :-The tube blowing machine is supplied as standard with the pressure relief valve set at 110 Bar and the pressure switch set at 80 Bar, these settings are suitable for tubes in the range 5-12 O.D. 9) Open the sub-duct clamp on the pivot bolts, select and fit the correct size venturi tube collet, sub duct seal and sub duct clamp collets for the tube and sub duct being used. (Refer to Sections 8 and 9 & Appendix 7 & 9 in this manual for further details). Always check and verify the correct size collets are fitted before operating the blowing machine. 10) Place the sub-duct into the sub-duct seal collet and subduct clamp collet. Ensure the sub-duct is fully engaged into the sub-duct seal collet. 11) Clamp the sub-duct and tighten the two retaining nuts. 12) ENSURE THAT THE SUB-DUCT IS FULLY PREPARED FOR USE, I.E. a) FULLY CONNECTED b) PRESSURE TESTED c) TUBE(S) EXIT RETAINING DEVICE FITTED d) LUBRICATED (If required) FOR FURTHER DETAILS ON SUB-DUCT LUBRICATION REFER TO SECTION

18 THE TUBE BLOWING MACHINE IS FITTED WITH THE COLLET TYPE INFEED GUIDE BRACKET ASSEMBLY (5 12mm OD TUBE(S)) 13) Open the collet retaining bracket on the pivot bolt. 14) Select the correct size tube infeed collet to suit the size and quantity of tubes to be installed and locate on to the capscrew in the lower housing. Always check and verify the correct size collets are fitted before operating the blowing machine. 15) Close the infeed tube guide upper housing and secure with the swing bolts and thumb nuts 18

19 16) Adjust the height of the intake tube guide bracket to suit the size of the collet and the size of the tubes to be installed. To adjust the height, unscrew the locking ring back to the adjusting knob, rotate the adjusting knob on the underside of the bracket until the tubes just contact the aluminium measuring roller between the infeed guide collet and the tractor drive chain, this will ensure that the speed/distance measuring function operates, (the upper most tubes should not touch the nylon guide in the top housing). When the correct setting is achieved hold the adjusting screw and turn the locking clock wise to lock in position and prevent any movement during installation. (Refer to Section 10 for details). 17) With the tractor drive unit in its upper position, guide the tubes through the infeed guide assembly, tractor drive, Venturi collet and feed approximately 2 metres into the sub-duct, by hand. 18) Ensure the tube(s) is/are correctly located in the bore of the collet. 19) Release the adjusting screw locking ring to adjust the height of the air chamber, turn the adjusting knob until the Venturi tube guide collet is in alignment with the grooves in the tractor drive belt, (this is best achieved with tubes in place) Tighten the locking ring to prevent any movement during installation. (Refer to Section 10 for details). 19

20 NOTE: ENSURE THAT THE COMPRESSOR AIR SUPPLY IS NEVER ALLOWED TO ENTER THE AIR CHAMBER OR SUB-DUCT WHEN THE TOP TRACTOR DRIVE FRAME IS IN THE UPPER POSITION. (i.e. NOT CLAMPING THE TUBE(S) AND / OR THE INFEED GUIDE BRACKET IS OPEN OR NOT CORRECTLY SECURED. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY DUE TO THE TUBES BEING EJECTED FROM THE TUBE BLOWING MACHINE WITH HIGH FORCE AND VELOCITY. 20) Close the tractor drive, ensuring that all the tubes are located correctly in the grooves of both upper and lower drive chains. SET THE TUBE(S) CLAMPING FORCE THE CORRECT TUBE(S) CLAMPING FORCE IS VITAL TO THE PERFORMANCE OF THE MACHINE. IT SHOULD BE SET AS FOLLOWS: TIGHTEN THE HANDLE WITH ONE HAND WHILST ROTATING THE CLAMP WASHERS WITH THE OTHER. THE CLAMP WASHERS WILL TURN EASILY UNTIL THE HANDLE BEGINS TO CLAMP THEM. WHEN THE CLAMP WASHERS BECOME ALMOST IMPOSSIBLE TO TURN WITH ONE HAND, THIS IS THE START POINT FOR THE CLAMP FORCE SETTING. CONTINUE TO TURN THE HANDLE A FURTHER ½ - 1 FULL TURN. THIS WILL ENSURE THE CORRECT TUBE(S) CLAMP FORCE. (DO NOT OVERTIGHTEN) 21) Re-fit the air chamber lid ensuring correct location on the dowels and tighten down the 4 retaining knobs. 20

21 ENSURE THAT: 22) The hydraulic control valve is in the OFF position. 23) THE SPEED CONTROL KNOB IS IN THE MIN POSITION (FULLY ROTATED ANTI-CLOCKWISE). 24) THE EMERGENCY STOP BUTTON IS SET. (I.E. IN UPPER POSITION). IF NOT SET, TWIST TO RESET IN THE DIRECTION INDICATED ON TOP OF THE PUSH BUTTON. 25) IF NOT ALREADY CONNECTED. CONNECT UP TO THE POWER PACK OR HYDRAULIC POWER SOURCE. NEVER RUN THE BLOWING MACHINE WITHOUT THE EMERGENCY STOP CABLE BEING CONNECTED. Connect the two hydraulic hoses and the emergency stop cable to the power pack (or hydraulic power source). Ensure the plug to socket & socket to plug connections are correctly made. NOTE: ONLY AUTHORISED, FULLY TRAINED OPERATORS SHOULD BE ALLOWED TO OPERATE THE HYDRAULIC POWER PACK (OR HYDRAULIC POWER SOURCE). 21

22 26) Check the air valve is in the closed position and connect the air supply from the compressor (if not already connected). NOTE: ENSURE THE AIR VALVE REMAINS IN THE CLOSED POSITION UNTIL REQUIRED. 27) NOTIFY INSTALLATION TEAM NOTIFY INSTALLATION TEAM THAT PREPARATIONS ARE COMPLETE AND TUBE(S) BLOWING OPERATIONS ARE READY TO COMMENCE. 28) NOTE: ONLY AUTHORISED, FULLY TRAINED OPERATORS SHOULD BE ALLOWED TO OPERATE THE AIR COMPRESSOR AND THE POWER PACK/HYDRAULIC POWER SOURCE. ENSURE THAT BOTH SERVICES ARE AVAILABLE AND RUNNING AND HAVE ENOUGH FUEL FOR THE DURATION OF THE BLOWING OPERATION. NOTE: THE AIR SHUT OFF VALVE IS STILL IN THE CLOSED POSITION. 29) Turn hydraulic valve to ON position. 30) Ensure the emergency stop button is in the reset position. (I.E. IN UPPER POSITION). IF NOT SET, TWIST TO RESET IN THE DIRECTION INDICATED ON TOP OF THE PUSH BUTTON. 22

23 31) Press the on/off button. NOTE: DO NOT PRESS THE RST BUTTON WHILST POWERING UP THE COUNTER The display will indicate the speed and distance travelled by the tubes. To toggle between speed and distance press the SEL button. R displayed on the left side of the screen designates speed (rate). To reset the distance press RST. Note: It is possible to reset the distance to zero whilst installing, even if speed is being displayed on the screen. Should it be necessary to replace the speed-distance measuring device please contact CBS (KT) Products Ltd. 32) Turn the speed control valve clockwise (towards max ) until the speed of 30m/min (or as required) is achieved. TUBE INSTALLATION INTO SUB-DUCT 33) CONTINUE TO INSTALL TUBES INTO SUB-DUCT. THE OPERATOR WEARING WORK GLOVES SHOULD HAND GUIDE THE TUBE(S) INTO THE BLOWING MACHINE THROUGH A DRY CLEAN CLOTH, THIS IS TO PREVENT ANY DEBRIS ON THE TUBES ENTERING THE BLOWING MACHINE AND TO ENSURE THE TUBES ENTERS THE MACHINE INLINE WITH THE TRACTOR DRIVE BELT WITHOUT ANY BENDING OR DEVIATION. NOTE: CARE MUST BE TAKEN TO AVOID INJURY BY CLOTHING OR FINGERS BEING DRAGGED INTO THE MACHINE. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE TUBES FROM THE DRIVE BELTS AND/OR JAMMING OF THE TUBES IN THE AIR CHAMBER. 23

24 34) WHEN APPROXIMATELY 200 METRES OF TUBE(S) HAS BEEN INSTALLED INTO THE SUB- DUCT OR THE HYDRAULIC PRESSURE BEGINS TO RISE. OPEN THE AIR VALVE TO ALLOW THE COMPRESSED AIR TO ENTER THE AIR CHAMBER, THIS WILL ASSIST THE INSTALLATION OF THE TUBES THROUGH THE DUCT. 35) When the tubes reach the destination the machine will stop automatically (assuming the tubes exit retaining device is fitted to the end of sub-duct). THE OPERATOR IS RESPONSIBLE FOR ENSURING THIS IS FITTED, PRIOR TO BEGINNING THE TUBE(S) INSTALLATION). Turn the hydraulic valve to the off position. 36) Screw the speed control knob to the min, (counter clockwise) and press the reset button. 37) TURN THE AIR VALVE TO THE CLOSED POSITION. ALLOW THE AIR PRESSURE TO EXHAUST. THIS MAY TAKE SEVERAL MINUTES, AS THERE MAY BE A CONSIDERABLE AMOUNT OF AIR IN THE SUB-DUCT. DO NOT OPEN THE AIR CHAMBER UNTIL THE AIR PRESSURE GAUGE READS ZERO. 24

25 40) IF THE BLOWING MACHINE STOPS SUDDENLY If the tube blowing machine stops suddenly during the blowing operation it is likely that the pressure switch has tripped, the probable reasons for this are: - A) The tubes have reached the destination and the tube(s) exit retaining device has stopped the travel of the tubes. B) The tubes have become jammed, has hit an obstruction in the duct or the tube(s) blowing operation has reached its maximum capability. C) The power pack has developed a problem or has run out of fuel. BATTERY A single battery is supplied with the Tube Blowing Machine, it may be beneficial to purchase a spare battery, this gives the advantage of changing a flat battery for a charged battery and enabling re-charging (subject to availability of an automotive type battery charger and mains power supply) while still using the Tube Blowing Machine. TUBE BLOWING MACHINE FRAME 1. When the Tube Blowing machine is not being moved, the frame mounted handles should be fully retracted and secured. Fully Retracted Fully Extended 2. For moving the Tube Blowing Machine the handles can be extended to suit the operator, when not required for moving the Tube Blowing Machine the handles should be fully retracted and secured as the extended handles may pose a tripping hazard. 3. The Tube Blowing Machine pusher unit can be positioned at 3 different angles to suit the tube(s) installation. 25

26 IN THE EVENT OF AN EMERGENCY 1. Push the emergency stop. 2. Turn the hydraulic valve to the off position. 3. SCREW THE SPEED CONTROL KNOB TO MIN POSITION (FULLY COUNTER- CLOCKWISE). 4. Press the on/off button (to turn off the electric s off, if required) 5. Isolate the air supply (if required). 6. Deal with the reason for stopping. 26

27 TO RESTART 7. Ensure the emergency stop button is in the reset position (I.E. IN UPPER POSITION). IF NOT SET, TWIST TO RESET IN THE DIRECTION INDICATED ON TOP OF THE PUSH BUTTON. 8. Ensure the power pack is running. 9. Turn the hydraulic on/off valve to on position. 10. Press the start button. (If the electric s have been switched off) 11. Turn the air valve to the open position (if air has been turned off). 12. Turn the speed control valve towards max (clockwise) until the speed of 30m/min (or as required) is achieved. 27

28 6. MAINTENANCE To ensure reliable service from your Tube Blowing Machine, CBS Products (KT) Ltd RECOMMEND THE UNIT BE COMPLETELY SERVICED EVERY 6 MONTHS. AIR CHAMBER The air chamber should be inspected after each operation for seal damage or wear. Seal cord should be replaced if damaged and secured in position with the adhesive provided. ALWAYS clean out any dirt/debris in the air chamber TRACTOR DRIVE INSPECT THE CHAIN DRIVE BLOCKS FOR WEAR OR DAMAGE EACH WEEK. CHECK the chain tension weekly and adjust if necessary with the two external adjustment screws (swing bolts). (Do not over tension) the chain should slightly lift off the chain guides, when pulled at the centre by finger. THE CHAIN SHOULD BE LUBRICATED EACH TIME USED by application of Metaflux spray grease This is achieved by running the tube blowing machine at about 45m/min without any tube(s) or applied air and carefully inserting the spray tube from the canister into the holes on the operator side of the aluminium drive castings (2). The spray tube should be carefully inserted until the chain can just be felt and then withdrawn about 20 25mm and spraying for approximately 1 second. DO NOT OVER LUBRICATE, AS THIS MAY LEAD TO THE DRIVE BELTS BEING CONTAMINATED WITH LUBRICANT. If contamination does result, wipe the belts clean thoroughly before attempting any blowing operation. (This is based on normal use where the chains are not exposed to excessive contamination). Bottom frame chain lubrication point Top frame chain lubrication point 28

29 GENERAL The machine should be stored under cover in a dry environment when not in use. The machine should be wiped clean after each time used. ALWAYS ensure that there are sufficient, cord seal and cord adhesive available in the toolbox to cover the next installation. ALWAYS ensure that the service battery and spare battery are fully charged, before the tubeblowing machine is to be used. Note: The battery is not charged by the power pack. The machine uses a conventional lead acid batteries, this may be charged using the battery charger supplied with the tube Blowing Machine or an ordinary automotive (car) type battery charger. CHECK the tyre condition weekly. Oil the frame pivot points monthly. Lubricate the olite bearings with light machine oil every month. Apply grease to the jacking screw thread each month clean out any dirt/debris from the tube-measuring wheel, measuring disc and speed pick up probe. Oil air chamber adjusting screw and tube infeed guide adjusting screw monthly. Grease axles every month. Check function of electrical panel each time. SERVICE CONNECTIONS CHECK the condition of the hydraulic hoses each time used and replace if worn or damaged. CHECK the condition of the emergency stop cable each time used and replace if worn or damaged. CHECK the condition of the compressed air hose each time and replace if worn or damaged. 29

30 6.1 MAINTENANCE SCHEDULE PROCEDURE DAILY WEEKLY MONTHLY Clean all assemblies and components thoroughly Inspect hydraulic hoses for leaks and cracks Inspect fasteners, screws and retaining pins / wire Check / adjust chain tension Check tractor drive pads for wear / damage Clean air chamber Check / replace cord seals Tyre condition Check condition of emergency stop lead Clean tube infeed guide bracket and collets Clean measuring wheel measuring disc and speed pick up probe Function of electronic panel Oil the frame pivot points Grease jacking screw thread Oil air chamber adjusting screw Oil olite bearings with light machine oil Grease mounting frame axles Clean and lubricate chain* Clean and lubricate the chain support slide bars Check the condition of service (and spare) 12V DC battery Check condition of the compressed air hose * Should be more often if subjected to abnormal use and / or excessive contamination. 30

31 6.2 TYPICAL PROBLEMS EXPERIENCED WHEN TUBE BLOWING: PROBLEM Tractor feed does not pull the tube off the drum SOLUTION Assist the drum by turning it or pulling the tube(s) off the drum by hand. The Tube Blowing Machine stops. Hydraulic pressure gauge reads zero. Machine has tripped out on pressure switch, tube(s) has hit an obstruction or become jammed. Turn hydraulic valve to off position. Turn speed control knob to min. If tube(s) is jammed try restarting the Tube Blowing Machine, if this fails it may be necessary to pull the tube(s) out a short distance and start again. Investigate obstruction in duct. If all else fails it may be necessary to remove the sub-duct and remake the bad connection. It is difficult to keep the tube(s) moving near the end of a duct run The tube(s) is/are hard to re-start having stopped Assist the Tube Blowing Machine by manually pushing the tubes into the tractor drive. DO NOT BEND OR CRIMP THE TUBE(S). Put air to the system with the tube(s) clamped between the upper and lower drive chains. The tractor feed can be restarted after the air pressure has increased and stabilised. If the tube(s) can not be restarted, this may be due to the weight of tube(s) in the sub-duct, it will be necessary to pull the tube(s) out and restart the installation with the full air pressure applied. 31

32 6.3 BASIC TOOL KIT SUPPLIED WITH TUBE BLOWING MACHINE PART NO. DESCRIPTION QTY. D F Allen Key 3mm 1 D F Allen Key 4mm 1 D F Allen Key 5mm 1 D F Allen Key 6mm 1 D F Spanner 13-17mm A/F OE 1 C-SEAL-OR-021-F Seal O Ring Cord 3mm Dia. x 2.5 metres Long 1 C-GREASE-1111-F Grease Dow Corning No. 7 1 D F Pliers combination 6 1 D F Screw Driver 6 rectangular Blade 1 D f Knife Trimming 1 D F Allen Key Long Reach 1/8 A/F 1 D F Allen Key 3/32 A/F 1 Also Supplied With Tube Blowing Machine:- C-1250-AS1012 Battery Charger Assembly 1 C-1250-AS1020 Battery Level Indicator 1 C-C-SPRAY-1111-F Metaflux Chain Cling Spray (UK only) 1 C-DOWEL-030X350 Dowel Wood 30mm Dia. x 350 long 1 The toolbox is mounted on the underside of the Tube Blowing Machine Frame. 32

33 7. PROCEDURE FOR REPLACEMENT OF CHAIN DRIVES Tools required: 6mm Allen Key 13mm OE Spanner ENSURE THE HYDRAULIC HOSES ARE DISCONNECTED FROM THE BLOWING MACHINE BEFORE CARRYING OUT THIS PROCEDURE. Step 1 Disconnect the hydraulic motor from the top frame using 6mm Allen Key. Remove the stop washer on the bottom of the main jacking screw using a 6 mm allen key. Unscrew the main clamping screw and separate the top and the bottom housing assemblies of the pusher unit. Step 2 Bottom Housing Chain Removal Slacken the chain adjusters using a 13mm OE spanner. Remove the swing bolt from the operator side of unit using a 13mm OE spanner. Push the tensioner pin out through the sprocket assembly. Remove the tension sprocket assembly. Remove the chain-connecting link. Remove the chain. Check the chain support slide bars for wear and check the tension sprocket rotates freely, prior to fitting the new chains. Clean and re-lubricate the chain support slide bars. Step 3 Bottom Housing Chain Replacement / Refitting Pass the pre-lubricated chain round the drive sprocket. Feed the chain along the unit and reconnect the chain-connecting link, (closed end of connecting link in the direction of travel). Align the tension sprocket with the chain and locate into position in the bottom housing. Insert the tension pin through the tension sprocket, placing the tensioner pin spacer on the tension pin. Refit swing bolt using a 13mm OE spanner. Adjust the chain evenly via the swing bolts, checking free rotation of the chain. Do not over tighten the chain. Refer to Maintenance Section 6 for details. Step 4 Top Housing Chain Removal Slacken the chain adjusters using a 13mm OE spanner. Remove the swing bolt from the operator side of unit using a 13mm OE spanner. Push the tensioner pin out through the sprocket assembly. Remove the tension sprocket assembly. Remove the chain-connecting link. Remove the chain. Check the chain support slide bars for wear and check the tension sprocket rotates freely, prior to fitting the new chains. Clean and re-lubricate the chain support slide bars. 33

34 Step 5 Top Housing Chain Replacement / Refitting Pass the pre-lubricated chain round the drive sprocket. Feed the chain along the unit and reconnect the chain-connecting link, (closed end of connecting link in the direction of travel). Align the tension sprocket with the chain and locate into position in the top housing. Insert the tension pin through the tension sprocket, placing the tensioner pin spacer on the tension pin. Refit swing bolt using a 13mm OE spanner. Step 6 Top Housing - Reassembling the Top Housing to the Bottom Housing of the pusher unit / Chain refitting. Refit the main clamping screw into the bracket on the bottom frame assembly of the pusher unit. Replace the stop washer on the bottom of the main clamping screw using a 6mm allen key. Reconnect the hydraulic motor using the 6mm allen key. Adjust top chain evenly via the swing bolts, checking free rotation of the chain, do not over tighten chain. Refer to Maintenance Section 6 for details. Connect the power pack hoses and run the pusher unit for 3 minutes, check the chain tension, re-adjust if necessary. 34

35 8. PROCEDURE FOR REPLACEMENT OF TUBE COLLETS ENSURE THE AIR SUPPLY IS DISCONNECTED FROM THE BLOWING MACHINE BEFORE CARRYING OUT THIS PROCEDURE. Tools Required 4mm Allen Key Step 1 Air Chamber Tube Collet Removal Ensure that the air valve is closed and the air pressure is at zero. Open the air chamber to expose the collet. Remove the collet. Step 2 Air Chamber Tube Collet Refitting Select the replacement collet (refer to appendix 7 for collet information) Clean the air chamber with a dry cloth. Fit the appropriate collet, locate on to the socket head cap screw fitted in to the air chamber base. Re-new any worn or damaged radial cord seals and always renew both air chamber split cord seals. Ensure there is sufficient cord to butt up to the sub-duct. NOTE: CORRECT FITTING OF THE CORD SEALS IS A MAJOR FACTOR IN AIR LEAKAGE FROM THE AIR CHAMBER. Close the air chamber and tighten down the 4 retaining knobs. NOTE: The main seals in the air chamber consist of a 3mm cord seal, which is cut to the correct length and permanently fixed with adhesive. infeed Guide Tube Collet Removal Step 1 Infeed Guide Tube Collet Removal Open the top infeed tube guide housing to expose the collets. Remove the socket head cap screw using a 4mm allen key and remove the collet Step 2 Select the replacement collet (refer to appendix 7 for collet information) Clean the both infeed guide housings with a dry cloth. Fit the appropriate collet and secure with a socket head cap screw using a 4mm allen key. Close the upper infeed guide housing and tighten down the 2 retaining knobs. 35

36 9. PROCEDURE FOR REPLACEMENT OF SUB-DUCT COLLETS ENSURE THE AIR SUPPLY IS DISCONNECTED FROM THE BLOWING MACHINE BEFORE CARRYING OUT THIS PROCEDURE. ALWAYS CHECK AND VERIFY THE CORRECT SIZE COLLETS ARE FITTED BEFORE OPERATING THE BLOWING MACHINE. SUB-DUCT CLAMP COLLETS (Based on no sub duct being fitted) Tools Required 4mm Allen Key Step 1 Collet Removal Ensure that the air valve is closed and the air pressure gauge is at zero. Open the sub-duct clamp. Remove the socket head cap screws (2) using a 4mm allen key and remove the collet (2). Step 2 Collet Refitting Select the replacement collets (refer to Appendix 8 for collet information) Clean the sub-duct clamp with a dry cloth. Fit the required collets and secure with a socket head cap screw using a 4mm allen key. Close the sub-duct clamp. SUB-DUCT SEAL COLLETS (Based on no sub duct being fitted) Tools Required 4mm Allen Key Step 1 Collet Removal Ensure that the air valve is closed and the air pressure gauge is at zero. Open the air chamber to expose the collets. Remove the socket head capscrew (2) using a 4mm allen key. Step 2 Collet Refitting Select the collets (refer to Appendix 8 for collet information). Clean air chamber with a dry cloth. Fit the replacement collets and secure with a socket head capscrew using a 4mm allen key. Re-new any worn or damaged radial cord seals always renew both air chamber split cord seals. NOTE: CORRECT FITTING OF THE CORD SEALS IS A MAJOR FACTOR IN AIR LEAKAGE FROM THE AIR CHAMBER. Close the air chamber and tighten down the 4 retaining knobs. NOTE: The main seals in the air chamber consist of a 3mm cord seal, which is cut to the correct length and permanently fixed with adhesive. 36

37 10. PROCEDURE FOR THE AIR CHAMBER AND COLLET TYPE TUBE INFEED TUBE GUIDE ASSEMBLY HEIGHT Tools Required No tools are required. Step 1 When changing collets and seals to accept smaller / larger sizes of tube(s) it is necessary to adjust the height of the air chamber and the collet type infeed guide assembly. THIS SETTING MUST BE CARRIED OUT ACCURATELY, AS FAILURE TO DO SO WILL SERIOUSLY IMPAIR THE FUNCTION OF THE MACHINE. AIR CHAMBER: To adjust the air chamber bracket in either direction, release the adjusting knob locking ring and turn the knob placed directly under the air chamber until the Venturi tube guide collet is in alignment with the grooves in the tractor drive belt, (this is best achieved with tubes in place). Tighten the locking ring to prevent any movement during installation. A description of this procedure is outlined in Section 5 Operating Procedure including photographs of the machine in the area under discussion. TUBE INFEED GUIDE ASSEMBLY: To adjust the collet type tube infeed guide assembly bracket in either direction, release the adjusting knob locking ring and turn the knob placed directly under the infeed guide, rotate the adjusting knob on the underside of the bracket until the tubes just contact the aluminium measuring roller between the infeed guide collet and the tractor drive chain, this will ensure that the speed/distance measuring function operates, (the upper most tubes should not touch the nylon guide in the top housing). Tighten the locking ring to prevent any movement during installation. A description of this procedure is outlined in Section 5 Operating Procedure including a photograph of the machine in the area under discussion. 37

38 11. ALIGNMENT OF AIR CHAMBER TO THE TUBE PUSHER UNIT THIS SETTING MUST BE CARRIED OUT ACCURATELY, AS FAILURE TO DO SO WILL SERIOUSLY IMPAIR THE FUNCTION OF THE MACHINE. 1. Insert a round parallel bar between the top and bottom tube pusher housings and clamp down. Ensure the round parallel bar doesn t interfere with metering wheel and that it passes through the air chamber. (see picture). 2. Refer to Section 10.0 Procedure for adjusting the air chamber and infeed guide assembly height and the height of the air chamber. Adjust the air chamber such that the top face of the lower housing is inline with the centre line of the round parallel bar. 3. The lateral alignment of the air chamber needs to be checked / adjusted. The objective is to position the air chamber such that the centre line of the round parallel bar is parallel with the centre line of the air chamber, adjustment is made by slackening the four socket capscrews that secure the air chamber to the support bracket (see picture). When the alignment is correct re-tighten the four socket capscrews. 38

39 12. MONTHLY SERVICE CHECK LIST 1. Remove the drive chains from the pusher unit. Check both of the chains for excessive wear. Replace, if required and lubricate with the spray grease provided for details see Section 6 Maintenance. 2. Remove any debris from the housings. 3. Check the chain supports slide bars for excessive wear and lubricate with the spray grease specified in Section 6 Maintenance. Replace, if required. 4. Check all other moving parts e.g. bearings, shafts, sprockets etc. and lubricate. 5. Check main top housing jacking screw and lubricate. 6. Check all hydraulic fittings and check for leaks. 7. Check the hydraulic hoses for external damage. 8. Check the electrical lead for external damage. 9. Check the electrical plug and sockets. 10. Check the function of the electronic control module. 11. Check the operation of the emergency stop button. 12. Check condition of cord seals in the air chamber. 13. Check the operation of the tube measuring device. 14. Check the wheel tyre condition and free rotation. Lubricate, replace as necessary. 15. Clean the Air Chamber. 16. Clean the infeed tube guide bracket and housings. 17. Check that there is sufficient O ring cord and silicon grease in the tool box for the next installation. 18. Complete service history record. 39

40 13. SERVICE HISTORY RECORD Service No Date Carried Out By Record of Repair 40

41 14. SUB-DUCT INTEGRITY AND LUBRICATION SUB-DUCT INTEGRITY AND LUBRICATION IS ENTIRELY THE RESPONSIBILITY OF THE OPERATOR. CBS Products (KT) Ltd, CANNOT BE HELD RESPONSIBLE FOR SUB-DUCT INTEGRITY AND LUBRICATION 1. Ensure that the sub-duct is fully prepared for use i.e.: Fully connected Pressure tested Tube(s) exit retaining device fitted lubricated (if required) VERIFYING AIR FLOW AND LUBRICATION (IF REQUIRED) 2. Clean the air chamber with a dry cloth, fit the correct size venturi tube collet and seals and blanking plug or blank collet part number C , sub-duct seal collets and subduct clamp collets refer to Sections 8 & 9 and appendices 7 & 8 for further details. If applicable, the collet with the horizontal O Ring groove is fitted into the base of the air chamber and secured with a capscrew. Refit the radial seal cords. 3. Open the sub-duct clamp and place the sub-duct into the sub-duct seal collet and subduct clamp collet. Ensure the sub-duct is fully engaged into the sub-duct seal collet. 4. Clamp the sub-duct and tighten the two retaining nuts. 41

42 5. If a cable seal venturi collet is used, fit the cable seal plug and two cable seals into the lower half cable seal collet. Ensure that the split of the innermost seal is in the lower half of the air chamber slightly rotated from the vertical. The split of the outer most seal is also in the lower half of the air chamber slightly rotated from the vertical in the other direction to the innermost seal. Both grooves face away from the tractor drive. 6. Fit the upper cable guide collet ensure both seals are correctly located. 7. Re-fit the air chamber lid ensuring correct location on the dowels and tighten down the 4 retaining knobs. 8. Check the air valve is in the closed position and connect the air supply from the compressor. 42

43 9. NOTIFY INSTALLATION TEAM Notify installation team that preparations are competed and that checking the air flow through the sub-duct is about to commence. 10. NOTE: ONLY AUTHORISED FULLY TRAINED OPERATORS SHOULD BE ALLOWED TO OPERATE THE AIR COMPRESSOR. With the air compressor ready to provide air, turn the air valve to the open position. 11. Confirm that air is being expelled from the far end of the sub-duct under pressure. If not this indicates the run is too long, there is leak, an obstruction or the sub-duct is crushed or otherwise damaged or disconnected. This must be remedied before any tube(s) blowing is undertaken, when confirmation is received, turn the air valve to the closed position and shut down the compressor. 43

44 12. Ensure all air has exhausted from the air chamber and sub-duct. Open the air chamber and sub-duct clamp and withdraw the sub-duct. Add a suitable lubricant to the sub-duct at the rate of ½ litre of lubricant per 1 kilometre of sub-duct, (or as required). NOTE: NEVER OPEN THE AIR CHAMBER UNTIL THE AIR PRESSURE GAUGE READS ZERO. 13. Insert a suitable foam plug into the sub-duct and re-fit the sub-duct into the air chamber and secure with the sub-duct clamp as already described. The foam plug should be sized so as to be a snug fit in the sub-duct. By blowing this plug down the sub-duct the lubricant will be evenly distributed along the length of the sub-duct. Before blowing the plug through the sub-duct, ensure the sub-duct tube(s) exit retaining device is fitted at the end of the run, to prevent the plug flying out of the open end of the sub-duct causing injury. 14. Re-fit the air chamber lid ensuring correct location on the dowels and tighten down the 4 retaining screws. 44

45 15. NOTIFY INSTALLATION TEAM Notify installation team that preparations for lubricating the sub-duct are complete and ready to commence. 16. With the compressor ready to provide air, turn the air valve to the open position. 17. When the foam plug has been expelled from the end or the sub-duct, turn the air valve to the closed position and shut down the compressor. ALLOW THE AIR CHAMBER AND SUB-DUCT TO EXHAUST ALL THE COMPRESSED AIR. NOTE: NEVER OPEN THE AIR CHAMBER UNTIL THE AIR PRESSURE GAUGE READS ZERO. 18. Open the air chamber and remove the cable seal collet and plug or blanking collet. 45

46 15. TROUBLESHOOTING GUIDE INITIAL STARTING HYDRAULIC PRESSURE AT THE POINT OF STARTING A TUBE(S) INSTALLATION THE HYDRAULIC PRESSURE MUST BE BETWEEN BAR. IF NOT, DO NOT CONTINUE, SEE SECTIONS WILL NOT ACHIEVE MAX PRESSURE AND RUNS AT HIGHER THAN EXPECTED PRESSURE TO RECTIFY PROBLEM BEFORE COMMENCING TUBE(S) INSTALLATION. WILL NOT ACHIEVE MAX PRESSURE ON/OFF control valve not open fully Faulty power pack (check performance) Tube(s) Clamping force not set correctly (Allowing belt slip) Worn pads due to tube(s) slip Excessive lubrication of chains (on to pads causing belt slip) RUNS AT HIGHER THEN EXPECTED PRESSURE Excessive clamping force on tubes. Poor lubrication of drive belt chains Seized chain links (Drive Belt) Over tightening of chain tensioning adjuster nuts (Drive belts) Misalignment of air chamber height adjustment for tubes Tube(s) drum not rotating freely Misalignment of infeed guide assembly for tubes Poor duct and installation causing tight tube(s) friction Insufficient out-put from compressor (See recommendations for duct diameter) Incorrect collet fitted Dirt/debris in pusher housings PROVISIONAL BELT ROTATION TEST: With Hydraulic power pack running and without tubes, revolve the Drive Belts and monitor the minimum hydraulic pressure required. This should be around Bar as a benchmark. TUBE BLOWING MACHINE STOPS SUDDENLY DURING TUBE(S) INSTALLATION Max pressure achieved Obstacle in duct installation Power Pack out of fuel Emergency button pressed Damaged lead between Power Pack and blowing machine ENGINE DOES NOT STOP AT MAX PRESSURE Emergency lead not connected Electrical control panel/display not switched on Battery low on power Pressure switch unplugged Fuse blown in control panel 46

47 EXCESSIVE AIR LEAKAGE FROM AIR CHAMBER Damaged cord seal Incorrect size collet to tube size, incorrect height adjustment of air chamber bracket in relation to tube(s) diameter Incorrect tube collets COUNTER NOT READING OR GIVING INCORRECT READINGS Battery low on power Counter program has been changed clear program and re-program as described in Appendix

48 16. RECOMMENDED SPARES LIST Part No Description Qty Required See Appendix 7 Chain ½ Duplex 2 No C M Motor (50 cc/rev) 2 No R-SEAL-021-F Seal Cord (Cut to length as required) 10m C-GLUE-1111-F Super Glue 4 Bostik Tube C-WHL F Wheel Ref. 260 (Puncture Proof) 2 No OR C-WHL-044-F Wheel Ref. PBW280-2 (Solid) 2 No C Chain Support Slide Bar 2 No C-C-SPRAY-1111-F Metaflux chain spray No C-BTY F Battery 12 V.dc 1 No C-FUSE Fuse 3.15 amp 1No OPTIONAL SPARES C-1250-AS1012 Battery Charger 1 No C-1250-AS1020 Battery Level Indicator 1 No C Collet Blank (Sub Duct Integrity) 1No Tube Collets as per customer requirements. Cable Seal Collets as per customer requirements. Cable Seals and Seal Plugs as per customer requirements. Sub-Duct Seal Collets as per customer requirements. Sub-Duct Clamp Collets as per customer requirements. For spare parts always quote the machine type and serial number and contact: CBS Products (KT) Ltd Pillings Road OAKHAM RUTLAND LE15 6QF TEL: FAX: sales@cbsproducts.com Website: 48

49 17. BATTERY TESTING AND CHARGING The Tube Blowing Machine is supplied with its own charger suitable for charging the battery located in the electronic control panel and a battery level indicator allowing the user to check battery charge before using the machine. To Check the battery level: Plug the supplied battery level meter into the socket labelled battery charging socket. While either the battery charger or battery indicator are plugged into the Tube Blowing Machine the electrics within the machine including the counter will be isolated to prevent damage. The Tube Blowing Machine should not be used while checking the battery level. If the indicator reads in the green section the battery is charged sufficiently to use, if it reads in the red the battery requires charging. To Charge the battery: The charger supplied with the Tube Blowing Machine is not suitable for charging outside. Do not charge for more than 8 hours. The Tube Blowing Machine should not be used while charging. Connect the charger to the Tube Blowing Machine via the socket labelled Battery Charger Connection. Plug the charger into a suitable 230V ac (+/-10%) supply. An LED on the charger indicates the state of battery charge. 49

50 18. BATTERY REPLACEMENT The battery is located under the electronic control panel, see Fig 18.1 Fig 18.1 Turn the spring clips through 90 and lower the battery holder and battery, see Fig 18.2 Fig 18.2 Tilt the battery holder backwards and pull forwards and downwards to release from the electronic control panel, see Fig 18.3 and Fig 18.4 Fig 18.3 Fig

51 Release the tape retaining the polyurethane terminal covers, fold back the polyurethane covers to expose the battery terminals, see Fig 18.5 Fig 18.5 The battery leads can now be pulled off of the battery terminals and the battery removed for recharging or re-placement. The above procedure is reversed for re-installation of the battery. 51

52 LAYOUT OF TUBE BLOWING MACHINE 1 Tube Pusher Unit 2 Air Chamber 3 Sub-Duct Clamp 4 Tube Infeed Bracket Assembly (5-12mm OD Tables) 5 Micro-Duct Tube Blowing Machine lifting Point 6 Hydraulic Control Panel 7 Electronic control Panel 8 Air Open/Close Valve 9 Air Hose Connection 10 Hydraulic Hose Connections 11 Emergency Stop 12 Frame Levelling Foot 13 Tool Box 14 Mounting Frame 15 Tractor Drive Movement Indicator 16 Tube Pusher Unit Tilting Brackets 17 Emergency Stop Connection 18 Battery Charge Connection 19 Tractor Drive Open/Close Handle 20 Drive Chain Tension Adjusting Screw 21 Battery Holder (Located Under Electronic Panel) 22 Sub Duct Clamp Nut Spanner 52

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59 HYDRAULIC AND ELECTRONIC CONTROL PANEL LAYOUT Air Pressure Gauge 2 Hydraulic Pressure Gauge 3 Speed Control Knob 4 Hydraulic On / Off Valve 5 Power On / Off Button 6 Emergency Stop 7 Length / Speed Digital Display 8 Hydraulic Control Panel 9 Electronic Control Panel 59

60 AIR CHAMBER COMPONENTS Tube Collet 2 Air Chamber 3 Air Chamber Seal 4 Sub Duct Seal Collet 5 Sub Duct Clamp Collet 60