CONDUX USER’S GUIDE & SAFETY MANUAL WINCH LINE BLOWER SYSTEM
IMPORTANT SAFETY NOTICE Read and understand all procedures and safety instructions before using a Condux Winch Line Blower. Observe all safety information on this page and note specific safety requirements as explained by procedures in this manual. Failure to follow these instructions could result in serious personal injury or death. ADVERTENCIA: Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si Ud.
Table of Contents_________________________ 1. GENERAL INFORMATION Purpose of the Winchline Blower……………………….2 Technical Information…………………………………..2 Safe Operating Practices………………………………...3 Winch Line Blower Selection………..…………………..4 2. OPERATOR’S INSTRUCTION Winch Line Blower Installation…………………………5 Winch Line Blowing Procedure…………………………11 Winch Line Blower Removal...………………………….12 3. WINCH LINE BLOWER ADAPTER Purpose of the Winch Line Blower Adapter…………….15 Winch Line Blower Adapter Installation………………...
1. General Information Purpose of the Winch Line Blower The Condux Winch Line Blower is a unique device for inserting winch lines directly into underground conduit before cable pulling or conduit proving operations.
Safe Operating Practices All tools, materials and equipment manufactured and supplied by Condux International are designed to only be used by trained craft personnel. The information in this manual is essential for the safe use of the Condux Winch Line Blower. Operating procedures and guidelines must be read and understood by all personnel prior to using any tools, materials, or equipment from Condux International.
Winch Line Blower Seal-Off Selection 1. Determine type(s) and diameter(s) of conduit in which the winch line will be inserted. 2. Select the correct threaded adpater to cover the range of conduit types and sizes being used. 3. Select the proper size rope venture. Comes standard with ½” – 9/16” venture. 4. Select the proper missile size for the conduit sizes that are going to be used.
2. Operator’s Instructions Winch Line Blower Installation Procedure !WARNING: Do not use around live circuits. The Winch Line Blower is constructed of steel and aluminum, as such is highly conductive. Electric shock may occur is contact is made with live circuits. Always be certain that power has been disconnected. !CAUTION: Standard utility service access vault opening procedures must be followed which include work area protection and gas detection.
!CAUTION: Always know approximate length of the conduit runs and make certain the winch drum contains enough winch line cable to reach the entire distance before using the winch line blower. !CAUTION: Inspect the winch line cable or know the condition of the cable before using the winch line blower. Replace any cables that are kinked or have worn or broken strands before using the winch line blower. 4. Insert the missile into the conduit and push into the conduit approximately one arms length. (See Fig.
Figure 3 Place Threaded Adapter into Duct Figure 4 Tighten Threaded Adapter Using a Wrench 6. Install winchline blower body onto the threaded adapter by matching the threaded adapter’s lip to the winchline blower body’s groove.
Figure 7 Close and Secure Winchline Blower Body 7. Close winchline blower body and secure by tighten the speedball handle securely. do not over tighten. See Figure 7 !WARNING: The Threaded Adapters should be screwed tight into the duct to ensure that the Winchline blower does not blow out of the conduit and severely injure persons or damage property. Figure 8: Align The Winch Line 8. Ensure that winchline is entering in a straight line.
Figure 9: Attach Air Hose 9. Attach the air hose to the seal-off body assembly and tighten the locking ring on the air connector. Rotate the 45° angle fitting away from the winch line channel and the winch line to prevent tangling and wear of the air hose or connectors. See Figure 9 10. Run the air hose out of the utility service access vault, attach to the Control Valve assembly, and tighten the locking ring on the air connector.
Figure 10: Close Control Valve 12. Attach the compressor hose to the control valve assembly and insert the locking pin the connector assembly. 13. Start the air compressor. The recommended air compressor size should be 75 to 185 CFM and 50 to 110 psi. You are now ready to blow the winch line into the conduit. Winch Line Blowing Procedure !DANGER: ALL PERSONNEL MUST BE OUT OF THE START AND EXIT UTILITY SERVICE ACCESS VAULTS DURING THE BLOWING PROCEDURE.
Note: One person should be in charge of the control valve assembly and, if positioned properly, should be able to view the winch line feeding off the winch drum, view the cable feeding down into the utility service access vault around the sheave, blocks, etc., and monitor the condition of the winch while it is being propelled. A second person should assist in monitoring the winch line and keep in contract with the exit utility service access vault.
Figure 12: MONITOR STATUS 5. Continue monitoring the winch line status and the pressure gauge on the control valve assembly, Figure 12. Average pressure reading during normal missile blowing operations should be approximately 70 – 90 psi. !DANGER: DO NOT ATTEMPT TO GRAB ONTO THE WINCH LINE TO ASSIST ITS TRAVEL OR SLOW IT DOWN. SERIOUS PERSONAL INJURY OR DEATH MAY RESULT FROM FAILURE TO OBEY THESE RULES. !DANGER: DO NOT LEAVE THE MOVING WINCH LINE UNATTENDED.
!WARNING: Winch line cable must be kept tight and must not be allowed to jump, flap, surge, or become slack. Damage to utility service access vault equipment may result. 7. If the winch line is proceeding smoothly and consistently, listen for the exit end personnel to relay that missile and winch line have arrived. If the winch line does not proceed smoothly or stops before reaching the exit, follow the troubleshooting guide in the following section.
5. Remove the winchline blower assembly from the conduit by turning the winchline blower body counter-clockwise until the unit can be removed from the duct. 6. Set the winchline blower off to one side and out of the way. 7. The missile and connector must be removed from the winch line at the exit utility service access vault. The winch line can then be prepared to pull in the cable assemblies or a mandrel, depending on job requirements.
3. Installing Measuring Tape Installation Procedures 1. Clean out the end of the conduit to remove any dirt or gravel that may get between the conduit and the Threaded Adapter. Apply a ¼” cup of lubricant into the duct system. 2. Remove rope venture if installed See Figure 1 Figure 1 Remove Rope Venturi 3.
4. Remove Hex plug using a 5/16” hex wrench and install 3/8” rope adapter see Figure 3 and Figure 4. Figure 3 Remove Hex Plug Figure 4 Insert 3/8” Rope Adapter !CAUTION: Always know approximate length of the conduit runs and make certain the measuring tape reel contains enough measuring tape to reach the entire distance before using the winch line blower blower.
5. Insert measuring tape through the 3/8” rope adapter See Figure 5 Figure 5 Insert Measuring Tape through 3/8” Rope Adapter 6. Attach measuring tape to carrier and install carrier into the duct See Figure 6 Figure 6 Attach Measuring Tape to Carrier and Insert into Duct !CAUTION: Before each use, visually inspect the winchline blower body assembly, threaded adapters and missiles for signs of wear, fatigue, and/or breakage.
7. Screw threaded adapter into pipe until tight by hand. Use adjustable wrench and screw threaded adapter one more full turn See Figure 7 & 8 Fig. 7 Insert Threaded Adapter into Duct Fig. 8 Insert Threaded Adapter into Duct 8. Install winchline blower body onto the threaded adapter. Close winchline blower body and secure by tighting the speedball handle securely, do not over tighten See Figure 9 and Figure 10.
Figure 9 Install Winchline Blower Body Figure 10 Secure Speed Ball Handle CONDUX WINCH LINE BLOWER 19
9. You are now ready to install your measuring tape 10. For Winch Line installation procedures refer back to Section 2 of this manual.
4. Troubleshooting Solutions to possible problems !WARNING: DO NOT ENTER THE UTILITY SERVICE ACCESS VAULT TO CHECK THE MISSILE OR SEAL-OFF WHILE THE SYSTEM IS UNDER PRESSURE. SHUT OFF THE AIR SUPPLY AND DUMP THE RELIEF VALVE PRIOR TO ENTERING THE UTILITY SERVICE ACCESS VAULT. PROBLEM SOLUTION THREADED ADAPTER DOES NOT FIT INOT THE CONDUIT. 1. Wrong size threaded adapter was selected MISSILE GOES INTO CONDUIT A DISTANCE BUT WILL NOT EXIT AT OTHER END. 1.
OBSTRUCTION. will clear the conduit of light obstructions. The missile is also able to maneuver through most areas where the conduit may be deformed and flattened. If the missile is not able to pass through the conduit, the conduit is fully plugged or has a major conduit obstruction. MISSILE GOES INTO CONDUIT A DISTANCE BUT WILL NOT EXIT AT OTHER END DUE TO TOO MUCH BACK FORCE ON THE MISSILE. 1.
5.
Winchline Blower Body Assembly ITEM PART NUMBER 1 08780126 3.5mm CS QUAD-‐RING KIT 1 2 02288000 MALE LOCKING COUPLER -‐ 1/2NPT-‐M 1 3 02288596 CAPSCREW,C-‐SINK M04-‐0.7 x 16MM 18-‐8SS 2 4 02288665 NUT,NYLOC M06-‐1.00 CZ 1 5 02288694 NUT,NYLOC M08-‐1.25 CZ 1 6 02288787 HEX DRIVER -‐ 2.5MM 1 7 02289293 SWING BOLT M10-‐1.
Condux Control Valve Assembly P/N 08209300 ITEM QTY PART NUMBER DESCRIPTION 1 02047800 3/4NPT-‐F 90DEG ELBOW FITTING 2 02129710 SAFETY CLIP 3 02222100 3/4NPT-‐M x 3/4NPT-‐M PIPE NIPPLE FITTING-‐1 1/2LG 4 02222200 3/4NPT-‐M x 3/4NPT-‐M PIPE NIPPLE FITTING-‐2 1/2LG 5 02222300 3/4NPT-‐F CROSS FITTING 6 02222400 3/4NPT-‐M x 1/2NPT-‐F
Condux Air Hose Assembly P/N 08209310 ITEM PART NUMBER DESCRIPTION 1 07022100 FEMALE LOCKING COUPLER -‐ 3/4NPT-‐F 2 08209311 300PSI AIR HOSE x 25FT -‐ 3/4NPT-‐M BOTH ENDS CONDUX WINCH LINE BLOWER 26
Condux Conduit Missile Wear/Replacement Parts Conduit Missile Conduit Range Replacement Item A Wear Item B Wear Item C In (mm) 08203920 3.83(97)4.17(106) 08581237 08209128 08209108 08204020 4.03(102)4.32(110) 08581237 08209129 08209109 08204920 4.81(122)5.05(128) 08581237 08209130 08209110 08205020 5.05(128)5.34(141) 08581237 08209131 08209111 08205920 5.76(146)6.07(154) 08581237 08209132 08209112 08206020 6.07(154)6.
Accessories Threaded Adapters PART NUMBER DESCRIPTION 08201108 WINCHLINE DUCT ADAPTER -‐ 3/4IN 08201110 WINCHLINE DUCT ADAPTER -‐ 1IN 08201112 WINCHLINE DUCT ADAPTER -‐ 1 1/4IN 08201115 WINCHLINE DUCT ADAPTER -‐ 1 1/2IN 08201020 WINCHLINE DUCT ADAPTER -‐ 2IN 08201025 WINCHLINE DUCT ADAPTER -‐ 2 1/2IN 08201030 WINCHLINE DUCT ADAPTER -‐ 3IN 08201035 WINCHLINE DUCT ADAPTER -‐ 3
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Warranty Information A. FACTORY ASSISTANCE Condux International Inc. can provide further advice regarding any problems with the installation, service, assembly, or disassembly of the Winch Line Blower. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Winch Line 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.
C O N D U X I N T E R N A T I O N A L , I N C . P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • e-mail: cndxinfo@condux.com © Copyright 2012, Condux International, Inc. Printed in USA Literature Part Number: 08201098 Revision Number: 1.
