Fremco PowerFlow RAPID Operating Manual

Rev. 1.0 FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Operating manual Responsible manufacturer: Fremco A/S Machine: PowerFlow RAPID & MultiFlow RAPID This is the original operating manual for PowerFlow RAPID and MultiFlow RAPID from Fremco. PowerFlow RAPID MultiFlow RAPID For single cable For both single cable and relining

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK TABLE OF CONTENTS 1. INTRODUCTION .......................................................................................................... 6 2. GENERAL .................................................................................................................... 7 2.1. MANUFACTURER ........................................................................................................ 7 2.2. THE MACHINE’S DESIGNATION ................................................................................. 7 2.3. MACHINE PLATE ......................................................................................................... 7 2.4. MACHINE MARKINGS ................................................................................................. 8 3. OVERVIEW AND APPLICATION ................................................................................. 9 3.1. GENERAL DESCRIPTION ........................................................................................... 9 3.2. THE MACHINE’S PURPOSE AND INTENDED USE .................................................... 9 3.3. WARNING - FORESEEABLE MISUSE ....................................................................... 10 3.4. TECHNICAL SPECIFICATIONS ................................................................................. 10 3.4.1. PHYSICAL DIMENSIONS IN METRIC UNITS ............................................................ 11 3.4.2. PHYSICAL DIMENSIONS IN IMPERIAL UNITS ......................................................... 11 3.4.3. PNEUMATICS ............................................................................................................ 11 3.4.4. HYDRAULICS ............................................................................................................. 12 3.4.5. NOISE ........................................................................................................................ 12 3.5. OPERATING POSITIONS, LOCATION AND ARRANGEMENT .................................. 12 3.6. USER INTERFACE ..................................................................................................... 13 3.7. MACHINE ASSEMBLY AND ADJUSTMENT .............................................................. 15 4. SAFETY AND RESIDUAL RISKS .............................................................................. 18 4.1. BUILT-IN SAFETY MEASURES ................................................................................. 18 4.1.1. SAFETY FUNCTIONS ................................................................................................ 18 4.2. SAFETY MEASURES, TO BE TAKEN BY THE USER ............................................... 19 4.2.1. CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE) ............................. 19 4.2.2. HANDLING OF DANGEROUS SUBSTANCES AND MATERIALS ............................. 20 4.2.3. RESIDUAL RISKS ...................................................................................................... 20 4.2.4. WORK PROCEDURES ............................................................................................... 20 4.2.5. IN CASE OF EMERGENCY ........................................................................................ 21 4.2.6. VIOLATION OF SAFETY REGULATIONS .................................................................. 21 5. TRAINING .................................................................................................................. 22 5.1. OPERATORS ............................................................................................................. 22

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 5.2. MAINTENANCE PERSONNEL ................................................................................... 22 6. OPERATION .............................................................................................................. 23 6.1. TRANSPORTING THE MACHINE .............................................................................. 23 6.2. START/STOP ............................................................................................................. 23 6.3. ENERGY SUPPLY CONNECTION/DISCONNECTION .............................................. 23 6.4. FEEDING/REMOVING PRODUCTS ........................................................................... 25 6.5. AIR/WATER SUPPLY ................................................................................................. 25 7. MAINTENANCE, TROUBLESHOOTING AND REPAIR ............................................. 26 7.1. QUICK GUIDE TO MAINTENANCE, TROUBLESHOOTING AND REPAIR ................ 26 7.2. PREPARATION FOR MAINTENANCE AND REPAIR ................................................. 26 7.2.1. CLEANING AND ORDER ........................................................................................... 26 7.2.2. CORRECTIVE MAINTENANCE .................................................................................. 27 7.2.3. REPAIR ...................................................................................................................... 27 7.3. SERVICE AND REPAIR ADDRESS ........................................................................... 27 7.4. DISCONNECTION AND DEPRESSURIZATION OF ENERGY SOURCES ................ 28 7.5. MAINTENANCE SCHEDULE ...................................................................................... 29 7.5.1. VISUAL INSPECTION ................................................................................................ 30 7.5.2. CHAIN SUPPORT RAIL .............................................................................................. 31 7.5.3. LUBRICATION OF THE CHAINS AND CHAIN SUPPORT RAIL ................................ 31 7.5.4. CHAIN ADJUSTMENT ................................................................................................ 31 7.5.5. CHAINS AND SPROCKET WEAR .............................................................................. 32 7.5.6. SPINDLE LUBRICATION ............................................................................................ 33 7.6. SPARE PARTS ........................................................................................................... 34 8. BLOWING TECHIQUE ............................................................................................... 36 8.1. BEFORE FIBER BLOWING ........................................................................................ 36 8.2. PREPARING THE DUCTS FOR FIBER BLOWING .................................................... 36 8.3. INITIATING FIBER BLOWING .................................................................................... 37 8.4. USE OF COMPRESSED AIR FOR FIBER BLOWING ................................................ 38 8.5. USE OF WATER FOR FIBER FLOATING .................................................................. 38 9. CESSATION OF USE ................................................................................................. 39 9.1. DISMANTLING ........................................................................................................... 39 9.2. SCRAPPING ............................................................................................................... 39

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 10. EC DECLARATION OF CONFORMITY ..................................................................... 40 11. APPENDIXES ............................................................................................................. 41 11.1. HYDRAULICS SCHEMATICS ..................................................................................... 41 11.2. PNEUMATICS SCHEMATICS .................................................................................... 42 11.3. DRAWINGS OF MECHANICAL CONSTRUCTION ..................................................... 43

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK BEST WARRANTY IN THE BUSINESS We offer a unique 36 months warranty on all our fiber blowing machines resulting, guaranteeing you the best value for your money. Our 12 months warranty is automatically included when you purchase your Fremco fiber blowing machine, you automatically get our 12 months warranty. You can then claim your additional 24 months warranty at any point during the following three months in order to obtain the best cost- beneficial warranty in the business. To maintain your 36 months warranty, you must meet the given annual service and maintenance requirements for each machine as described in the operating manual. Learn more at www.fremco.dk/warranty and get the best factory warranty in the business today!

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 1. INTRODUCTION Original instructions These instructions are Fremco A/S’ original instructions for the PowerFlow RAPID and/or MultiFlow RAPID (hereafter called the machine). Purpose The purpose of these instructions is to ensure correct installation, use, handling and maintenance of the machine. Accessibility The instructions are to be kept in a location known to the staff and must be easily accessible for the operators and maintenance personnel. Knowledge It is the duty of the employer (the owner of the machine) to ensure that everybody operating, servicing, maintaining, or repairing the machine reads and understands the instructions. As a minimum, they should read the part(s) relevant to their work. In addition to this, everybody operating, servicing, maintaining, or repairing the machine is obliged to seek out information in the operating manual when needed.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 2. GENERAL 2.1. MANUFACTURER The machine is manufactured by Company name: Fremco A/S Company address: Ellehammervej 14 DK-9900 Frederikshavn 2.2. THE MACHINE’S DESIGNATION The machine’s complete designation is PowerFlow RAPID or MultiFlow RAPID. 2.3. MACHINE PLATE The machine plate is situated on the front of the machine: Figure 1: Location of machine plate

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 2.4. MACHINE MARKINGS The machine is equipped with the following safety markings: • Hand crush hazard symbol • Max. air pressure on the Flex block RAPID

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 3. OVERVIEW AND APPLICATION 3.1. GENERAL DESCRIPTION The machine consists of: • Hydraulic control valve unit • PowerFlow RAPID/MultiFlow RAPID unit: o Inlet with digital counter o Chain drive unit o Flex block RAPID 3.2. THE MACHINE’S PURPOSE AND INTENDED USE The machine is constructed for blowing fiber optic cables into microducts. MultiFlow RAPID can also be used to reline multiple microducts. The machine may only be used for these exact purposes. PowerFlow RAPID has a fiber/cable OD of 5.5-25 mm and a duct size OD of 10-63 mm*. MultiFlow RAPID has a fiber/cable OD of 5.5-32 mm and a duct size OD of 10-63 mm*. Only instructed operators may operate the machine. Similarly, only qualified personnel may perform service, maintenance, and repairs on the machine. The machine is suited for use in an outdoor environment. Inlet Chain drive unit Flex block RAPID Control valve unit

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Only suitable CE-marked equipment (hydraulic and pneumatic compressor) may be connected to the machine. The machine is not to be used for any other purpose than those provided above *Standard duct size OD for PowerFlow RAPID and MultiFlow RAPID: 14-60 mm. Custom duct size OD for PowerFlow RAPID and MultiFlow RAPID: 10-13 mm & 61-63 mm. 3.3. WARNING - FORESEEABLE MISUSE Before using the machine, operators must ensure that: • The guarding is intact • The operator is able to monitor all machine movements • The hydraulic and pneumatic hoses are undamaged • There is no damage to any pressure caring component • The machine is mounted/placed in a stable and secure manner regarding its foundation and general surroundings • The required energy supply is available • All safety functions are active and functional The operator must NOT under any circumstances: • Reach into/touch the chain drive while the machine is in operation • Exceed the maximum supply pressure of hydraulic control unit, water and air. Machine surfaces must be kept clear of clutter and must not be used as work surfaces. 3.4. TECHNICAL SPECIFICATIONS Service life expectancy The machine gas a minimum service life expectancy of 20 years. Maintenance and replacement of machine parts and safety-related components must be carried out on a routine basis. This must be done in accordance with the operating instructions of the individual components.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 3.4.1. PHYSICAL DIMENSIONS IN METRIC UNITS Machine: Hydraulic control unit: PowerFlow RAPID: MultiFlow RAPID: Length: 950 mm Length: 1050 mm Width: 400 mm Width: 400 mm Height: 500 mm Height: 500 mm Weight: 45 kg Weight: 51 kg 3.4.2. PHYSICAL DIMENSIONS IN IMPERIAL UNITS Machine: Hydraulic control unit: PowerFlow RAPID: MultiFlow RAPID: Length: 38” Length: 41” Width: 16” Width: 16” Height: 20” Height: 20” Weight: 99Ibs Weight: 112Ibs 3.4.3. PNEUMATICS Air consumption: up to 10 m3/min free air per minute at max. 16 bar The quality of compressed air must at least comply with the requirements of ISO 8573-1:2010 “Compressed air - Part 1: Contaminants and purity classes”. Particles: Class 5 Water: Class 7 Oil: Class 4 The compressed air temperature should not exceed 8°C above the ambient temperature. Control unit Length: 260 mm Width: 230 mm Height: 300 mm Weight: 12 kg Hose length: 1500 mm Control unit Length: 10” Width: 9” Height: 12” Weight: 26Ibs Hose length: 60”

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 3.4.4. HYDRAULICS Oil consumption: 18 l oil per minute at max. 110 bar Filtrated to below 25 μm 3.4.5. NOISE Airborne noise emitted by the machine: Measured sound pressure level: 85 dB(A) Necessary measures must be taken to reduce noise at the workplace to an acceptable level. The discharge of compressed air from the machine may cause noise level to increase. This can be reduced by using the correct gasket size. Worn gaskets can also result in an increased noise level. In addition to noise generated by the machine, the noise produces by additional process equipment (e.g. the compressor or hydraulic pump). 3.5. OPERATING POSITIONS, LOCATION AND ARRANGEMENT The operator’s workstation is located the front of the machine, next to the control unit. During maintenance and repair: - The area adjacent to the machine should also be considered as the workstation. Space requirements: There must be sufficient space in the workplace for the operator to operate the machine unrestrictedly and comfortably. It is recommended to maintain a space of at least 700 mm between barriers (walls, building parts. Etc.) and controls. Operation and storage limits: Ambient temperatures -5 °C to 40 °C Relative humidity (non-condensing) Min. 10 % RH Max. 80 % RH

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 3.6. USER INTERFACE Below, you will find all operating handles and a short description of their use: Handle for control valve • Provides Manometer readout of max. hydraulic oil pressure (110 BAR/1595 PSI) • Enables speed and torque adjustment • Handle moves forward/backwards • Attach the end of the hose with the yellow markers to the hydraulic unit. Air valve • Controls the amount of air entering the blowing chamber. • Picture shows the OPEN position. • Turn clockwise to close, turn anticlockwise to open. Vent valve • Releases air pressure from the duct and blowing chamber before opening the Flex block. • Picture shows the OPEN position, turn anticlockwise to close.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Quick coupling (air/water) • Connects to the EU/US claw coupling for the airhose. • The EU (DIN 3238) claw coupling is mounted by default. • The US claw can be found in the box. Safety valve • Air over pressure relief valve. Set to release pressure above 16 BAR/230 PSI. Handle for spindle. • Rotate clockwise to move top chain down towards bottom chain. • Rotate anticlockwise to move top chain up and away from bottom chain. Manometer • Provides readout of currentl pressure in flex block RAPID. • Maximum pressure 16BAR/230 PSI.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Digital distance and speed counter • Readout 1 shows the total length of fiber passing the counter. • Readout 2 shows the speed of fiber passing the counter. • Blue button resets total meter counter. 3.7. MACHINE ASSEMBLY AND ADJUSTMENT Parts in the Flex block RAPID Duct holder inserts and adaptors are chosen according to the duct size. The same goes for choosing nylon sealing and cable sealings. The O-ring should be adjusted depending on the adaptor and duct size. Nylon seals Adaptor (top) Duct holder insert Cable sealings x3 Adaptor (bottom) O-ring Duct holder insert Duct holder

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 1. 2. Not mounted 3. Mounted Mounting the Flex block RAPID Mounting the Flex block RAPID to the machine involves sliding the bottom part of the Flex block RAPID onto the steel bracket bars (Picture 1). Slide the block onto the bars until it clicks into place, and tighten the hand knob (Picture 3). If you have not mounted the Flex block RAPID properly, you will not be able to see the locking mechanism (Picture 2). However, when the Flex block RAPID is mounted properly, the lock mechanism will be shown (Picture 3). To dismount the Flex block RAPID, repeat the process backwards. 1. 2. 3. 4. Adjusting the Flex block RAPID Before any fiber blowing job, ensure that the flex block RAPID is adjusted to the machine. You can adjust the height and length. Adjusting the height Find the hand knob beneath the Flex block RAPID (Picture 1) and turn to adjust the height of the flex block RAPID until the nylon guides aligns with chains on the machine (Picture 2). Adjusting the length Find the hand knob at the end of the steel bracket bars (Picture 3) and turn to adjust the length until the gap between the nylon seal and chain is as small as possible (approximately 2 mm). Make sure that the nylon guides do NOT touch the chains. Steel bracket bars Hand knob

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 1. 2. 3. 4. 5. Opening and closing the Flex block RAPID To open the Flex block RAPID, unscrew four hand knobs (Picture 1). The two hand knobs on the operational side can now be loosened/moved away. Pull the round hand knob on top of the flex block RAPID upwards and and pull away from the operational side to open the flex block RAPID (Picture 2). Now continue with the duct holder, as shown in pictures 3, 4 & 5. To close the Flex block RAPID, repeat the process backwards. 1. Inlet for single cable 2. Inlet for relining Parts in the inlet • Adjust the rollers to centre the cable or multiple ducts. • The digital distance and speed counter is pre- mounted on the inlet. Rollers Nylon guides for microduct

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 4. SAFETY AND RESIDUAL RISKS This information is relevant for both operators and maintenance personnel. 4.1. BUILT-IN SAFETY MEASURES The machine has been fitted with fixed guards for the safety of personnel/operators. To prevent over pressurising the pneumatic system, the machine is equipped with an over pressure relief valve. 4.1.1. SAFETY FUNCTIONS Safety Function 1 Safety function Description Hold-to-run system for forward and backward operation of the chain drive. The operation of the machine is implemented as a hold-to-run system. This means that the operator must perform a continuous actuation on the joystick on the hydraulic control unit in order for the machine to produce movement. If the actuation ceases, the joystick will return to neutral and all machine movement stops immediately. Over pressure relief valve for the pneumatic system The machine is equipped with an over pressure relief valve, to prevent over pressurising the pneumatic system. These safety features must always be active and must not be overridden. Shut-off valve: The machine is equipped with a quick coupling to enable the quick release of the hydraulic and pneumatics systems. Test intervals: If the below test limits are exceeded, consider the safety features to invalid and unable to protect operators from the hazards of the machine. Safety features must be tested several times a year.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 4.2. SAFETY MEASURES, TO BE TAKEN BY THE USER 4.2.1. CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE) During daily use: The designated PPE must always be used in accordance with Fremco A/S’ guidelines and safety data sheets and according to the applicable national regulations. • PPE, in the form of safety glasses and safety shoes must be used during daily operation of the machine. Do NOT wear any loose clothing, jewellery, scarves, etc. while operating the machine. During maintenance and repair: Appropriate PPE must be used for repair and maintenance work. The area around the machine must be cleaned of spills and other items. The manufacturer's instructions must be followed when replacing a machine component. • PPE in the form of work gloves, safety shoes and head protection must be worn when transporting parts. • Approved lifting equipment in the form of a crane and hoist must be used when handling heavy parts.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 4.2.2. HANDLING OF DANGEROUS SUBSTANCES AND MATERIALS Chemicals and hydraulic fluids: PPE must be used in accordance with the individual product’s safety data sheets when: • Handling/using hydraulic fluids • Installing of liquid-filled components • Maintaining liquid-filled components • Handling hoses/couplings containing liquid, etc. Disposal of products and other waste must be done in accordance with the guidelines for the materials in question. 4.2.3. RESIDUAL RISKS Consider the following residual risks during maintenance and repair: • Accumulated energy in pneumatics or hydraulics • Contact with hydraulic oil and/or lubricants Before service and repair or maintenance, ensure the following: • The machine has been disconnected from its energy supply • Accumulated energy has been relieved • The proper PPE is being used. 4.2.4. WORK PROCEDURES Before operating the machine, the following must to be ensured: • The site of operation suitable or has been made safe for operation • Weather conditions allow for safe operation of the machine • The area adjacent to the machine is kept clean and free from objects that may cause the operator to slip and fall or getting caught in the machine’s cables • The area adjacent to the machine is kept free from unwanted personnel • There is adequate lighting to safely operate the machine • The safety glasses and gloves are worn when connecting and disconnecting hydraulic components • Protective glasses and protective gloves are worn when servicing hydraulic components. • All machine components and energy supplies have been correctly installed.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK • The ducts and fibers have been properly connected and adequately secured • Compressed air is not being supplied to an open flex block RAPID. Start up and operation to be performed under the following conditions: • Operations are initiated and monitored by trained personnel. • Operation can be ceased from the control panel. 4.2.5. IN CASE OF EMERGENCY In case of emergency, follow these three steps: 1. Turn off the machine 2. Disconnect all power sources (compressor and power pack) 3. Call for help 4.2.6. VIOLATION OF SAFETY REGULATIONS Any violation of the safety regulations can result in serious personal injury and possible machine damage.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 5. TRAINING 5.1. OPERATORS The machine may only be operated by qualified operators. Operators must be familiar with the machine's function and safety conditions. Operators must read and understand the operating manual, workplace instructions, etc., and understand of the machine's function and safety measures. They must also be able to perform general adjustments, etc., and be trained/instructed in the machine's use, handling etc. through reviewing the operating manual, operating instructions, and workplace instructions. Operators must be familiar with the location of secure access ways. 5.2. MAINTENANCE PERSONNEL Service, repairs, and maintenance may only be carried out by qualified maintenance personnel. Maintenance personal must understand the machine's function and safety measures and be familiar with the location of secure access ways and emergency stops. Maintenance personnel must have read and understood the operating manual, workplace instructions, etc. Before starting work, maintenance personnel must be instructed in the machine’s safety. New maintenance personnel must be trained by an experienced colleague.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 6. OPERATION The information in this section is relevant for operators. 6.1. TRANSPORTING THE MACHINE When transporting the machine, it is important you make sure that the machine is secure and stable throughout the entire journey. When the machine arrives at the fiber blowing site, it must be carried by two people must or be transported in accordance to national requirements and regulations. Before initiating fiber blowing, it is important that the operator fixes the machine on e.g. a trolley or a box. 6.2. START/STOP Before initiating operation, the operator must ensure that they have full visibility over the machine, and that no unnecessary personnel are in the immediate vicinity. This also means that the area must be adequately lit. In addition, the operator must ensure that the controls and connectors are clearly and unambiguously marked in order to prevent faulty operation. When in close proximity to machine, operators must be extra aware of the machine’s movement. 6.3. ENERGY SUPPLY CONNECTION/DISCONNECTION AIR/WATER CONNECTED AIR/WATER DISCONNECTED

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK HYDRAULICS CONNECTED HYDRAULICS DISCONNECTED Push the joystick towards yourself to make the fiber/cable go forward. To reverse fiber/cable, push the joystick away from yourself. Use the hand knobs to adjust the maximal speed. Turning the hand knob clockwise decreases the speed and torque. Turning the knobs anticlockwise increases the maximum speed and torque.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 6.4. FEEDING/REMOVING PRODUCTS The operator manually feeds the machine with a fiber optic cable, by passing it through the inlets, chain drive and Flex block RAPID. After the operation has been completed, the fiber optic cable is manually removed from the machine. 6.5. AIR/WATER SUPPLY To apply air to the machine and Flex block RAPID, gradually turn the air valve gradually on. Never supply compressed air to an open Flex block RAPID. AIR ON AIR CLOSED

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 7. MAINTENANCE, TROUBLESHOOTING AND REPAIR The information in this section is relevant for maintenance personnel. 7.1. QUICK GUIDE TO MAINTENANCE, TROUBLESHOOTING AND REPAIR Before repair, maintenance, etc. commences, disconnect (lock) and vent or depressurize energy sources. • Disconnect and vent/depressurize pneumatics and hydraulics • Do not reconnect the supply until the maintenance work is complete This prevents accidental start-up of the machine • Always use suitable PPE when performing repair or maintenance work • If additional light is needed, maintenance personnel must obtain this before starting work • Machine personnel must exercise extra caution when the machine is in operation if they have disassembled the machine or are handling spare parts or tools • Following completion of maintenance or repair, the operator must inspect the entire machine for faults and defects before restarting. 7.2. PREPARATION FOR MAINTENANCE AND REPAIR 7.2.1. CLEANING AND ORDER Maintenance personnel must be informed of the location of potential hidden hazards before the work commences. During cleaning, the machine must be switched off (disconnected from energy supply), and PPE must be used in according with the data sheets for the product in question. During daily operation, the operators must not handle tools or spare parts near the machine. Operators must also keep the area adjacent to the machine clear of people and objects that may cause operators to slip and fall or to get tangled and caught in the machine.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 7.2.2. CORRECTIVE MAINTENANCE If the machine produces noise, unusual vibrations, etc., locate the fault and rectify it. If this is not possible, contact maintenance personnel. In general, maintenance and repairs should be carried out by qualified personnel with the necessary background. Parts and components should only be replaced with identical parts fitted by the manufacturer. All written information and warnings must be formulated in the official community language. In the case of unreadable or indistinct information and warnings, these must be immediately replaced with new ones. 7.2.3. REPAIR Maintenance personnel must be informed of the location of potential hidden hazards before the work commences. Before commencing any repair or maintenance work the machine must be disconnected and vented from the pneumatic and hydraulic. This is to prevent unintentional start-up of the machine. Machine personnel must exercise extra caution when the machine is in operation if they have disassembled the machine or are handling spare parts or tools. 7.3. SERVICE AND REPAIR ADDRESS In the case of defects or need for repairs, please contact either the designated reseller in your country or Fremco for help. Company name: Fremco A/S Address: Ellehammervej 14, DK-9900 Frederikshavn, Denmark

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 7.4. DISCONNECTION AND DEPRESSURIZATION OF ENERGY SOURCES Before disconnecting energy sources, the systems should be depressurized • Stop compressor and hydraulic Power Pack • Depressurise the hydraulic system by moving the hydraulic control unit joystick forwards and backwards two times (this may make the machine’s chains move a little) • Depressurise the pneumatic system by opening the vent valve on the flex block RAPID and then slowly opening the main air valve until all air has been vented out • Now disconnect the hydraulic and pneumatic quick couplings. Vent valve Main valve Joystick Power connections Air/water coupling: Hydraulic coupling:

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 7.5. MAINTENANCE SCHEDULE Below, you will find the daily, weekly, monthly and annual inspection and maintenance schedule. If spare parts are defective or worn to an extend that is unacceptable, these parts should be replaced/fixed before continued use. Daily inspection and maintenance Daily inspection and maintenance must be performed by a trained operator, before startup and with energy sources disconnected (quick couplings) # Task Instructions 1 Check that pressure bearing hydraulic parts undamaged Visual inspection 2 Check that pressure-bearing pneumatic parts are undamaged Visual inspection 4 Check that mechanical parts, including guards, are undamaged and correctly mounted Visual inspection 5 Check that warning signs are intact Visual inspection 6 Check that the chain is intact and undamaged Visual inspection 7 Perform daily cleaning tasks Brush with a stiff brush (not a steel brush) and wipe with a slightly damp cloth, possibly using a mild detergent PPE for inspection and maintenance * Gloves for protection against hydraulic fluids and lubricating oil * Safety glasses Weekly inspection and maintenance Weekly inspection and maintenance must be performed by a trained operator before startup and with energy sources disconnected (quick couplings) # Task Instructions 1 Ensure the chains and chain support rail are sufficiently lubricated See description 2 Check the chain adjustment See description 3 Check the gaskets Inspect for visible signs of wear. Replace any parts in the case of excessive wear PPE for inspection and maintenance * Gloves for protection against hydraulic fluids and lubricating oil * Safety glasses

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Monthly inspection and maintenance Monthly inspection and maintenance must be performed by a trained operator before startup and with energy sources disconnected (quick couplings) # Task Instructions 1 Ensure the spindle and 2 pcs. of nipples are sufficiently lubricated See description 2 Check the chain support rails See description 3 Check the chains and sprockets See description 4 Check the format parts Inspect for visible signs of wear. Replace any parts in case of excessive wear 5 Monthly cleaning Brush with a stiff brush (not a steel brush) and wipe with a slightly damp cloth, possibly using a mild detergent. Wipe the chain support rail, chains, and sprockets clean of lubricant residues, using a suitable cleaning agent (with the chains removed) PPE for inspection and maintenance * Gloves for protection against hydraulic fluids and lubricating oil * Safety glasses Annual inspection and maintenance Annual inspection and maintenance must be performed by Fremco or another qualified service partner before startup and with energy sources disconnected (quick couplings) # Task Instructions 1 Check the safety functions Ensure that the hold-to-run function works as intended and the machine stops when the control valve is released 2 Check the pressure gauge Check the pressure gauge for accuracy 3 Check the air pressure relief valve Ensure the air pressure relief valve functions as it should 4 Check the hydraulic pressure relief valve Ensure the hydraulic relief valve functions as it should PPE for inspection and maintenance * Gloves for protection against hydraulic fluids and lubricating oil * Safety glasses 7.5.1. VISUAL INSPECTION If any components are visibly worn, damaged and/or incorrectly mounted, this must be rectified before the machine is operated.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 7.5.2. CHAIN SUPPORT RAIL The chain support rail must be replaced in case of one of the following wear indicators: • The rail is worn to 8.5 mm • The distance between the chain and chain support rail reaches a minimum of 1 mm 7.5.3. LUBRICATION OF THE CHAINS AND CHAIN SUPPORT RAIL Chains are lubricated using a suitable chain lube spray. Spray a thin coat of chain lube between the chain and chain support rail, along the full length of the support rail and on both sides of chains (top and bottom). 7.5.4. CHAIN ADJUSTMENT Adjust the chains using the two sets of chain tensioning screws. The chain has been tightened correctly when it can be lifted 2-3 mm from the chain support rail with two fingers (see picture below). This test should be performed in the middle of the machine. When adjusting the chain, remember to tighten the screws evenly to ensure that the shaft is perpendicular to the chain and chain support rail.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Tensioning screw 7.5.5. CHAINS AND SPROCKET WEAR Visually inspect the chains and sprockets for any wear. If the wear exceeds what is reasonable, the chains and sprockets must be replaced. Indications of worn chains and sprockets: • The chains have clear and deep wear marks from the chain support rail • The rubber on the chains have large deformations on the front and back edges due to wear • The chain teeth of the sprockets are clearly and visibly deformed It is always recommended to replace the chain and sprockets together with chain support rail. Pictures of chains and chain parts that exceed reasonable wear: Chains: 2-3 mm

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Support rails Sprockets 7.5.6. SPINDLE LUBRICATION Lubricate the spindle with multipurpose grease. • To start, screw the spindle handle all the way up to expose the threads, and lift it off. Now, brush a light coat of grease onto the threads before screwing the main bolt down again • Pump grease into the two grease nipples using a suitable grease gun. Use one or two pumps for each nipple

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK • Finish by wiping all excessive grease off the machine 7.6. SPARE PARTS The list below is an overview of spare parts for the machine. It is important to replace spare parts when they are no longer viable for use. This should be checked during the daily, weekly, monthly, or annual inspection and maintenance of the machine. Cable sealings Cable sealings are available in multiple sizes. Spare parts can be ordered through the designated reseller in your country. Chains and support rails The chain and support rails are available in multiple sizes. Spare parts can be ordered through the designated reseller in your country.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK Nylon seals Nylon seals come are available in multiple sizes. Spare parts can be ordered through the designated reseller in your country. Air/water-tight plug for microducts This part is used for relining with the MultiFlow RAPID Relining, and is available in multiple sizes. Spare parts can be ordered through the designated reseller in your country Valve for microduct This part is used for relining with the MultiFlow RAPID Relining, and is available in multiple sizes. Spare parts can be ordered through the designated reseller in your country

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 8. BLOWING TECHIQUE The information in this section is relevant for operators. 8.1. BEFORE FIBER BLOWING 1. Check the compressor air levels. It is important to have enough air (at least 10 bar with the larger machines)* PowerFlow RAPID & MultiFlow RAPID o Airflow: 8000-12000 l/min o Pressure: 8-12 bar *Never exceed the recommended air pressure 2. Take note of the distance marking on the fiber/cable. 3. Do not fill duct to exceed 70-75% capacity 8.2. PREPARING THE DUCTS FOR FIBER BLOWING 1. Clean the duct For cable between 3 and 32 mm, clean the duct with sponges before installing cable. Check that the sponge/sponges have arrived at the end of the duct. Blow the sponge/sponges through duct until they are clean (1-3 times).

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 2. Perform a pressure test Perform a pressure test by blocking the duct at the opposite end and applying max. 10 bar of air pressure. Check for pressure loss. The duct should be able to hold the pressure for a minimum of 5 minutes. 8.3. INITIATING FIBER BLOWING 1. Apply lubrication Put a ‘leading’ sponge inside the duct and apply the recommended amount of lubrication. Add 1-3 sponges after the lubrication has been applied. Apply air pressure. The extra sponge/sponges hold the lubrication, allowing for a smooth application of lubrication to the duct. 2. Remember the airflow principle Start the fiber blowing installation according to the airflow principle A) Start feeding the cable into duct without applying air. B) Check with your hand that you can hold/stop the cable at all times. This should make the wheel/chain spin while the cable is not moving. C) Apply the air in ¼ amounts as the speed is decrease. D) Reduce speed in cases of obstacles during full airflow. 3. Reduce speed in case of obstacles during full airflow

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 8.4. USE OF COMPRESSED AIR FOR FIBER BLOWING ▪ Add approximately 100-500 ml lubricant to the duct, and then place a foam plug in the duct as well. Follow the instructions on the lubrication bottle ▪ Connect the duct to the flex block RAPID ▪ Connect the compressed air to the flex block RAPID ▪ Turn on the air to the flex block RAPID – only for a short time – until the foam plug comes out at the other end of the duct ▪ Turn on the hydraulic MultiPower Pack and let it run for 2-3 minutes. Start the machine by moving the joystick on the hydraulic control unit. ▪ Gradually increase the airflow to the flex block RAPID. CAUTION: Check continuously that the drum is turning smoothly. If not, check the pressure of the top chain on the fiber cable. Increase the pressure if necessary. 8.5. USE OF WATER FOR FIBER FLOATING ▪ Connect the duct to the flex block RAPID. ▪ Connect the suction tube from the water pump to the water supply. ▪ Start the engine on the water pump and let it run for approximately 4-5 min. ▪ Connect the pressure tube from the water pump to the flex block RAPID Turn on the hydraulic MultiPower Pack and let it run for 2-3 minutes. Start the machine by moving the joystick on the hydraulic control unit. ▪ Gradually increase the airflow to the flex block RAPID. CAUTION: Check continuously that the drum(s) is turning smoothly. If not, check the following: • Is there sufficient air pressure in the microduct(s)? • Is there sufficient water pressure and flow= • Is there sufficient pressure on the top chain on the microduct(s)?

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 9. CESSATION OF USE 9.1. DISMANTLING Before dismantling the machine, a plan must be prepared detailing this purpose. The plan must include a risk assessment for the work as well as for the disposal of machines and machine parts. 9.2. SCRAPPING The machine must not be disposed of as unsorted household waste. Use the local WEEE collection points to dispose the machine and make sure that all relevant provisions are complied with.

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 10. EC DECLARATION OF CONFORMITY 2006/42/EC Annex II A Manufacturer: Name Fremco A/S Address Ellehammervej 14 Postal code and city DK-9900 Frederikshavn The person authorized by the manufacturer to compile the technical file: Name Jacob Lindrup Kühn Address Ellehammervej 14 Postal code and city DK-9900 Frederikshavn Hereby declares that machine type: - PowerFlow RAPID/MultiFlow RAPID Has been produced in accordance with the following EU directives: - 2006/42/EC Machinery directive with the employment of the following harmonized standards: - EN ISO 4413 - EN ISO 4414 Managing Director DK-9900 Frederikshavn 01.01.2021 Kim Lindblad Carlsen Occupation Place Date

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 11. APPENDIXES 11.1. HYDRAULICS SCHEMATICS

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 11.2. PNEUMATICS SCHEMATICS

FREMCO A/S ELLEHAMMERVEJ 14 | DK9900 FREDERIKSHAVN, DENMARK | VAT NO.: DK30815416 TELEPHONE +45 7230 1213 | [email protected] | WWW.FREMCO.DK 11.3. DRAWINGS OF MECHANICAL CONSTRUCTION