Comstar Supply

5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426

Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
USER’S GUIDE & SAFETY MANUAL
Y-Block
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Fax: 610-831-5012
Important Safety Notice

Read and understand all procedures and safety instructions before using a Condux Y-
Block. 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. No comprende las instrucciones favor de consultarle a su jefe.
Save this user’s guide for future reference
COMMUNICATIONS WITH THE MANUFACTURER

For information related to the machine (use, maintenance, spare parts) always-state model
number, manufacturing Year and Order. This date can be found on the parts identification
label
Manufacturer:
Condux International, Inc.
145 Kingswood Road
Mankato, MN 56002-0247
1-507-387-6576
Fax 1-507-387-1442
E-mail: [email protected]
If you have questions on:
Safety – Operations – Applications
Call 1-800-533-2077
5 Blue Heron Drive
Fax: 610-831-5012
Table of Contents
General Information…………………………………………. Page 4
Y-Block Set Up ……………………………………………… Page 5 – 9
Y-Block Orientation………………………………………….. Page 8
Y-Block Parts Breakdown……………………………………. Page 9
Y-Block Duct Pack Selection Chart…………………………... Page 10
Recommended Blowing Lubricant……………………………. Page 10
Replacement Parts & Accessories…………………………….. Page 11
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5 Blue Heron Drive
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General Information
General Product Use
a. Only qualified operators should use this product. The operator should only
be the person who received qualified training from the product owning
company or trained by the manufacturer.
b. Product must only be used for the work it was designed for.
c. Product is not to be used with unauthorized personnel on the job site
d. Should there be any doubt concerning use, functioning, maintenance or
anything else, please contact the factory or factory representative.
Operator Qualifications
a. Operator must know the required safety directives to run the product that
are pertinent to the country where it is being used.
b. Operator in charge of the product and installation project must be
appropriately dressed, avoiding large clothes, hanging jewelry or whatever
might become entangled in the moving parts
c. Operator must also wear the necessary protective equipment such as
gloves, boots, helmet, etc.
d. Operator must carefully follow all advisements contained in the instruction
manual or on the machine
e. Operator must have work area kept clean of obstacles that might inhibit a
safe working area.
Maintenance Qualification
a. Periodically inspect product for wear and tear.

b. Authorized and trained personnel must do all maintenance operations.
Trained personnel are defined as people who have received qualified
training from the using company or from the manufacturer
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Set Up the Y-Block

1. Loosen the 8 nuts on the Y-Block assembly (Figure 1). Remove Innerduct
Clamp (Figure 2) and Air Block Cover (Figure 3).
Figure 1 Loosen Nuts Figure 2 Remove Duct Clamps
Figure 3 Remove Air Block Cover
1. Select the correct Condux Duct Components according to the innerduct

size. Refer to the Duct Selection Chart on Page 10
2. Choose the correct Innerduct Seal and install both halves securely. Use
the provided 3/32-inch hex wrench (Figure 4).
3. Choose the correct Conduit Clamp and install both halves (same color
as the conduit seal). Use the provided 3/32-inch hex wrench (Figure 5).
5 Figure 4 Inseart Duct Clamps Figure 5 Insert Duct Seals
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5. Place innerduct in the Innerduct Seal and Innerduct Clamp on both the enter
and exit side of the Y-Block. Note placement up to ridge on Innerduct Seal
(Figure 6). Make sure lay static cable in the Y-Branch of the Y-Block as seen
in Figure 6.
6. Clamp Innerduct in place (See Figure 7).
Figure 6 Insert Duct Figure 7 Clamp Innerduct
7. Choose correct Cable Seal and install around cable (Figure 8) and push into the
provided slot, split side down (Figure 9).
8. Hand push cable to be installed from the blower into the Y-Block (Figure 10)
Figure 9 Install Cable Seal in Slot

Figure 8 Install Cable Seal
6 Figure 10 Hand Push Cable into Y-Block
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9. Install Air Block Cover and Secure (Figure 11) Tighten bolts securely, but do
not over tighten. Use a cross tightening procedure with the hold down bolts.
Note: Figure 12 shows a correctly sealed Condux Y-Block
Figure 11 Install Air Block Cover
Figure 12 Sealed Y-Block
!WARNING: Forced air creates flying debris. Always wear

personnel protective equipment. Severe personnel injury could
result.
!WARNING: Ensure no personnel are in the destination access vault

during the blowing operation. Severe personal injury could result.
!WARNING: Y-Block Assembly contains compressed air when

blower is operated. Opening the Y-Block while under pressure may
cause serious personal injury. Ensure blower is depressurized before
removing Y-Block Cover.
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Y-Block Orientation
Cable Seals Existing Fiber Cable
Duct Clamp
Duct Seal
Blower Entrance Side

Exit Side
8
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Y-Block Parts Breakdown
Figure 1 - Condux Y-Block Parts Breakdown
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Item Part Number Description QTY

1 FLATWSHR 0.25 TYPEA-NARR ST CZ 8
2 02228100 PIN,DOWEL 0.250 DIA-1.500 LONG 8
3 02241900 HANDLE,FLDNG-2.25HGH-4.25LG-CZ 2
4 02269734 LABEL,WARNING-AIR SPLY 1.5X4.5 1
5 02269737 LABEL,WARNING-135 MAX 1.5X4.5 1
6 QUAD-RING,.210CS CORDSTOCK X 30.88 (SEE KIT 08761443) 1
7 NUT 0.37-16 HEX SWIVEL FLANGE 8
8 02288362 CAPSRW #10-32X0.75 CSSTALY PL 8
9 02288894 LABEL,ISO WARNING-HOT SURFACE 1
10 02289161 CAPSRW 0.25-28X1.25 SHSTALY PL 20
11 08089753 LABEL,CONDUX 1.75 X 5.50 WHITE 1
12 08761856 Y-BLOCK BODY - LOWER 1
13 08761857 Y-BLOCK BODY - UPPER 1
14 BLOCK,LOWER CLAMP/SEAL-YBLK (SEE KIT 08761891) 2
15 BLOCK,UPPER CLAMP/SEAL-YBLK (SEE KIT 08761891) 2
16 BLOCK,SWING BOLT PIVOT-LOWER (SEE KIT 08761889) 4
17 BLOCK,SWING BOLT CLAMP-UPPER (SEE KIT 08761890) 4
18 BOLT,CLAMP Y-BLOCK (SEE KIT 08761888) 8
19 BLOCK,CABLE SEAL RUBBER SM SGL (SEE KIT 08761892) 1
20 BLOCK,CABLE SEAL RUBBER LG DBL (SEE KIT 08761893) 1
21 NUT 0.25-20 NYLOC ST GR2 CZ 8
REPAIR KITS
08761443 KIT,SEAL REPLACEMENT-FO BLOWER-INCLUDES ITEM 6
08761888 KIT,CLAMP BOLT REPAIR
-INCLUDES ITEMS 1 (1), 2 (1), 7 (1), 18 (1), 21 (1)
08761889 KIT,CLAMP BOLT BRKT LOWER
-INCLUDES ITEMS 10 (2) AND 16 (1)
08761890 KIT,CLAMP BOLT BRKT UPPER
-INCLUDES ITEMS 10 (2) AND 17 (1)
08761891 KIT,CLAMP BLOCK
-INCLUDES ITEMS 1 (2), 2 (2), 7 (2), 10 (2), 14 (1), 15 (1), 18 (2), 21 (2)
08761892 KIT,CABLE SEAL - SINGLE
08761893 KIT,CABLE SEAL - DOUBLE
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5 Blue Heron Drive
Fax: 610-831-5012
Y-Block Duct Pack Selection Chart
Part Duct
Number Description OD
08761386 DUCT PK,Y-BLOCK 1.315 (33.4) 1.315
08761387 DUCT PK,Y-BLOCK 1.660 (42.2) 1.660
08761388 DUCT PK,Y-BLOCK 1.900 (48.3) 1.900
08761389 DUCT PK,Y-BLOCK 2.375 (60.3) 2.375
Recommended Blowing Lubricants
Polywater® Prelube 2000™

Specially formulated for use with fiber optic cable blowing systems, Polywater® Prelube 2000™ has been
field proven with the Deluxe LW Blower. This lubricant is a special lubricant used to prelubricate the conduit
system before installing the cable. Prelube 2000™ is compatible with all types of cable jackets and
conduit types.
Std
Pkg
Part Number Description Qty
08230600 1 Quart (.9 liter) Squeeze Bottle 12/case
08230601 1 Gallon (3.8 liter) Jug 4/case
08230900 1 Quart (.9 liter) Squeeze Bottle Winter Grade 12/case
08230901 1 Gallon (3.8 liter) Jug Winter Grade 4/case
Polywater® Prelube 2000™ recommended usage quantity
Lubricant Quantity
Duct Size Per 1,000 Feet Per Kilometer
1 inch 3 fl. oz. 300 ml
1.25 inch 4 fl. oz. 400 ml
1.5 inch 5 fl. oz. 500 ml
2 inch 6 fl. oz. 600 ml
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Replacement Parts & Accessories
Cable Jacket Slitter

This popular tool makes quick, safe work or removing sheath and turnplate from communication
cables. With a turn of the handle, the toothed wheel pulls the tool forward while the angled blade
makes a clean cut. Blade guard protects conductors from damage. Also excellent for slitting
innerduct. Minimum cable diameter 1” (25mm)
Part Number Description

08012900 Cable Jacket Slitter
08012901 Replacement Blade
Triple Shuttles
These unique, flexible shuttles in a triple parachute configuration make installing rope; pull tape
or fiber cable in occupied duct a breeze.

08761868 SHUTTLE,CABLE 1.00/1.25 DUCT
08761869 SHUTTLE,CABLE 1.50/2.00 DUCT
PVC & Polyethylene Cutter

Razor sharp cutting blade makes a fast, clean, burr-free cut in PVC and polyethylene. Ratcheting
handle provides for secure, steady cutting action, Reduces cutting and preparation time.

08948050 Small diameter-upto 1-1/4" (32mm) conduit with 1-1/2" (38mm) OD
08948060 Large diameter-upto 2" (51mm) conduit with 2-3/8" (60mm) OD
08948051 Replacement Blade Small Cutter
08948061 Replacement Blade Large Cutter
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5 Blue Heron Drive
Fax: 610-831-5012
Warranty Information
Condux International, Incorporated extends the following warranty to the original purchaser of these goods for use,
subject to the qualifications indicated:
Condux International, Incorporated warrants to the original purchaser for use that the goods or any component thereof
manufactured by Condux International will be free from defects in workmanship for a period of 1 year form the date of
purchase, provided such goods are installed, maintained, and used in accordance with Condux’s written instructions.
Components not manufactured by Condux International but used within the assembly provided by Condux International
are subject to the warranty period as specified by the individual manufacturer of said component, provided such goods
are installed, maintained, and used in accordance with Condux’s and the original manufactures written instructions.
Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any
and all claims arising out of the purchase and use of goods, shall be limited to the repair or replacement of the goods
that do not conform to this warranty.
To obtain repair of replacement service under the limited warranty, the purchaser must contact the factory for a Return
Material Authorization (RMA), Once obtained, send the RMA along with the defective part or goods, transportation
prepaid, to:
Condux International, Inc.
145 Kingswood Road
Mankato, MN 56001 USA
THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN

AS SET FORTH ABOVE. THE IMPLIED WARRANTIES OR MERCHANTABILITY AND
FITNESS FOR PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR
FROM DATE OF PURCHASE
CONDUX ASSSUMES NO LIABILITY IN CONNECTION

WITH THE INSTALLATION OR USE OF THIS PRODUCT,
EXCEPT AS STATED IN THIS LIMITED WARRANTY,
CONDUX WILL IN NO EVENT BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES
©Copyright 2005, Condux International, Inc.

Printed in USA
Literature Part Number 08761899
Revision Number 1.0
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5 Blue Heron Drive

Comstar Supply, INC Collegeville, PA 19426

USER’S GUIDE & SAFETY MANUAL

Important Safety Notice

Save this user’s guide for future reference

COMMUNICATIONS WITH THE MANUFACTURER

Safety – Operations – Applications

Y-Block Set Up ……………………………………………… Page 5 – 9

Y-Block Orientation………………………………………….. Page 8

Y-Block Parts Breakdown……………………………………. Page 9

Y-Block Duct Pack Selection Chart…………………………... Page 10

Recommended Blowing Lubricant……………………………. Page 10

Replacement Parts & Accessories…………………………….. Page 11

a. Periodically inspect product for wear and tear.

Set Up the Y-Block

Figure 1 Loosen Nuts Figure 2 Remove Duct Clamps

Figure 3 Remove Air Block Cover

1. Select the correct Condux Duct Components according to the innerduct

5 Figure 4 Inseart Duct Clamps Figure 5 Insert Duct Seals

6. Clamp Innerduct in place (See Figure 7).

Figure 6 Insert Duct Figure 7 Clamp Innerduct

Figure 9 Install Cable Seal in Slot

6 Figure 10 Hand Push Cable into Y-Block

Figure 11 Install Air Block Cover

Figure 12 Sealed Y-Block

!WARNING: Forced air creates flying debris. Always wear

!WARNING: Ensure no personnel are in the destination access vault

!WARNING: Y-Block Assembly contains compressed air when

Cable Seals Existing Fiber Cable

Blower Entrance Side

Y-Block Parts Breakdown

Figure 1 - Condux Y-Block Parts Breakdown

Item Part Number Description QTY

Y-Block Duct Pack Selection Chart

Recommended Blowing Lubricants

Polywater® Prelube 2000™

Polywater® Prelube 2000™ recommended usage quantity

Replacement Parts & Accessories

Cable Jacket Slitter

Part Number Description

Part Number Description

PVC & Polyethylene Cutter

Part Number Description

THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN

CONDUX ASSSUMES NO LIABILITY IN CONNECTION

©Copyright 2005, Condux International, Inc.

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