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In some instances more setup turns can be added to improve reel performance.
Use following equation to find maximum allowed setup turns.
Active Turns-number of spool turns to unwrap active cable (pull off cable and count turns.)
Total Turns-see chart above
Setup -see chart above
Maximum Setup = Total Turns - (½ x Setup) - Active Turns
Example: 1475-16-320 cable reel using 33 Active Turns to wind cable
SERVICE
Always disconnect electrical power before dismantling any part of the reel. Fuse size must
not be greater than maximum amperage capacity of cable. Remove all spring tension
WARNING:
before attempting any service. Hazards or unsafe practices COULD result in severe
personal injury or death.
INSTALL/REPLACE WORKING CABLE (Both new installations and for replacement of working cable.)
NOTE: Add about 10 ft. extra to active cable length (3 ft. for a dead wrap on spool and 7 ft. for slip ring
connections). Also add required length for your connection at cable fixed end.
Remove slip ring cover, cable clamp from spool assembly and cable connector. Determine length to strip
outer-jacket of cable by inserting it through gooseneck fitting until reaching most distant brush terminal.
Mark outer-jacket at location inside connector. Remove cable, and strip outer-jacket six inches above
mark to ensure adequate conductor length to connect to brush terminals. Pull stripped end of cable
through slot in spool assembly flange adjacent to cable clamp. Insert cable through cable connector until
outer-jacket becomes visible in fitting. Feed conductors though entrance ring into the collector assembly
to reach their proper brush terminals. Tighten watertight cable connector. Secure individual conductors to
proper brush terminals. Install cable clamp making sure cable is not kinked or pinched. Load working
cable onto spool assembly by manually winding the reel. Count the number of turns required to fully load
cable; you can use this to determine maximum setup turns.
NOTE: While winding, observe cable-wrapping pattern and make sure that all twists and kinks are
removed from the cable. Cable twists can cause an erratic wrapping pattern and shorten cable
life. See "Cable Winding" section on page 2.
Wrapping of cable will produce a clinking sound as the springs disengage from the drive hubs. This is a
protective feature to prevent damage to springs. All springs will re-engage when spool is wound in
opposite direction. Terminate the free end of working cable only after setup turns are applied.
COLLECTOR RING REPLACEMENT
Disconnect and lock out all power to reel before servicing collector ring assembly.
WARNING:
Hazards or unsafe practices COULD result in severe personal injury or death.
Check continuity and replace all covers before turning on electrical power. Hazards or
CAUTION:
unsafe practices MAY result in minor personal injury or product or property damage.
Remove collector ring cover. Disconnect working cable lead wires from terminals of brush holder.
Disconnect main shaft lead wires and remove assembly by loosening set screws and sliding collector ring
off the main shaft. To reassemble, reverse the above procedure, making sure each brush is properly
centered on its corresponding ring with full contact. The collector ring assembly should be snug against
the entrance ring assembly.
SM321009D
54 – (½ x 10) – 33 = 16 maximum allowed setup
Page 4 of 9
©Aero-Motive Nov-03
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