Endo CRL-4000 Series Instruction Manual

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INSTRUCTION MANUAL

CABLE REEL

CRL - 4000 SERIES

CRL - 5000 SERIES

CRL - 6000 SERIES

CRL - 7000 SERIES

・・・・ Read this manual before use.

・・・・ Keep this manual available.

ENDO KOGYO CO., LTD

Supply this manual to the user.

RM-10547a

Issued on Apr 2013

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Page 1 CRL - 4000 SERIES CRL - 5000 SERIES CRL - 6000 SERIES CRL - 7000 SERIES ・・・・ Read this manual before use. ・・・・ Keep this manual available. ENDO KOGYO CO., LTD RM-10547a Issued on Apr 2013...
Page 2 Copyright and liabilities The copyright for this manual belongs to Endo Kogyo Co., Ltd. The manual is provided for the limited purpose of supporting the safe and proper use of the product. It cannot be used for other purposes. The customer may not use or make copies of this manual, in whole or in part, outside of this purpose without receiving prior consent from Endo Kogyo Co., Ltd.
Page 3 SAFETY ALERT SYMBOL AND ALERT SIGNS Please read this manual carefully and follow its instructions. The SAFETY ALERT SYMBOL ( ), WARNING, CAUTION, and NOTE carry special messages. This SAFETY ALERT SYMBOL is used to call your attention to items or operations that could be dangerous to you or other persons using this equipment.
Page 4: Table Of Contents
Contents Safety instruction ———————————————————————————————————————————————————————— 2. Terminology definitions —————————————————————————————————————————————————————————————————————————————————————————— 3. Product description ———————————————————————————————————————————————————————————————————————————————————————————————— 3-1. Models and specifications 3-2. Names of main parts 4. Installation ———————————————————————————————————————————————————————————————————————————————————————————————————————————— 4-1. Checks before installation 4-2. Installation 4-3. Ground connection work 5. Cable connection ———————————————————————————————————————————————————————————————————————————————————————————————————— 5-1. Calculation of required cable length on winding side 5-2.
Page 5 Safety instructions Regarding name plates, warning labels and labels: ・・・・ Never remove or deface any name plates, warning labels or labels which are attached to the body. The operator should always observe them. Regarding installation (page 8): ・...
Page 6 Regarding initial tension setting (page 14): ・・・・ Never let go of the drum during any work. When released, the drum suddenly rotates, possibly causing personal injury. ・・・・ After setting the initial tension, wire connection requires more than 2 people to secure the drum and connect the cable.
Page 7 Regarding brush and slip ring replacement (page 20): ・・・・ Electric shock hazard. Turn off the power and verify safety using some kind of electrical test sensor before carrying out replacement. ・・・・ Allow the cable to fully wind onto the drum to give the minimum winding tension before carrying out replacement.
Page 8: Terminology Definitions
2. Terminology definitions The terminology used in this manual will be explained here. If there is any terminology which is unclear or not included in this section, please contact our company. Winding methods: Figure 1 ＭｏｖｉｎｇｒｅｅｌＦ...
Page 9: Product Description
3. Product Description 3-1. Models and specifications (1) Models Please observe the name plate attached to the main body. Refer to Figure 5 (page 7) for the attached location. ＭｏｄｅｌＳｌｉｐｒｉｎｇｃａｐａｃｉｔｙ Figure 4 MODEL: The product model is shown.
Page 10 (2) Specifications Table 1 Maximum Calculated Total Reference spring maximum number of Spring mass Model torque spring spring structure N・m tension turns { kgf・m } N { kgf } CRL-4M424 23.5 CRL-4M424-R { 2.4 } { 17.0 } CRL-4424W 23.5 CRL-4424W-R { 2.4 } { 17.0 }...
Page 11: Names Of Main Parts
3-2. Name s of main parts ＤｒｕｍＣｏｎｎｅｃｔｏｒ Figure 5 ＤｕｓｔｐｒｏｏｆｓｐａｃｅｒＤｒｕｍｃｏｖｅｒＢ...
Page 12: Installation
4. Installation 4-1. Checks before installation ・ Please check whether the items ordered were received. (Check the name plate.) ・ Check there is no damage to the product caused during transportation. 4-2. Installation Figure 6 ・・・・ Never use in ignitable or explosive atmospheres. ・...
Page 13: Ground Connection Work
4-3. Ground connection work ・・・・ Electric shock hazard. Do the ground connection work. ・・・・ Never connect the earth line to the following: Gas pipes, etc. : Danger of ignition or an explosion. Phone lines / lightning rods : Danger of being struck by lightning. Along plastic water pipes : Does not act as an earth.
Page 14: Cable Connection
5-2. Cable connection ・・・・ Electric shock hazard. Turn off the power before carrying out any work. Figure 11 ・・・・ Do not install cable to drum more than 2-3 times round. (2-3 times means winding length & initial spring turns) Make free space in drum, otherwise cable could spill out from drum cover.
Page 15 Figure 14 ＷｉｎｄｉｎｇｓｉｄｅｃａｂｌｅＣａｂｌｅｇｕｉｄｅＣｏｎｎｅｃｔｏｒＣｏｎｎｅｃｔｏｒＤ...
Page 16 (4) Peel the required length of jacket from the cable, and pass the cable through the cable guide. Decide on the required length for peeling to allow sufficient room for connecting the cable core to the farthest brush holder from the cable guide exit. (5) Tighten the connector nut to secure the cable while leaving sufficient room for connecting each cable core to the brush.
Page 17: Spring Tension Adjustment
6. Spring tension adjustment 6-1. Relationship between winding torque and drum turns ＭＡＸ Figure 19 ＷｉｎｄｉｎｇｔｏｒｑｕｅＭＡＸＮｕｍｂｅｒＮｕｍｂｅｒｏ...
Page 18: Initial Tension Setting
Example) Model CRL-6M7112W, for the case of 12 drum turns According to table 1, total number of spring turns = 24. According to table 2, standard value of initial spring turns = 2 - 6, Number of spare spring turns = 3 or more. Upper limit of initial spring turns = 24 - (12 + 3) = 9.
Page 19: Adjustments
7-2. Adjustments (1) Initial tension modification Increase the number of initial spring turns one by one without exceeding the upper limit. If there is no improvement, set the initial tension back to the first value. (2) X axis modification Tilt the X axis at a small angle by inserting a spacer under the bracket. Figure 20 Ｓ...
Page 20: Special Accessories
9. Special accessories ＰｉｐｅｔｙｐｅｇｕｉｄｅｒｏｌｌｅｒＡｒｍｔｙｐｅｇｕｉｄｅｒｏｌｌｅｒＳ...
Page 21: Periodic Inspections
(3) Arm type guide roller Figure 23 This is required when the reeling direction Ｇｕｉｄｅｒｏｌｌｅｒ angle varies during operation. For installation, remove the connector, then Ａｒｍ attach the arm to the spindle and fix with the hexagon socket head cap screw.
Page 22: Slip Ring Inspections
・ Are there any twists or damage on the cable? 10-2. Slip ring inspections ・・・・ Electric shock hazard. Turn off the power before removing the dust proof cover. ・・・・ Verify safety using some kind of electrical test sensor before carrying out inspections. ・...
Page 23 (3) Brush holders Figure 26 ・ Are carbon powders adhering to the Ｈｅｘａｇｏｎｓｏｃｋｅｔｈｅａｄｃａｐｓｃｒｅｗ brush holders? ＢｒｕｓｈｈｏｌｄｅｒＢ...
Page 24: Troubleshooting
11. Troubleshooting Malfunction Main causes Solution Unable to set the initial Direction of initial spring Rotate in the cable paying out tension. turns is incorrect. direction. The spring is broken. Replace with a new spring. The reel cannot retrieve the The initial tension is Increase the initial spring cable.
Page 25: Brush Replacement
12-1. Brush replacement ＨｅｘａｇｏｎｓｏｃｋｅｔＨｅｘａｇｏｎｈｅａｄｂｏｌｔｈｅａｄｃａｐｓｃｒｅｗ Figure 28 Ｂ...
Page 26 Figure 31 Figure 32 ＩｎｓｕｌａｔｉｏｎｐｉｐｅＢｒｕｓｈｂｏｌｔＢｒｕｓｈｈｏｌｄｅｒＬｅａｄｂｏｌｔＦ...
Page 27: Brush Holder Replacement
12-3. Slip ring replacement (See figure 30 (page 21), 31 (page 22)) (1) Remove the terminal plate (10A, 20A and 50A only), plate and brush holders in the same manner as section 12-2. " Brush holder replacement". Figure 34 NOTE: When replacing the slip rings alone, the slip rings can be removed without removing the brush holders.
Page 28: Disassembly Of Slip Ring Assembly And Bracket
13-1. Disassembly of slip ring assembly and bracket (Common method for all spring structures) (1) Turn off the power and allow the cable to fully wind onto the drum to give minimum winding tension, then dismantle the mating equipment side wiring. Allow the dismantled cable to wind around the drum, slowly turning the drum until the winding tension in the drum is released.
Page 29 ■ For spring structure E (1 spring) ・The spring has a weight of approximately 5kg to 22kg. Take care when handling the spring. For spring types 112 (see chapter 3, section 3-1."Model and specifications"), lifting work requires more than two people. ・...
Page 30 (7) While pressing the attached notch key in the slot with a Figure 38 finger, push the spindle downward so that the actuation Ｎｏｐｒｏｔｒｕｓｉｏｎ plate keeps the notch key in the slot. Ｎ...
Page 31 ■ For spring structure F (2 springs, double-torque) ・The spring has a weight of approximately 5kg to 16kg. Take care when handling the spring. For spring types 150 (see chapter 3, section 3-1."Model and specifications"), lifting work requires more than two people. ・...
Page 32 (8) Install the spring case with the protruding plates Figure 41 Ｓｐｒｉｎｇｃａｓｅｗｉｔｈ into the drum. ｓｔｏｐｐｅｒｐｌａｔｅｓ Rotate the spring case back and forth until the spring case fits into the actuation plate.
Page 33 ■ For spring structure G (2 or more springs, double-stroke) ・The spring has a weight of approximately 5kg to 22kg. Take care when handling the spring. For spring types 112 (see chapter 3, section 3-1."Model and specifications"), lifting work requires more than two people. ・...
Page 34 (7) Lubricate the spring with grease (KYODO, ONELUBER MP No. 2 or equivalents) with the specified volume shown in table 4 (page 26). Spread grease all over the spring. (8) Install all spring cases, to which the bush with the circular hole is attached, into the drum in the same manner as (6) to (7).
Page 35 ■ For spring structure H (4 springs, double-torque and double-stroke) ・The spring has a weight of approximately 5kg to 16kg. Take care when handling the spring. For spring types 150 (see chapter 3, section 3-1."Model and specifications"), lifting work requires more than two people. ・...
Page 36 (4) Lightly lubricate the bush attaching Figure 45 Ｓｐｒｉｎｇｃａｓｅｗｉｔｈｓｔｏｐｐｅｒｐｌａｔｅｓ portion of the spindle and the inside Ｂ...
Page 37 (16) While pressing the attached notch key in the slot with a finger, push the spindle downward so that the bush keeps the notch key in the slot. See figure 38 (page 25). (17) Install the spring case with the stopper plates, to which the bush with the non-circular hole is attached, into the drum.
Page 38 (3) Before reassembly, clean and inspect all the disassembled parts. Replace worn, cracked, damaged or deformed parts. (4) Lightly lubricate the bush attaching portion of the spindle and the inside surface of each bush with grease (IDEMITHU, DAPHNE EPONEX GREASE EP-1 or equivalents). (5) Attach the bushes to the springs.
Page 39 ■ For spring structure K (Type 48W: 4 springs, double-torque and double-stroke) ・The spring has a weight of approximately 5kg. Take care when handling the spring. ・・・・ The spring assembly work requires more than two people to lift the spring and hold the bush (the spring center) in order to prevent the spring from bursting out.
Page 40: Common Reassembly Method
(8) Place the notch key and notch springs into the lower slot of the spindle. Take care as the assembling direction of the notch key depends on the winding direction of the reel. See figure 37 (page 25). (9) While pressing the attached notch key in the slot with a finger, push the spindle downward so that the bush keeps the notch key in the slot.
Page 41: Spring Disposal1
13-4. Spring disposal The spring is dangerous due to remaining tension even if it is broken. Weld steel plates to the spring in order to prevent the spring from expansion before disposal. Never use gas welding, only use arc welding. ・Weld steel plates to the spring in order to Figure 49 prevent the spring from expansion.
Page 42 ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ＳｅｅＳａｄｄｌｅＳｅｅＣｏｎｎｅｃｔｏｒ Quantity List No. or Description Part No. ４Ｍ４２４４４２４Ｗ４４２４Ｔ４４２４Ｆ４５２４Ｗ４５２４Ｔ４５２４Ｆ－...
Page 43 ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY ■ＣＲＬ－４Ｍ４２４～４５２４Ｆ　MAIN BODY Quantity List No. or Description Part No. ４Ｍ４２４４４２４Ｗ４４２４Ｔ４４２４Ｆ４５２４Ｗ４５２４Ｔ４５２４Ｆ－ Drum cover assembly １１１１－－－ＬＲＰ００３８１６－ＬＲＰ００３８１７ Drum cover assembly －－...
Page 44 ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ＳｅｅＳａｄｄｌｅＳｅｅＣｏｎｎｅｃｔｏｒ Quantity List No. or Description Part No. ５Ｍ６３６５６５５Ｗ５６３６Ｗ５６５５Ｔ５６３６Ｔ...
Page 45 ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY ■ＣＲＬ－５Ｍ６３６～５６３６Ｆ　MAIN BODY Quantity List No. or Description Part No. ５Ｍ６３６５６５５Ｗ５６３６Ｗ５６５５Ｔ５６３６Ｔ５６３６Ｆ－ Spring assembly １－２－３４ＬＲＰ００３８３１－ＬＲＰ００３８３２ Spring assembly －２－３－－...
Page 46 ■ＣＲＬ－６７７Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６７７Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６７７Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６７７Ｗ～６７５６Ｖ　MAIN BODY ＳｅｅＳａｄｄｌｅＳｅｅＣｏｎｎｅｃｔｏｒ ■ＣＲＬ－６Ｍ７１１２Ｗ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ　MAIN BODY ＳｅｅＳａｄｄｌｅＳ...
Page 47 ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY Quantity List No. or Description Part No. ６Ｍ７１１２Ｗ６７７５Ｗ６７７５Ｔ６７７５Ｆ６７５６Ｆ６７５６Ｖ－ Bracket assembly １－－－－－ＬＲＰ００３８４４－ Bracket assembly －１１１１１ＬＲＰ００３８４５...
Page 48 ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY ■ＣＲＬ－６Ｍ７１１２Ｗ～６７５６Ｖ　MAIN BODY Quantity List No. or Description Part No. ６Ｍ７１１２Ｗ６７７５Ｗ６７７５Ｔ６７７５Ｆ６７５６Ｆ６７５６Ｖ－ Notch key assembly １１１１－－ＬＲＰ００３８３８－ Notch key assembly －－－－１...
Page 49 ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ＳｅｅＳａｄｄｌｅＳｅｅＣｏｎｎｅｃｔｏｒ Quantity List No. or Description Part No. ７８７５Ｔ７８７５Ｆ－ Bracket assembly １...
Page 50 ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY ■ＣＲＬ－７８７５Ｔ～７８７５Ｆ　MAIN BODY Quantity List No. or Description Part No. ７８７５Ｔ７８７５Ｆ－ Drum cover assembly １１ＬＲＰ００３８２０－ - Drum cover assembly １１ＬＲＰ００２０１９６ - - Drum cover １１－２９...
Page 51 ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring ＳｅｅｃｏｎｎｅｃｔｏｒＳｅｅｓａｄｄｌｅ Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ１２Ｐ１４Ｐ１６Ｐ２０Ｐ２４Ｐ２８Ｐ３２Ｐ－...
Page 52 ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ１２Ｐ１４Ｐ１６Ｐ２０Ｐ２４Ｐ２８Ｐ３２Ｐ８ＬＲＰ００３０３５ - Slip ring －－－１１１１１１...
Page 53 ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ１２Ｐ１４Ｐ１６Ｐ２０Ｐ２４Ｐ２８Ｐ３２ＰＬＲＰ００３７８５ - Brush set ３４６８１０１２１４１６２０２４...
Page 54 ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring ■２０Ａ　Slip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ１２Ｐ１４Ｐ１６Ｐ２０Ｐ２４Ｐ２８Ｐ３２Ｐ－ＬＲＰ００３３８６ Dust proof spacer assembly －－－１－－－－...
Page 55 ■５０Ａ　Slip ring ■５０Ａ　Slip ring ■５０Ａ　Slip ring ■５０Ａ　Slip ring ＳｅｅｃｏｎｎｅｃｔｏｒＳｅｅｓａｄｄｌｅ Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ...
Page 56 ■５０Ａ　Slip ring ■５０Ａ　Slip ring ■５０Ａ　Slip ring ■５０Ａ　Slip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ１２Ｐ１３Ｐ１Ｒ３０１９７２ - Ring holder ３４６８１０１２１４Ｐ１Ｒ４００４７８ - Ring cover １１１１...
Page 57 ■５０Ａ　Slip ring ■５０Ａ　Slip ring ■５０Ａ　Slip ring ■５０Ａ　Slip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ６Ｐ８Ｐ１０Ｐ１２ＰＬＲＰ００３３８６ Dust proof spacer assembly －－－１－－－－ＬＲＰ００３３８７ Dust proof spacer assembly －－...
Page 58 ■１００Ａ Srip ring ■１００Ａ Srip ring ■１００Ａ Srip ring ■１００Ａ Srip ring ＳｅｅｃｏｎｎｅｃｔｏｒＳｅｅｓａｄｄｌｅ Quantity List No. or Description Part No. ３Ｐ...
Page 59 ■１００Ａ Srip ring ■１００Ａ Srip ring ■１００Ａ Srip ring ■１００Ａ Srip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ１３Ｐ１Ｒ４０５２６０ - Insulating collar ３４ - Plate １４Ｐ１Ｒ４１１５４６１１ - Hex. nut ２３ＫＡ２０１４０６００６８...
Page 60 ■１５０Ａ Slip ring ■１５０Ａ Slip ring ■１５０Ａ Slip ring ■１５０Ａ Slip ring ＳｅｅｃｏｎｎｅｃｔｏｒＳｅｅｓａｄｄｌｅ Quantity List No. or Description Part No. ３Ｐ４Ｐ－ＬＲＰ００３５３３１－ Slip ring assembly －...
Page 61 ■１５０Ａ Slip ring ■１５０Ａ Slip ring ■１５０Ａ Slip ring ■１５０Ａ Slip ring Quantity List No. or Description Part No. ３Ｐ４Ｐ１１ＬＲＰ０１６９４０２－ - Brush bolt １１ＬＲＰ０１６９４９ - Brush bolt －２１２－２２ - - Insulation pipe ２５...
Page 62 ■ACCESSORIES ■ACCESSORIES ■ACCESSORIES ■ACCESSORIES Parts No. Description Size Selection by cable diameter Connector ＣＳ－１５～φ１４．５ＬＲＰ００３４２１ Connector ＣＳ－１７ φ１４．６～φ１６．５ＬＲＰ００３４２２ Connector ＣＳ－２０ φ１６．６～φ１９．５ＬＲＰ００３４２３ Connector ＣＳ－２３ φ１９．６～φ２２．０ＬＲＰ００３４２４ Connector ＣＳ－２７ φ２２．１～φ２６．０ＬＲＰ００３４２５ Connector ＣＳ－３０ φ２６．１～φ２９．０ＬＲＰ００３４２６ Connector ＣＳ－３４ φ２９．１～φ３３．０ＬＲＰ００３４２７ Connector ＣＳ－３８...

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Endo CRL-4000 Series Instruction Manual

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