Related Manuals for Conductix-Wampfler PowerReel 1900 Series
Summary of Contents for Conductix-Wampfler PowerReel 1900 Series
- Page 1 Spring Cable Reel Manual Spring Cable Reel Manual 1900/2400 Series PowerReel Series 1900 & 2400 XA-962100.7-US | 06.11.21 1900 / 2400 SERIES POWERREEL MANUAL 962100.5.1 1900 & 2400 SERIES CABLE REEL MANUAL...
- Page 2 CONDUCTIX INCORPORATED The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS MANUAL. Conductix Inc. makes no warranty (and assumes no liability) as to function of equipment or operation of systems built according to customer design or of the ability of any of its products to interface, operate or function with any portions of customer systems not provided by Conductix Inc.
- Page 3 Ask us for a quote on expert system installations,inspections, preventative maintenance, and repairs/retrofits. As the world’s largest single source manufacturer of mobile electrification products, Conductix-Wampfler has the unique ability to offer a degree of service not found anywhere else. Conductix-Wampfler’s team of highly qualified service technicians and engineers have years of experience servicing our complete line of products.
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION 1 - SAFETY 1.0 Safety Information Responsibility 1.1 Safety Messages 1.2 Limitation of Liability 1.3 Personnel Requirements-Qualifications 1.4 Personnel Requirements-Unauthorized Personnel 1.5 Personnel Requirements - Training 1.6 Personnel Protective Equipment 1.7 Electrical Warnings 1.8 Operational Warnings 1.9 Maintenance Warnings SECTION 2 - PRODUCT DISPOSAL 2.0 Product Disposal &... - Page 5 TABLE OF CONTENTS SECTION 4 - INSTALLATION 15-23 4.10 Electrical Connections 4.11 Spool Cable Connections 4.12 Supply Cable Connections 4.12.1 Reels Without Junction Boxes 4.12.2 Reels With Junction Boxes 4.13 Spring Tension Adjustment 4.13.1 Spring Cycling 4.13.2 Spring Pre-Tensioning 4.13.3 Adjusting Spring Tension SECTION 5 - OPERATION 5.0 Operational Warnings SECTION 6 - MAINTENANCE...
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Page 6: Section 1 - Safety
SECTION 1 - SAFETY 1.0 Safety Information Responsibility 1.0.1 All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before installation, operation, or maintenance. 1.0.2 The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and follow the information provided could cause harm to yourself or others and/or cause product damage. -
Page 7: Personnel Requirements-Qualifications
SECTION 1 - SAFETY 1.3. Personnel Requirements-Qualifications WARNING Inadequately trained persons are at risk of injury! Improper use can result in serious personal injury or material damage. All activities must only be performed by qualified personnel. 1.3.1 Only persons who can be expected to perform their work reliably are acceptable personnel. People whose reactions are impaired by drugs, alcohol or medications, for example, are not authorized. -
Page 8: Personnel Requirements-Training
SECTION 1 - SAFETY 1.5 Personnel Requirements-Training 1.5.1 Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better traceability. Example of a training log: Date Name Training Type Training Instructor Signature 11/5/2019 John Doe First safety training for personnel Dave Miller... -
Page 9: Maintenance Warnings
SECTION 1 - SAFETY 1.9 Maintenance Warnings WARNING Modification of this equipment may cause excessive wear and will void the warranty. Contact the manufacturer regarding changes or modifications of equipment which could affect reliability or safety. WARNING DO NOT DISASSEMBLE THE SPRING MOTOR FOR ANY REASON. Serious personal injury could result. This cable reel is equipped with springs under tension. -
Page 10: Section 2 - Product Disposal
SECTION 2 - PRODUCT DISPOSAL 2.0 Product Disposal and Recycling 2.0.1 Once the product has reached it’s end of life it must be disassembled and disposed of in accordance with local and regional environmental requirements. 2.0.2 In the absence of a return and disposal agreement, disassembled components must be recycled as follows: •... -
Page 11: Section 3 - Overview
SECTION 3 - OVERVIEW 3.0 Specifications & Listings (cULus) 3.0.1 The following specifications apply to standard 1900 & 2400 Series Cable PowerReels: • 1900 & 2400 Series Cable Reels are intended for commercial / industrial use and are provided with a permanent mounting base. •... -
Page 12: Allowable Ampacities For Flexible Cord & Cable
SECTION 3 - OVERVIEW 3.3 Allowable Ampacities for Flexible Cord & Cable Type W (90°C) Cable Ampacity Cable Ampacity Cable Ampacity Cable Ampacity W 8/2 W 6/2 W 4/2 W 2/2 W 8/3 W 6/3 W 4/3 W 2/3 W 8/4 W 6/4 W 4/4 W 2/4... - Page 13 SECTION 3 - OVERVIEW 3.3 Allowable Ampacities for Flexible Cord & Cable Type SOW-A, SOOW-A (90°C) Cable Ampacity Cable Ampacity Cable Ampacity Cable Ampacity 16/2 14/2 12/2 10/2 16/3 14/3 128/3 10/3 16/4 14/4 12/4 10/4 16/5 14/5 12/5 10/5 16/6 14/6 12/6...
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Page 14: Parts Breakdown
SECTION 3 - OVERVIEW 3.4 Parts Breakdown Guide Rails (optional) Reel Safe Brake “speed governor” (optional) Roller Guide Assembly Spring Motor Assembly Frame Ratchet Teeth Guide Rail Mounting Bolts (optional) (optional) Ratchet Pawl Assembly Ball Stop (optional) (optional) Spool Lock Assembly (optional) Pivot Base... -
Page 15: Section 4 - Installation
SECTION 4 - INSTALLATION 4.0 Application Types 4.0.1 Strech Applications (Automatic) un-supported 4.0.1.1 The cable is suspended without any intermediate support. Stretch reels generally require a line pull equal to two times the weight of the cable, which allows approximately 10% sag at full extension. -
Page 16: Pivot Base Mounting
SECTION 4 - INSTALLATION 4.1.2 Pivot Base Mounting 4.1.2.1 All 1900 & 2400 Series Cable Reels can be furnished with a pivot base to allow the reel to rotate and keep the extended cable perpendicular to the application. See Figure 4-6. 4.1.2.2 Pivot Bases rotate up to 345°. -
Page 17: Roller Guides
SECTION 4 - INSTALLATION 4.4 Roller Guides 4.4.1 All 1900 & 2400 Series Cable Reels are equipped with an adjustable roller guide. The guide’s function is to center the cable on the spool and to help the reel wrap cable more evenly. 4.4.2 Level winding is inhibited by the cable bearing against either of the spool flanges during operation. -
Page 18: Ratchet Option Installation
SECTION 4 - INSTALLATION 4.6 Ratchet Option Installation WARNING Power should be disconnected from the reel before beginning any service or maintenance functions. Follow lock-out/tag-out procedures appropriate to the installation. 4.6.1 Ratchet Pawl Installation The ratchet pawl assembly is attached to the reel frame as a unit. The holes provided for the attachment of The ratchet pawl assembly are located in the lower middle area of the frame. -
Page 19: Spool Lock
SECTION 4 - INSTALLATION 4.7 Spool Lock 4.7.1 All 1900 & 2400 Series Cable Reels can be equipped with an optional Spool Lock. See Figure 19-1. 4.7.2 The Spool Lock allows the power spring tension to be locked out from the cable spool. Applications that often require cable replacement would benefit from the addition of the Spool Lock. -
Page 20: Cable Installation & Replacement
SECTION 4 - INSTALLATION 4.8 Cable Installation & Replacement 4.8.1 Cable Removal 4.8.1.1 If an existing cable is being replaced you must first remove the old cable. 1. Disconnect all power as per Lock-Out/Tag-Out procedures as outlined in OSHA Section 1910.147. 2. -
Page 21: Slip Ring Replacement
SECTION 4 - INSTALLATION 4.9 Slip Ring Replacement 1. Disconnect and secure the electrical power as per Lock- Out/Tag-Out procedure outlined in OSHA 1910.147. 2. Remove the Slip Ring cover. 3. Disconnect the Spool Cable Connections from the Slip Ring Brush Terminals. Mark/Note the existing cable connections. -
Page 22: Electrical Connections
SECTION 4 - INSTALLATION 4.10 Electrical Connections WARNING 4.10.1 Electrical connections are determined by the requirements of the application and the configuration of the reel. 4.10.2 All electrical work should be performed by a qualified electrician. 4.10.3 Factory installed cable is wired with ring one (the ring closest to the drive collar) designated as ground, wired with the green cable conductor. -
Page 23: Spring Tension Adjustment
SECTION 4 - INSTALLATION 4.13 Spring Tension Adjustment NOTE: • More demanding applications may require spring tension Travel adjustments for proper cable retraction. Direction WARNING Do not allow cable to retract without restraining the retraction speed. Walk the cable back to the reel. The retraction speed should not exceed 150 ft/min. -
Page 24: Section 5 - Operation
SECTION 5 - OPERATION 5.0 Operational Warnings WARNING • Do not exceed the voltage or ampere rating of the reel. Overheating, fire, damage to equipment or personal injury could result. Do not allow cable to retract without restraining the retraction speed. •... -
Page 25: Section 6 - Maintenance
SECTION 6 - MAINTENANCE 6.0 Maintenance Warnings WARNING • Be sure the power is off for maintenance. • Follow lock-out/tag-out procedures as outlined in OSHA Section 1910.147. 6.1 Lubrication 6.1.1 All springs and bearings are lubricated for life at the factory. Additional lubrication should not be required. 6.1.2 Do not apply any lubricants or solvent cleaning agents to the slip ring, brush, or insulator surfaces. -
Page 26: Spring Motor Replacement
SECTION 6 - MAINTENANCE 6.3 Spring Motor Replacement 1. Disconnect Power (as per Lock-Out/ Tag-Out Procedures). 2. Some procedures may require mechanical assistance. The combined weight of the Cable, Spool, and Spring Motor may exceed 200 lbs. 3. Disconnect the terminated end of the cable. Wrap the cable onto the Reel Spool. Secure the cable on the spool using a zip-tie or similar fastener. - Page 27 SECTION 6 - MAINTENANCE Figure 6-5 1. Ratchet Plate Studs (longer than others) Figure 6-4 1. 1/4-20 Keps Nut 2. Frame Hub Set Screw 2. Ratchet Teeth (optional) 3. Spool Lock (optional) 3. Set Screw Alignment Holder 4. Spring Motor 1900 / 2400 SERIES POWERREEL MANUAL 06.11.21...
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Page 28: Section 7 - Replacement Parts
SECTION 7 - REPLACEMENT PARTS 7.0 R Series Slip Rings for 1900 & 2400 Series 7.1.1 To identify the slip ring in 1900 & 2400 Series reels for Replacement parts, it is necessary to precede the amperage profile section with the product code “RA-”. This code specifies that the Slip Ring is a member of the R Series Slip Ring family and designates the bore size as 1.50”. -
Page 29: Reel Part Description
SECTION 7 - REPLACEMENT PARTS 7.1 Reel Part Description 1900 / 2400 SERIES POWERREEL MANUAL 06.11.21... -
Page 30: Powerreel Part Descriptions
SECTION 7 - REPLACEMENT PARTS 7.2 Power Reel Part Descriptions 7.2.1 PowerReel Standard Parts - ie. 192121005011 Spool Assembly Guide Rails 40212A 40212AA 40212B 40212BB Pivot Base Base Assembly 40200 40203 40274 Range Diameter 19.00 24.00 Drum Diameter 12.00 12.00 17.00 18.50”... -
Page 31: Gafferreel Part Descriptions (Theatre)
SECTION 7 - REPLACEMENT PARTS 7.3 GafferReel Part Descriptions (Theatre) 7.3.1 GafferReel Standard Parts - ie. 192121005011B Spool Assembly Guide Rails 40212A-BLK 40212AA-BLK 40212B-BLK 40212BB-BLK Pivot Base Base Assembly 40200PB 40203PB 40274 Range Diameter 19.00 24.00 Drum Diameter 12.00 12.00 17.00 18.50”... -
Page 32: Section 8 - Troubleshooting
SECTION 8 - TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Reel will not retract cable but has some 1) Improper pretension 1) See Tension Adjustment section. tension. 2) Incorrect reel for application (lift vs. 2) Quantify application vs. reel selection. stretch). 3) Install correct cable type and length. 3) Improper cable or cable length installed. -
Page 33: Notes
NOTES 1900 / 2400 SERIES POWERREEL MANUAL 06.11.21... - Page 34 www.conductix.us www.conductix.us USA / LATIN AMERICA CANADA MÉXICO BRAZIL 10102 F Street 1435 Norjohn Court Calle Treviño 983-C Rua Dois, 493 Omaha, NE 68127 Unit 5 Zona Centro Itu, São Paulo, Brasil Burlington, ON L7L 0E6 Apodaca, NL México 66600 CEP: 13312-820 Customer Support Customer Support...
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