Professional Documents
Culture Documents
FOR
MOTOR CABLE REEL TYPE
300.4 DM1935-50G K4121/FC/R
DISCLAIMER
This Instruction Manual is intended as a guide to the installation, usage and maintenance of the
specified Cavotec equipment.
Cavotec does not accept liability for any loss or damage suffered as a result of using this manual.
Prior to installing, operating or maintaining the equipment, read the GENERAL WARNINGS AND
SAFETY GUIDELINES located on the following page.
If in doubt, always refer to the original equipment manufacturer.
The equipment warranty will be voided if the technical guidelines for the installation, usage and
maintenance have not been correctly followed.
Only suitably qualified maintenance personnel who have read and understood every part of this
document are authorised to maintain the specified equipment.
The information contained within this document is subject to change at any time without notice.
VERSION HISTORY
Revision
Rev. Revised by: Approved by: Comments
Date
A E. Rossetto G. Pengue 09.05.2018 Primary issue
Reel operation is remotely controlled by the machine on which it is installed. Drum rotation
can therefore occur at any time, so it is important to keep well clear during machine
operation.
If it is necessary to be near the reel during operation (eg. while commissioning), be aware
of the location of the nearest emergency stop button and exercise caution.
Prior to performing maintenance on the reel, ensure that the machine long travel and reel
motor are isolated by an authorised person.
If work is to be done inside the collector enclosure, the drive centre or the motor terminal
blocks, ensure that all relevant circuits are isolated by an authorised person prior to
removing any covers.
Warning labels on the collector enclosure are there to remind personnel of the danger.
Prior to touching any electrical connection, confirm with an appropriate meter that there is
no power. Failure to do so may lead to serious injury or death.
Note that any heaters or travel limit switches in the collector enclosure may still have
tension on the terminals even if the main power is switched off.
Only suitably qualified maintenance personnel who have read and understood every part
of this document are authorised to maintain the specified equipment.
Before storage:
• Using the grease supplied in the inside of the gearboxes, lubricate the pinions, the
shafts and the inside of the housings.
• Apply grease on the outer joints.
• Every 6 months, open the bleed nipples of the motor to evacuate moisture. Put them
back in place.
During storage:
• Check regularly the condition of the paint. If necessary, make paint retouching.
• Every 6 months, using the grease supplied in the inside of the gearboxes, lubricate the
pinions, the shafts and the inside of the housings.
• If possible, turn the spool axis from 4 to 5 turns, to modify the position of the bearings
parts.
Drums storage:
• All drums, wheels, wheel-halfs, flange and generally, all galvanized material must come
and be sent by inserting spacers between material components (PEHD).
• The material should be non-hygroscopic and non-reactive to galvanized material and
resistant at -50° C/50° C in order to prevent accum ulation of water as often happens
with cardboard spacers.
• The whole must be stored inside the warehouse and not weatherproof.
Prereducer
Motor
S2
S1
D c
a b
DRUM JACKS
CABL E
ROUN D BAR
DRU M JAC KS
DRUM JACKS
OPENING
INNER RING
CABLE
FRONT BOX
CABLE REELER
CABLE
CABLE GUIDE
DRUM JACKS
5.2.8 The cable can now be wound onto the reel, and it is essential that this be done with the
cable under some tension to ensure uniform tight layering on the reel. It is most important
that the cable be wound onto the reel drum without any induced twist. Figure 12 shows
the correct method of cable transfer from the storage drum. The use of any other method
will induce twist in the cable.
Alignment Check
7.1 GENERAL
Ensure that all live electrical circuits have been isolated before performing any
maintenance inside the collector housing.
7.4.1 Check that the wires are properly connected to the terminals, and that the terminal screws
are correctly tightened.
10.2 COMMISSIONING
10.2.1 Preliminary Checks
• Ensure that the reeler installation has been completed.
• Confirm that the machine is capable of movement and is ready to operate.
• Confirm that the feed point cable/hose connection is securely clamped.
• Confirm that the gearbox oil level is correct.
• Manually operate the drive motor to ensure correct recovery direction. Correct as
necessary.
10.2.2 Operational Checks
• Position the machine about five (5) metres from the feed point. Accelerate the machine
to full speed from rest towards the feed point and ensure that the reeler recovers the
cable/hose without undue slack. Adjust the torque setting on the torque unit if
necessary by following the instructions in section 8.2 and then repeat this test.
• Position the machine about five (5) metres from the end of travel. Accelerate the
machine to full speed from rest away from the feed point and ensure that the reeler
pays out the cable/hose without excessive tension. Reduce the torque setting on the
drive if necessary by following the instructions in section 8.2, and then repeat this test
and the test above.
1191
480 696
35
15
∅3500
∅1900
816
477
639
245
407
162
Cable glandM63x1.5
cable range ∅44 - ∅57mm
20
N°2 blind plug M20x1.5 125
40
6
N°2 blind plug M63x1.5 ∅2
211.5
CL
DRUM
640
720
428.5
Limit switch cable gland M20x1.5 22.5 440
cable range ∅7 - ∅16mm 485
245
355
426
851
788
426
505.5
955
B
TITLE
Cable Reel
300.4 DM1935-50G K4121-FCi-R
CLIENT PROJECT
REVISION STATUS
The geared rotary limit switch is used for reel full-reel empty detection.
During commissioning, the reel full switch is set to trip approximately 1~2 metres before the feedpoint,
and reset a similar distance beyond this feed point. The resultant closed contact is utilised to bypass
the under tension detection circuit, thus allowing the cable to pass through the vertical position as the
machine travels over the turn over point.
The reel empty switch is set to trip when the last turn of cable is reached on the reeler drum. It should
only trip if (a) the machine limits fail or (b) the cable is snagged at some point resulting in it being
pulled from the reeler instead of recovering. The switch would then stop the machine before all the
cable is pulled from the reel.
MOTOR OPERATION
The direction switches, together with the travel direction signal from the machine, determines how the
reeler drive motor/s will operate.
• When the machine is travelling towards the feed point, the reel needs to recover cable.
Therefore, the motor/s must be energised in the reeling in direction. In this case, the direction
switch output and travel direction will be equivalent.
• When the machine is travelling away from the feed point, the cable will be pulled off the reel.
Therefore, the motor/s must be de-energised. In this case, the direction switch output and
travel direction will be opposing.
• At the end of any recovery cycle, the reeler motor/s should remain energised for a few
seconds. This is typically achieved with a ‘Coasting’ timer. This allows the reeler to continue
recovering the cable as the machine coasts to a complete stop. The duration of the coasting
timer is typically between 3-5 seconds.
HEATERS
Anti-condensation heaters mounted in the collector housing/s need to be energised at all times to
prevent the build-up of moisture. Motor and brake heaters need to be energised whenever they are
not running.