7 + 9 1 2 1 + 5 3 3 + 6 0 5 + 0 0 0 2 + 0 2 8 E 3 T Sümko Sitesi Isil Apt. M7 A-Blok K:4 No:17 Kozyatagi\Istanbul - Turkey Tel: +090 216 361 42 05 ; Fax : +090 216 372 64 87 [email protected], www.partnerteknik.com This Drawing / document is the property of and it can not be used, reproduced or loaned to third parties without the written permission of PARTNERTEKNIK Issued for Scale : Size : A4 SUBCODE LISCO - Libyan Iron & Steel Co. - MISURATA Expansion Of The Raw Material Handling System Cable Reel Data Sheet-(CONDUCTIX) Sht. 1 Of 85 REV Descpriction Drawn Chk'd Approved Date Rev. 0 APPROVAL 24.08.2013 Y.UZUN A.YASLAK ISSUED FOR OWNER APPROVAL Y.UZUN 0 LIBYAN IRON AND STEEL CO MISURATA STEEL COMPLEX, LIBYA TITLE : EXPANSION OF THE RAW MATERIAL HANDLING SYSTEM CD FILE NO. DRAWING No. TS - 28E3 CONSULTING DASTUR ENGINEERING INTERNATIONAL GmbH DÜSSELDORF ENGINEERS M. N. DASTUR AND COMPANY (P) LIMITED KOLKATA Page 1 of 79
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Expansion of the Raw Material Handling System Cable Reel Data Sheet-(CONDUCTIX)
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This Drawing / document is the property of and it can not be used, reproduced or loaned to third parties without the written permission of PARTNERTEKNIK
Issued for
Scale :
Size : A4
SUBCODE
LISCO - Libyan Iron & Steel Co. - MISURATA
Expansion Of The Raw Material Handling SystemCable Reel Data Sheet-(CONDUCTIX)
Sht. 1 Of 85
REV Descpriction Drawn Chk'd Approved Date
Rev. 0
APPROVAL24.08.2013Y.UZUN A.YASLAKISSUED FOR OWNER APPROVAL Y.UZUN0
LIBYAN IRON AND STEEL COMISURATA STEEL COMPLEX, LIBYA
TITLE : EXPANSION OF THE RAW MATERIAL HANDLING SYSTEMCD FILE NO.DRAWING No. TS - 28E3
CONSULTING DASTUR ENGINEERING INTERNATIONAL GmbH DÜSSELDORF ENGINEERS M. N. DASTUR AND COMPANY (P) LIMITED KOLKATA
Page 1 of 79
Quote No.D-E-2013-50220-371-C-134413UE
30, avenue Brillat Savarin - 01300 Belley - France
Technical parameters of the application (Customer data)
Application Horizontal retriever with deflection, Reel installed on mobile equipment
Equipment travel length 1020 m Feeding point Center feeding Reel travel length 510 m Traveling speed 30 m/min Acceleration 5 s (0,1 m/s²) Installation height 6.5 m (between spool center and ground)
Ambient temperature 5°C / 45°C Wind speed 20 m/s Environment MA3 - seaside
Mains voltage 10000 V Cable type WG-D - WG-D 8.7/15 - 3x95 + 2x50/2 + 12FO
Motor voltage 400 V Three phase 50 Hz
Reeling direction Clockwise (1)
Please note that any deviation from the above parameters may cause the reel not to perform properly or may lead to damage. If the actual values vary from the above, please inform us. We will be pleased to revise our quote.
Equipment description
Motorized cable reel type BNA700.3CN55.M2575VS 3TH12+TFO40.6FO62.5
Gearbox Type Bevel gear. Cast iron housing Model 1 main gearbox type BNA700 + 3 additional gearboxes(s) type 55 Maintenance The gearbox and gear reducers all have gears running in grease for 5 years or 15,000
operating hours without any maintenance. The sealed ball bearing requires little or no maintenance.
Treatment and paint Paint: SP200 . Thickness : 200 microns, final color: Orange RAL 2008
Drive Motor 3 x AC induction motor, 1.5 kW. 400 V AC - 50 Hz - three phase - Class F - IP55 3 with
brake. Using brake(s) allows to de-select one or more motors along the run while unwinding to limit the pull applied to the cable. (To de-select a motor means the motor in not powered and brake is loose)
Treatment and paint molded aluminum alloy body Name plate + bolts & nuts in stainless steel
1-b
Quote No.D-E-2013-50220-371-C-134413UE
30, avenue Brillat Savarin - 01300 Belley - France
Mag Drive 3 permanent magnet coupler(s) type CN with brake motor preventing the cable from spooling off the reel when the motor is not energized.
Spool Type Mono spiral spool with spiral ferrule
Spool delivered in kit Model M2575VS Inner diameter 2,5m Outer diameter 7,5m Number of dead turns 2 Number of extra turns (without element) 1 Treatment and paint Spool in galvanized steel
Slip ring Model 3TH12 Description 3 power rings H12 + ground - 500A - Rated 12000 V, - 100% ED, molded bronze rings each
fitted with a double brush holder including 2 carbon copper alloy brushes and 2 springs for constant pressure
INSTALLATION INSTRUCTIONS MONOSPIRAL SPOOL IN KIT FORM MOTOR DRIVEN REELS WITH MAGNETIC COUPLERS AND ACCESSORIES Cn MOTO COUPLER CABLE REEL SPOOL FASTENING TO CRANE CONNECTIONS TABLE D-E-2013-50220-0371-C-Drawing Data sheet-Cable WG-D-WG-D 8.715-3x95+2x502 +12FO (539m) GEAR BOX LUBRICATION GUIDING DEVICES LS - LD - LDD MAIN GEARBOX TYPE BNA700710 NOTES SLIPRING ASSEMBLY-H7-H12-H24 SLIPRINGS AND TERMINALS MARKING OPTICAL FIBER TRANSMITTER ELECTRICAL DIAGRAM END LIMIT SWITCH SPACE HEATER 500 W LONG TIME STORAGE 79
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
A - GENERAL INFORMATION
A.1. Responsabilities
The user is responsible for the installation and use of the equipment supplied according to the regulations described hereafter. CONDUCTIX-WAMPFLER will not be able to guarantee the equipment if these regulations are not adhered to, except in the case of prior agreement. All operation of the equipment must be carried out by qualified personnel, in accordance with current norms and regulations.
A.2. Data and modifications
This document provides the information required for the start up, use and maintenance of the reel. CONDUCTIX-WAMPFLER reserves the right to modify the characteristics of its products at any time in order to include the most recent technological developments. The information contained in this document may, therefore, be modified at any moment without prior notice.
A.3. Safety
A.3.1. General information
During all maintenance and adjustment work and whenever the equipment is being operated with the protective covers open basic safety rules must be respected. During normal working all the covers must be in place and the safety systems must be operational. It is equally important to pay attention to parts which may move, for example the cable and the reel.
A.3.2. Slipring
The protective cover must never be opened unless power is off.
A.4. Restrictions of use
A.4.1. Wind
If the wind speed is ≤ 20 m/s : normal working
If the wind speed is > 20 m/s and ≤ 28 m/s : half speedworking.
If the wind speed is > 28 m/s and ≤ 35 m/s : stop working.The machine must be stopped with empty spool.
If the wind speed is > 35 m/s and ≤ 70 m/s : stop working.Lash down the reel and spool. The machine must bestopped with empty spool.
If the wind speed is > 70 m/s: risk of damage to completereel installation.
NEVER REMOVE SLIPRING COVER WHEN POWER IS ON.
DANGER OF DEATH
Page 8 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
B - INSTALLATION
B.1. Shipment
CONDUCTIX-WAMPFLER cable reels are shipped on a transport frame for easy handling by fork lift truck. All accessories and spools delivered in kit form are shipped on a wooden pallet Spools assembled in two parts are delivered in open-sided crates.
B.2. Erection of the cable reel
B.2.1. Handling
The main gear-box has a special opening to pass a lifting sling through.
B.2.1.1 - Small cable reel with semi-wide spool :
A single lifting sling is sufficient.
B.2.1.2 - Larger cable reel with monospiral spool :
Two lifting slings are required. One is hooked onto the spool and is used to balance the load.
If the cable reel is equipped with only one drive, use an extra sling to counteract the lateral weight, according to the further diagram.
B.2.1.3 - Reel with large slipring.
Balance the load with a sling hooked between the gear box and the slipring.
B.2.1.4 - Reel delivered without spool
Two lifting slings are required. One is hooked between the gear box and the slipring. Do not hook the lifting sling on the motors .
If the reel is equipped with a large slipring, use a third sling to balance the load.
Do not use metallic slings or chains which may
damage the cable reel paint .
Page 9 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
Installation of the reel
B.2.2.1. Checking of the support
Before installing the reel, check:
the base is flat,
the base is level in all directions, the center distance and the diameter of all fixing holes
The base must have dimensions which permit it to :
support the weight of the reel and cable,
Support the working stresses (speed of movement,vibrations…),
Support the environmental stresses (wind pressure onfully wound on spool).
B.2.2.2. Installation of the reel
Use fasteners of at least class 8.8, according to thediameter of the holes in the gear box.
B.2.3. Spools not mounted on the gear box
B.2.3.1. Preparation
See specific instructions :
Monospiral spool delivered in 2 or 4 parts
Monospiral spool delivered in kit form- with tubular arm - with profiled arm
Monospiral spool delivered in 2 parts withconnection box on the gear box.
...
B.2.3.2. Fitting of the spool onto the reel
It is ESSENTIAL to use the bolts provided on the hub with safety nuts.
Follow precisely the instructions concerning the position and tightening torque as indicated on tick-on label.
nut on gear box side
tightening torque for M18 = 23 mdaN
tightening torque for M20 = 33 mdaN
Tighten crosswise with :
initial tightening at half the maximum torque
final tightening at maximum torque.
B.2.3.3. Checks
If no value is specified on the spool assembly instructions manual :
Maximum out of round on the outside flange = ± 5 mm
Maximum out of flatness of the outside flange = ± 5 mm
Distance between 2 flanges = Test spacer +0 to -2 mm
B.3 - Fitting of accessories (Guiding device,
Anchoring device, Entry device, Diverting device,
Connection box)
B.4. Installation of the cable on the spool
B.4.1. Preparation
B.4.2. Installing the cable on the spool
It is essential to comply with the following: 1- Winding direction: It is the direction of the spool when motor(s) turned in the direction indicated by the arrow fixed on the motor(s) 2 - Positioning of the cable drum as per sketch
Check that the diameter of the cable complies
with the specifications.
If the difference is larger than 2 mm,
please contact your Conduxtix-Wampfler agency
Make sure that the outer surface of the cable is
not greasy or slippery
(grease, oil, paraffin wax, …).
If necessary, clean the cable before installing it
on the spool.
RISK OF DAMAGE ON THE SPOOL.
When fitting a cable guide, return cable guide or
anchoring device, make sure that these
accessories are in the same plane as the spool
For spool with spiral ferrule, check the winding
direction of the cable.
(See specific spool mounting instructions) .
NE JAMAIS RETIRER LE CAPOT DE COLLECTEUR DE L’ENROULEUR
LORSQUE CELUI-CI EST SOUS TENSION.
DANGER DE MORT.
Tous ces accessoires doivent être MONTES DANS
L'AXE DE LA BOBINE.
POUR UNE VIROLE SPIRALEE (VS sur désignation),
vérifier le SENS D’ENROULEMENT DU CABLE
(voir notices spécifiques de montage des bobines).
POUR UNE VIROLE SPIRALEE (VS sur désignation),
vérifier le SENS D’ENROULEMENT DU CABLE
(voir notices spécifiques de montage des bobines).
Tous ces accessoires doivent être MONTES DANS
L'AXE DE LA BOBINE.
Tous ces accessoires doivent être MONTES DANS
L'AXE DE LA BOBINE.
Page 10 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
B.4.3. Fixation of the cable to the moving part
In front of the spool
Bring the end of the cable on the spool according to thewinding direction.
Let a sufficient length for the connection to the slipring(See § Connection onto the rings).
Fix the collar and the cable reel.
Engage the cable in the cable gland on the moving part.
B.4.4. Winding on of the cable
Connect the drive motor(s) to wind the reel onto thespool.
The cable drum must be unwound manually to avoidany damage on the cable (caused by excessive loador twisting).
B.5. Connection of the cable to the motor reel
B.5.1. Low Voltage Sliprings
B.5.1.1. On the rings (Moving part - The cable is coming from the spool)
Push cable throufh the shaft of the reeling drum.
Allow a sufficient length of cable coming out of the slipring
( 300mm).
Tighten the cable gland and the tie wrap on the spool.
Strip the cable back and prepare the ends according tothe table « Connections ».
Connections by * Core lead terminals on C type Sliprings;* Stud fixings on P type Sliprings.
Position the terminals according to the below sketches. Secure the terminals with nut and washer
P080 / P120 / P180
P050
Type P Type C
Check that there is a clearance (A) between
the loops of cable and the slipring housing
(at least 30mm).
Tous ces accessoires doivent être MONTES DANS
L'AXE DE LA BOBINE.
Page 11 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
B.5.1.2. Onto the brushes (Fixed part - Cable supplied by the customer)
The slipring housing is fitted with a removable plate forcable glands.
Push the cable through the cable gland of the slipringhousing.
Let a sufficient cable length for the connections onto thebrushes (see attached ‘sliprings’ technical leaflet).
Strip back the cable up to the cable gland.
Attach the cable with a COLSON collar on the insulatorrod as per sketch to well organize the cores on the brushholders.
Connection :- with female Faston Terminal 6,35 for C type sliprings. - with lug for P type sliprings:
- Place the terminal as indicated on the sketch. - Tighten while holding the brushes parallel to the isolators.
Make sure that each brush is in line with its correspondingring without any pressure on the isolators.
Tighten the cable gland.
B.5.2. High Voltage Sliprings
Preparation of cable ends:FOR HIGH VOLTAGE, THE CHOICE OFCOMPONENTS AND THE JOB MUST BE ACHIEVEDBY CERTIFIED SPECIALISTS.
THESE COMPONENTS MUST BE DESIGNED FOR A HUMID OUTSIDE USE.
The extremity of the cable end, terminal side, must be made watertight with putty or appropriate adhesive.
The conductors connected to the brushes (fixed part) must be attached lateral on the housing in order that the insulation distances are respected.
The conductors connected to the rings (moving part) and the cable ends must not touch the rings, on which they are not connected.
Connection to the rings / brush holders:See attached technical leaftet (connections table).The High Voltage Housings are fitted with aREMOVABLE PLATE for the cable glands.
B.5.3. Option / TFO (Fiber Optic Transmitter)
Inlet and Outlet optical connections type ST (Other typeon request).
A removable plate, fitted on the housing, is designed toaccommodate the cable gland. Connection with opticalconnectors
It is absolutely essential to read the
instructions before attempting the optical
and mechanical connections.
Putty or adhésif
Putty or sticky strip
Page 12 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
B.6. Connection of the cable at the feed point
Avoid using any device which pinches the cable
For vertical application use an anchoring device withshock absorber and cable sleeve for the fixation of the
cable to the mobile equipment.
B.7. Electrical connection of the motor(s)
Connect the motor(s) in accordance with the motorsmanufacturer’s wiring diagram, especially for terminalbox.
B.8. Electrical connection of the accessories
Depending on the chosen options:
Space heater in the slipring.
End limit switch : contact on the end limit switch .
Over pull, under pull : switches on the cable guide.
Temperature sensor and motor heating : in motor connection box.
Brake motor: inside terminal box.
C - COMMISSIONING
C.1. Energizing the drive motor(s)
Before the drive motor(s) is energized, make sure that: - there is no slack cable - the cable is in the correct position on the spool and guiding device.
C.2. Limit switch adjustment ( (option)
Position the machine at the required point.
Adjust the cam to the tripping position : See attached ‘Endlimit switch’ technical leaflet.
Check that the adjustment is correct (travel through theend limit point several times).
Note: When using an under pull switch, the neutralising contact must be adjusted as close as possible to the middle point.
C.3. Over Pull adjustment onto guiding device
(Option)
See attached technical leaftet.
C.4. Various adjustements
C.4.1. Change of the cable winding direction
Reverse the direction of the cable on the drum:
Reverse the cable entry (depending on spool type)
Reverse the spiral ferrule (if fitted)
Reverse the cable clamp.
Reverse the free wheels (see data sheet for moto- couplers)
Reverse the rotation direction of the drive motors.
For TFO option: see specific instructions.
C.4.2. Cable of different diameter
Width of monospiral and trispiral spools assembled usingnuts and bolts are adjustable.
C.4.3. Adjustment of W - CN - D couplers
See attached technical leaftet.
C.5. Troubles shooting list
See list hereafter
During winding and unwinding, the drive motor
turns always in the same direction
(winding direction of the cable).
When drive motor(s) is energized, make sur
that the motor is rotating in the correct
direction (winding direction)
This equipment is designed for an industrial
use. Ensure that the operators are trained
in the use of this material.
This equipment is not designed to be used
in Explosive ATmospheres (ATEX)
(in accordance with the definition in
directive 1999/92/CE
dated 16th December 1999).
AT THE END OF PAYOUT, WHEN THE
SPOOL IS EMPTY, ONE DEAD TURN OF CABLE
MUST ALWAYS REMAIN
NE JAMAIS RETIRER LE CAPOT DE COLLECTEUR DE L’ENROULEUR
LORSQUE CELUI-CI EST SOUS TENSION.
DANGER DE MORT.
Tous ces accessoires doivent être MONTES DANS
L'AXE DE LA BOBINE.
POUR UNE VIROLE SPIRALEE (VS sur désignation),
vérifier le SENS D’ENROULEMENT DU CABLE
(voir notices spécifiques de montage des bobines).
POUR UNE VIROLE SPIRALEE (VS sur désignation),
vérifier le SENS D’ENROULEMENT DU CABLE
(voir notices spécifiques de montage des bobines). Tous ces accessoires doivent être MONTES DANS
Tous ces accessoires doivent être MONTES DANS
L'AXE DE LA BOBINE.
Page 13 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
PROBLEM POSSIBLE SOURCE CORRECTIVE ACTIONS
Cable spool’s off (unwinds) although cable reel main
power is OFF
Free-wheel failure or break down Replace free wheel by new.
Brake failure on brake motor Clean brake and replace if necessary.
Motor coupling failure Replace coupling by new.
Magnetic coupler failure Replace magnetic coupler.
Broken or worn gear in additional gear box Replace entry gear-set on coupler side if worn or broken. Replace complete additional gearbox if problem occurs inside of it.
Broken or worn gear in secondary gearbox Replace secondary gearbox if problem occurs inside of it.
Broken or worn gear in main gearbox Replace worn gear only.
Torque transmission failure between conical gear and spool’s shaft (key or thrust collar)
Replace the shaft with the conical gear and the thrust collar/key.
Cable reel does not wind cable fast enough or
cable is not wound in the right manner while reel motors are powered ON
Motor(s) spinning direction has not been setup correctly.
Change motor power wiring to the right setting (in order that motor(s) revolve in the right direction according to cable reel setup).
Motor failure/breakdown Replace Motor with one that has the exact same characteristics.
Free wheel has not been setup correctly Change the free wheel spinning direction according to coupler documentation/manual delivered with cable reel.
Brake failure on brake motor Clean brake and replace if necessary.
Cable does not wind up the spool in the right manner
Spool’s axle/shaft is not perfectly horizontal or perpendicular to cable lifting path. (spool is not well aligned with cable path/way)
Install / adjust the cable reel on its support in order that the spool is aligned in both directions.
Friction on cable is excessive Check and make sure that accessories (guiding device, roller boxes, anchoring…) are setup correctly and aligned with the spool. Check rollers on accessories and replace those that do not revolve freely. Check the gap/distance between the 2 flanges of the spool is setup correctly. Adjust it if possible. If the spool cannot be adjusted please contact your Conductix-Wampfler Agency.
Setup parameters are different from the one used to determine the cable reel (speed, acceleration, height)
Check and adjust parameters. If necessary please contact your Conductix-Wampfler Agency.
Cable submitted to torsion stresses Unwind the cable and disconnect it. Remove strains.
Coupler failure Replace coupler by new.
Secondary gearbox failure Replace secondary gearbox by new.
Additional gearbox failure Replace additional gearbox by new.
Main gearbox failure Check gears and ball bearings are not worn. Replace those if necessary.
The main gear box is defective. Check the good state of the pinions and rollers. Change them if necessary.
Page 14 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
PROBLEM POSSIBLE SOURCE CORRECTIVE ACTIONS
Guiding device returns wrong information (over
pull, under pull, position )
Proximity switch failure or proximity switch wrongly adjusted.
Adjust the switch or replace it if necessary.
Faulty electrical continuity through cable reel system
Cable failure Check cable integrity and replace it if necessary.
Connections are not properly tightened Check and tighten loose connections on slip-ring, connecting box, and control box.
Slip-ring brushes are worn Replace with new brushes.
Rings inside the slip-ring are dirty Remove dirt by gently polishing the rings with emery cloth.
Humidity inside the slip-ring housing Check and make sure the screws of the slip-ring cover are correctly tightened.. Check the gasket between slip ring and cover is not damaged nor worn (replace it if necessary). Check the respirators are not damaged nor worn and replace those if necessary.
Condensation appears in the slip ring housing. Check heating resistance is correctly powered and working. Replace it if necessary. Install heating resistance inside the slip ring housing if not originally provided.
Rings and brushes are not aligned. Align brushes with rings.
Slip-ring guiding roller breakdown Change worn or broken roller(s).
Faulty optical continuity through cable reel system
Cable failure Check cable integrity and replace it if necessary.
Connection problem Clean connectors and replace those if necessary.
Faulty equipotential protection continuity through cable reel system
Earth washers are missing on the bolts that tighten the spool onto the shaft flange
Place Earth washers.
Shunt failure between slip ring housing and earth ring Replace shunt.
Loosening of the slip ring hub Tighten the slip ring hub on the gear box shaft.
Page 15 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
D - MAINTENANCE
Frequency
1 Every 2 000 working hours / 6 months
2 Every 2 000 working hours / 1 year
3 Every 8 000 working hours / 2 years
4 Every 10 000 working hours / 3 years
5 Every 15 000 working hours / 5 years
All new cable has some twisting stresses due to the manufacturing process. After 200 working hours, these stresses must be eliminated in proceeding as follows:
Place the reel approximately 10 m from the cable anchoring position. Switch off power to the reel. Disconnect and free the cable from its anchoring position. If stresses exist, the cable will eliminate them by turning on itself. If necessary, help the cable to do this. Re-assemble and reconnect following the steps in reverse order.
PART Step OPERATIONS Fre-
quency Done Comments
SPOOL A Spool centre bolts. 1
B Rim gap at several points (every 3 arms). 2 Values =
C Geometry and visual aspect. 2
D Rim connector bolts. 2
E Cable entry : clamp and cable protection. 2
Firmly attach the spool to the crane to avoid cable pay-out.
Ensure POWER IS OFF !!!
BRAKE AND MOTOR
A Open and clean up. 1
B Electrical test. 1
C Evacuate moisture by bleed nipple opening.
1
MAGNETIC COUPLER
A Visual aspect. 1
B Free wheel - Anti run back bearing : working and visual aspect.
3
C Coupling ring aspect. 1
D Bolts tightening check. 2
ADDITIONNAL GEAR BOX and SECONDARY GEAR BOX
A Visual aspect of pinions (teeth). 2
B Pinions play. 2
C Grease leakage and aspect. 2
D Lubricant replacement. 5
Page 16 of 79
INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER
Frequency
1 Every 2 000 working hours / 6 months
2 Every 2 000 working hours / 1 year
3 Every 8 000 working hours / 2 years
4 Every 10 000 working hours / 3 years
5 Every 15 000 working hours / 5 years
PART Step OPERATIONS Fre-
quency Done Comments
MAIN GEAR BOX
A Gearbox fixings. 2
B Visual aspect (paint). 2
C Sealing and oil leakage. 2
D Grease level and use. 2
E Bearing lubrication (old BNA). 2
F Bearing use (noise ?). 2
G Grease replacement. 5
H Play between conical gears (0,3mm at contact point).
2
I Visual aspect of gears. 2
J Small conical gear bolt (if existing). 2
SLIPRING A Heating resistance. 2
B Alignment of the brush holders.
Wear of the brushes.
1
X = mm
C Aspect and wear of the rollers. 1
D Tightening of the hubs and screws. 2
E Cleaning of the rings. 1
F Tightening of the connections. 2
G Cleaning of the enclosure. 2
GUIDING DEVICE
A Visual aspect (geometry, position, corrosion). 2
Assembly & Installation Instructions Bobine Monospire en Kit - Bras en “C”
Monospiral Spool in Kit Form - C-Shape spokes
Page 19 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
Étape 10 Étape 10 -- Step 10Step 10 Renforts de bras Spoke reinforcements
Étape 6 Étape 6 -- Step 6Step 6 Bras (Face Avant)
Spokes (Front Side)
Étape 9 Étape 9 -- Step 9Step 9 Virole extérieure avant Front outside rim
5
1
2a
3
2b
9 6 7
4
6 7
�� LISTE DES PIECES LISTE DES PIECES -- PART LIST PART LIST ��
ECLISSE / RIM CONNECTOR
Page 20 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
�� OUTILLAGE ET PERSONNEL REQUIS OUTILLAGE ET PERSONNEL REQUIS -- REQUIRED TOOLS AND CREW REQUIRED TOOLS AND CREW ��
�� HORS FOURNITURE HORS FOURNITURE -- BY OTHERS BY OTHERS ��
�� SENS D’ENROULEMENT SENS D’ENROULEMENT -- WIND UP DIRECTION WIND UP DIRECTION ��
�� ENTRE FLASQUE ENTRE FLASQUE -- RIM GAP RIM GAP ��
A : 10 40 N.m min 339 N.m max 30 lb.ft min
251 lb.ft max
A : 17 - 19 - 30 A : 17 - 19 - 30
A : 17 - 19 - 30× 4
Zmini 150 mm � × 4
× 4
H ~ 1 m
X2 Ø 12 mm L ~150mm
X3 Ø 20 mm
L ØD
ØD
D1 max D2 d H
X1 Ø 650 Ø 400 Ø 22 ~ 1 m � p.13-13
SENS 1 DIRECTION 1
SENS 2 DIRECTION 2
B
ØC
Axe bobine Spool axis
Ø ext. câble O.D. cable
Entre flasque B Rim gap B
ØC ≤ 40 mm ØC + 10%
ØC >40 mm ØC + 4 mm
Vérifier le diamètre du câble avant assemblage de la bobine. Si l’écart relevé est supérieur à ± 2 mm par rapport au diamètre de câble prévu, contacter votre agent local CONDUCTIX-Wampfler.
Check the Outside Diameter of cable before assembling. If the difference in comparison with the expected cable diameter is greater than ± 2 mm, contact your local CONDUCTIX-Wampfler representative.
Page 21 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
��� ETAPE 1 ETAPE 1 ETAPE 1 --- STEP STEP STEP 111 ���
��� ETAPE 2 ETAPE 2 ETAPE 2 --- STEP STEP STEP 2 2 2 ���
A HM20 - ... × 4
B H M20 × 4
C Ø20 × 4
HORS FOURNITURE BY OTHERS
E1 H M20 × 2
RF1 CS 20 × 2
1 2
Trou de levage Handling hole
SENS D’ENROULEMENT-WIND UP DIRECTION Vue Face Avant -Front Side View
RF1
E1 3
X2
��� ETAPE 3 ETAPE 3 ETAPE 3 --- STEP STEP STEP 3 3 3 ���
Répéter pour chaque bras 2b. Repeat for every spoke 2b.
��� ETAPE 4 ETAPE 4 ETAPE 4 --- STEP STEP STEP 4 4 4 ���
Voir p.13-13 / See p.13-13 ⇐⇐⇐⇐ ΙΙΙΙ ΙΙΙΙΙΙΙΙ
V1 HM20-120 ×28 ×30
E1 H M20 ×56 ×60
RP1 Mu 20 ×28 ×30
RF1 CS 20 ×56 ×60
E1 H M20 × 3
RF1 CS 20 × 3
RF1
RF1
E1
E1
3
2b
B
E1 RF1
RP1
V1
2b
C
B
X1
4 1 A FACE AVANT FRONT SIDE
ASSEMBLAGE BOBINE - ASSEMBLY OF SPOOL La visserie ne doit pas être bloquée - Bolts and nuts should be lightly tightened only
Graisser la visserie avant montage suivant indication - Apply lubricant to threads where indicated:
Page 22 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
��� ETAPE 6 ETAPE 6 ETAPE 6 --- STEP STEP STEP 6 6 6 ���
Répéter pour chaque bras 2a. Ordre de montage suivant Étape 4.Repeat for every spoke 2a.
Mounting sequence order identical to Step 4.
��� ETAPE 7 ETAPE 7 ETAPE 7 --- STEP STEP STEP 7 7 7 ���
Bras 2a non représentés Spokes 2a not shown
2a
E1
RF1
ΙΙΙΙ ΙΙΙΙΙΙΙΙ
E1 H M20 × 81 × 87
RF1 CS 20 × 81 × 87
5a
5a
3
��� ETAPE 5 ETAPE 5 ETAPE 5 --- STEP STEP STEP 5 5 5 ���
Respecter l’ordre de montage des bras. Mounting order of the spokes should be observed.
1 3
5 7 9 11
10 8 6 4
2
RF1
E1
2b
ΙΙΙΙ ΙΙΙΙΙΙΙΙ
E1 H M20 × 54 × 58
RF1 CS 20 × 54 × 58
1 2
SENS D’ENROULEMENT-WIND UP DIRECTION Vue Face Avant -Front Side View
3
Page 23 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
��� ETAPE 7 (…) ETAPE 7 (…) ETAPE 7 (…) --- STEP 7 (…) STEP 7 (…) STEP 7 (…) ���
Conserver un jeu provisoire entre les 2 demies viroles
intérieures. Keep a temporary clearance
between the 2 inner drum halves.
��� ETAPE 8 ETAPE 8 ETAPE 8 --- STEP 8 STEP 8 STEP 8 ���
Assemblage de la virole extérieure arrière. Assembly of the back outside rim.
Ne pas serrer la visserie à ce moment.
Do not fully tighten the nuts at this time.
Faire correspondre les repères couleur. Assemble according to the coloured marks.
V2 RF2 E2
V2 RF2 E2
V2 HM12-35 × 4
E2 H M12 × 4
RF2 CS 12 × 4
ΙΙΙΙ ΙΙΙΙΙΙΙΙ
V4 CHcM12-30 × 80 × 90
E2 H M12 × 96 × 110
RF2 CS 12 × 96 × 110
��� ETAPE 9 ETAPE 9 ETAPE 9 --- STEP 9 STEP 9 STEP 9 ���
Assemblage de la virole extérieure avant suivant ETAPE 8.Assembly of the front outside rim identical to STEP 8.
V4-E2-RF2
V4-E2-RF2
2a
2b
6
7a
6
V4-E2-RF2
7b
����
☺☺☺☺ 6
Page 24 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
�� ETAPE 1 ETAPE 1 -- STEP 1 STEP 1 ��
REGLAGE ET BLOCAGE DE LA VIROLE EXTERIEURE ARRIERE Régler et bloquer une première éclisse suivant fig 1A puis fig 1B. Régler et bloquer ensuite une série de bras jusqu’à la seconde éclisse suivant fig 1C. Procéder ainsi pour toute la virole arrière.
ADJUSTMENT AND TIGHTENING OF THE BACK OUTSIDE RIM Adjust and tighten a rim connector first as shown in fig 1A and then fig 1B. Moving around the spool, adjust and tighten a series of spoke up to the second rim connector as shown in fig 1C. Repeat the same sequence all around the back outside rim.
REGLAGE & BLOCAGE DE LA BOBINE
SPOOL ADJUSTMENT & TIGHTENING
��� ETAPE 10 ETAPE 10 ETAPE 10 --- STEP 10 STEP 10 STEP 10 ���
Ne pas serrer la visserie à ce moment. Do not fully tighten the nuts at this time.
ΙΙΙΙ ΙΙΙΙΙΙΙΙ
V3 HM10-20 × 224 × 240
E3 H M10 × 224 × 240
RF3 CS 10 × 224 × 240
9
E3
RF3
V3
E2
Virole extérieure avant Front outside rim
Virole extérieure arrière Back outside rim
Fig.1A
E2 69 N.m 51 lb.ft
E2
Fig.1B
2
1
3 4
1
2 3
(4)
Fig.1C
E2
E2
Page 25 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
�� ETAPE 2 ETAPE 2 -- STEP 2 STEP 2 ��
Réglage et blocage de la virole extérieure avant suivant Étape 1.Adjustment and tightening of the front outside rim identical to Step 1.
�� ETAPE 3 ETAPE 3 -- STEP 3 STEP 3 ��
Répéter pour chaque axe épaulé 4.
Repeat for every shouldered stud 4.
�� ETAPE 4 ETAPE 4 -- STEP 4 STEP 4 ��
Préparer les 2 cales de réglage.
Prepare the 2 gauges.
Serrer au couple recommandé les écrous
E1.
Fully tighten the nuts E1 first.
E1
4
E1 339 N.m 250 lb.ft
ØC+2mm ØC+4mm
N°1 N°2
11
E1 339 N.m 250 lb.ft
REGLAGE DE L’ENTRE FLASQUE ADJUSTMENT OF THE RIM GAP
Nous recommandons d’opérer par zones successives de 3 à 4 paire de bras.
We recommend to proceed by successive areas covering 3 to 4 pairs of spokes.
Faire une vérification finale de l’entre flasque sur toute la cir-conférence de la bobine avant de bloquer les écrous Ex.
Finally check the rim gap all around the spool before fully tightening the nuts Ex.
ØC
+4
+2
Ex
2b
2a E1
4
N°1
Si… - If ... Alors… - Then ...
J
N°2
Si… - If ... Alors… - Then ...
Page 26 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
�� ETAPE 5 ETAPE 5 -- STEP 5 STEP 5 ��
E2 69 N.m 51 lb.ft
E2
E2
5
�� ETAPE 6 ETAPE 6 -- STEP 6 STEP 6 ��
Plaquer les renforts 9 contre la virole inté-rieure 5 avant blocage.
Push the spoke reinforcements 9 against the inner rim 5 before fully tightening.
==
E3
9
E3 40 N.m 30 lb.ft
MANUTENTION & INSTALLATION BOBINE
SPOOL HANDLING & INSTALLATION
�� ETAPE 1 ETAPE 1 -- STEP 1 STEP 1 ��
Répartir et fixer des cales entre les viroles extérieures et entre les bras pour conserver l’entre flasque pendant le levage de la bobine.
Distribute and secure spacers between the outside rims and between the spokes so as to keep the rim gap during the lifting sequence of the spool.
ØC+2mm
�� ETAPE 2 ETAPE 2 -- STEP 2 STEP 2 ��
���� ☺☺☺☺
BOBINE SPOOL
kg lbs
M 2565-VS 2 800 6 175
M 2570-VS 3 000 6 615
M 2575-VS 3 500 7 715
M 3080-VS 4 000 8 820
A titre indicatif - For information only
Page 27 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
�� ETAPE 3 ETAPE 3 -- STEP 3 STEP 3 ��
Cales en bois Wood blocks
Maîtriser la rotation et le balancement de la bobine pendant le levage.
Control both rotation and swing of the spool during lifting.
☺☺☺☺ ���� ����
☺☺☺☺
X3
����
• Respecter le montage des rondelles demise à la masse et les couples de serrage préconisés Cs (étiquette adhésive sur l’arbre du réducteur).
• Observe the mounting of the Earthconnection washers and the recommended torque values (self-tick on the gearbox shaft).
• Utiliser uniquement la visserie fournie sur le disque del’enrouleur. • Les écrous de sécurité doivent être installés du coté du ré-ducteur. • Pour des raisons de sécurité, ces consignes doivent être res-pectées en cas de démontage / remontage de la bobine.
• Use the bolts and nuts from the disc of the cable reel only.• The safety nuts must be installed at the gearbox side.• For safety reasons these rules should be also observed whenthe spool is to be removed.
Page 28 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
Pour corriger l’entre flasque de la bobine: ⇒ dévisser les écrous E3 maintenant les renforts de bras 9
⇒ agir sur les écrous Ex suivant ETAPE 4 (p.8-13) jusqu’à ob-tention de la correction voulue.
⇒ Bloquer à nouveau les écrous E3 suivant ETAPE 6 (p.8-13).
To improve the rim gap of the spool: ⇒ loosen the nuts E3 which hold the spoke reinforcements 9.
⇒ screw / unscrew the nuts Ex as described in STEP 4 (p.8-13)until the correction is achieved.
⇒ Fully tighten the nuts E3 according to STEP 6 (p.8-13).
2a
E3
Ex
2b 3
Effectuer d’abord un serrage initial croisé à ½ Cs puis un serrage final à Cs.
First carry out a primary crosswise tightening up to ½ Cs and then the final tightening up to Cs.
�� ETAPE 4 ETAPE 4 -- STEP 4 STEP 4 ��
CONTROLE - INSPECTION (câble non installé - uninstalled cable)
Contacter CONDUCTIX-Wampfler si ces tolérances ne sont pas respectées.
Contact CONDUCTIX-Wampfler if these permissible variations are not observed.
1
6
12 8
7
4
3
9 11
2
5
10
FAUX ROND SUR VIROLES EXTERIEURES OUTSIDE RIM RADIAL DEVIATION
���� = 20 mm max.
VOILE SUR VIROLES EXTERIEURES OUTSIDE RIM WARPING
= 50 mm max.
ENTRE FLASQUE RIM GAP
ØC +4/+2 mm
Page 29 of 79
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
�� ETAPE 5 ETAPE 5 -- STEP 5 STEP 5 ��
Vérifier qu’aucune bavure ou angle vif sur les bras et la virole extérieure ne puisse endommager le câble. Consulter la notice générale de l’enrouleur avant de: ⇒ mettre en place du câble sur la bobine⇒ raccorder le câble sur l’enrouleur motorisé
Check that the spokes and the outside rims are free from any sharp edges or burrs which could damage the cable. Consult the cable reel instruction manual before: ⇒ installing the cable onto the spool⇒ connecting the cable onto the motorized reel.
SENS D’ENROULEMENT 1 WIND UP DIRECTION 1
SENS D’ENROULEMENT 2 WIND UP DIRECTION 2
V2
RF2
E2
3 8
3 8 V2
RF2
E2
V2 HM12-35 × 2
E2 H M12 × 2
RF2 CS 12 × 2
�� ETAPE 6 ETAPE 6 -- STEP 6 STEP 6 ��
CONTROLE FINAL
FINAL INSPECTION (câble installé - installed cable)
Après un cycle déroulement - enroulement complet du câble en marche automatique, contrôler que l’entre flasque de la bobine en bout de bras est inférieur à ØC × 1,35. Corriger si nécessaire.
Wholly unwind and wind-up the cable (automatic running). Then check that the rim gap of the spool measured at spoke ends is less than ØC × 1.35 . Adjust where necessary.
NOTICE DE MONTAGE ET INSTALLATION - ASSEMBLY AND INSTALLATION INSTRUCTIONS BOBINE MONOSPIRE EN KIT - BRAS EN “C” / MONOSPIRAL SPOOL IN KIT FORM - “C” SHAPE
BOBINE / SPOOL : M _ _ _ _ – _ _ _ Entre flasque prévu ’B’ / Expected rim gap ‘B’ : mm
Sens d’enroulement / Wind up direction : 1 - 2 N° d’enrouleur / Motorized reel No :
BOBINE SPOOL
TYPE NOMBRE DE PAIRES DE BRASNUMBER OF SPOKE PAIRS
NOMBRE D’ECLISSES PAR VIROLE EXT. NUMBER OF CONNECTORS PER O. RIM
M __65-___
M ____-___
M __72-___
Ι × 28 × 4
M __73-___
M ____-___
M __80-___
ΙΙ × 30 × 5
Pot de graisse
Pot of lubricant TYPE Item Description Nb Item Descr. Nb Item Descr. Nb Item Descr. Nb
Ι V1
V2
V3
V4
H M20-120
H M12-35 H M10-20
CHc M12-30
28
6 224
160
E1
E2
E3
H M20
H M12 H M10
196
166 224
RP1 Mu 20 28 RF1
RF2
RF3
CS 20
CS 12 CS 10
196
166 224
1
ΙΙ V1
V2
V3
V4
H M20-120
H M12-35 H M10-20
CHc M12-30
30
6 240
180
E1
E2
E3
H M20
H M12 H M10
210
186 240
RP1 Mu 20 30 RF1
RF2
RF3
CS 20
CS 12 CS 10
210
186 240
1
TYPE DE CONSTRUCTION - ASSEMBLY TYPES
CONTENU DU REP.10 - ITEM 10 CONTENTS
Page 31 of 79
MOTOR DRIVEN REELS WITH MAGNETIC COUPLERS AND ACCESSORIES
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul
MOTOR DRIVEN REELS WITH MAGNETIC COUPLERS AND ACCESSORIES
Subject to sea spray but not exposed to (heavy) waves
Relative humidity 95% Ambient temperature from - 20°C to + 40°C
ELECTRIC MOTOR
Multi-Voltage plate, covering the following ranges:- 50Hz : 220-240 / 380-415 V - 60Hz : 440-460 V
IP 55 Protection.
Insulation class F.
Moulded alloy terminal box with insulation joint.
Compliance with UTE and CEI 72.1 - 72.2 - 34.1 standards.
Standard: cap or nickel-plated brass cable gland, as permotor manufacturer.On request: delivered with nickel-plated brass cablegland (nickel-plated brass cap if necessary).
External fasteners and identification plate in Stainlesssteel.
SLIPRING
Protection: - IP 55 for Low Voltage- IP 66 for High Voltage.
Respirator.
Cable inlets:
- On shaft by nickel-plated brass cable gland (supplied by Conductix-Wampfler)
- On slipring housing:
* Low Voltage - Hole with plug for mounting of thecable gland by the customer (round housing)
* High Voltage - Removable plate for mounting of thecable gland by the customer.
Thermostatic heating resistance.
GEAR BOX
With water tight housing MAINTENANCE FREE FOR 5YEARS or 15 000 working hours.
Slipring: - High voltage housing in 316L stainless steel.
- IP 66 protection for Low Voltage.
- Low Voltage: Square housing in 304L or 316L stainless steel, with A2 stainless steel fasteners and removable plate if the cable gland is mounted by the customer.
Spool: - Monospiral spool with arms and ferrule in 304L or 316L stainless steel.
General aspect: - A2 Stainless steel external fasteners.
- Paint: special color.
- SP 201 for spool, low voltage slipring, cable guide, anchoring device.
- 304L Stainless steel for cable guide, anchoring device, low voltage connection box.
- 316L Stainless steel for cable guide, anchoring device, low and high voltage connection box.
Fiber Optic Transmitter - Description as per technical leaflet 440N074.
End limit switch : - Possible installations:
At Low Voltage or High Voltage Slipring end.
On gear box entry.
Lateral mounting in the Fiber Optic Transmitter Housing.
3 25/10/11 B. FONTENEAU JC. VAUTARET P. HATZELIS
Rév. Date Etabli par Vérifié par Approuvé par
Page 35 of 79
Cn MOTO COUPLER
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
Cn Moto coupler
Moto coupleur type Cn
4 40N133 03/12 1/3
Weight
• With motor without brake : 34 kg
• With brake motor : 44 kg
The dimensions are given in mm.
4
7 1 Joint Ø189 x Ø 141 x 0,8
6 1 Elastic coupling ring
5 1 Coupling hub
4 1 Spacer (if mounting without anti-run back bearing)
3 1 Anti-run back bearing
2 1 Coupler Cn
1 1 Motor 1,5 kW
Item Qty Description
1 2
3
5 6
Screw HM8×20 +
Washer LL8
7
Overall dimensions and weight
Mounting ................................... Mounting with anti-run back bearing (motor without brake)
Mounting without anti-run back bearing
Page 37 of 79
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
Cn Moto coupler
Moto coupleur type Cn
4 40N133 03/12 2/3
DO NOT DISMANTLE JUST AFTER STOP :
WARM PARTS !
Note: Bolts and nuts are assembled using LOCTITE 243 thread-locking product.
The coupler is adjusted in our factory, according to the installation parameters given by the customer.
If one of these parameters changes or if a lack or an excessive torque is noticed (under-pull or over-pull
on the cable), it is necessary to re-adjust the coupler.
1. Withdraw the 2 screws item 11.
Remove the safety meshguard item 9.
2. Withdraw the 3 locking screws item 30.
3. Hold in position the flange item 17 using a
screwdriver placed between the blades.
Screw (+ torque) or unscrew (- torque) the flange
item 16 using an other screwdriver placed between
the blades.
� 1/6e of turn ~ 0,05 m.daN
Remark
If you don’t know the original adjustment parameters: Screw the flange item 16 up to the mechanical stop. This position corresponds to Co = 0,60 m.daN Unscrew by pitch of 1/6e of turn (~0,05 m.daN) up to obtain the good adjustment. Re-adjust if necessary.
4. Remove the screwdrivers.
Clean the screws and make the operations 2 and 1 (in
this order) for re-assembling.
The screws must be coat with LOCTITE 243 thread-
locking product.
Torque adaptation.....................
Torque
-
+
11
17 16
30 (×3)
9
Page 38 of 79
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
Cn Moto coupler
Moto coupleur type Cn
4 40N133 03/12 3/3
Frequency according to general instructions manual.
• Check the coupling ring item 6.
If the coupling ring shows signs of use or crakling or ir there is a clearance regarding the coupling hub
item 5, change the coupling ring.
• Check the good condition of the anti-run back bearing item 3 :
Remove the motor to access to the anti-run back bearing.
The rotation must be possible in only one direction. (fig.1 or fig.2)
If the rotation is
possible in the 2
directions (even a
little), change the anti-
run back bearing
(fig.3)
• Please indicate the cable reel number.
• MOTORCOUPLING type Cn
• COUPLER type Cn | Spare parts kit including:
- screws and bolts for mounting of the motor
- screws, bolts and joint for mounting on the gear box
- elastic coupling ring
- circlips and pinion drive key.
• OTHERS
Motorcoupling with brake 47C0026/2
Motorcoupling without brake, with anti-run back bearing 47C0026/1
Motorcoupling without brake, without anti-run back bearing 47C0026/3
Description Reference
Coupler type Cn without motor, without anti-run back bearing. 450N066/1
Description Reference
●
1st emergency
Joint Ø189 x Ø141 x 0,8 4J10033
Coupling hub 4 23336 11
Spacer (without anti-run back bearing) 1543081
Motor 1,5 kW 4T02005
● Elastic coupling ring 121082
● Anti-run back bearing 4 01112 40
1st emergency Description Reference
Maintenance .............................
Spare parts ...............................
6 3
fig.1 fig.2 fig.3
Page 39 of 79
CABLE REEL SPOOL FASTENING TO CRANE
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul
LY R E S DE GU I D A G E LS - LD - LDD GU I D I N G DE V I C ES LS - LD - LDD
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
09/09
H = 20 × Ø cable (recommended)or to be adjusted according to the max admissible pull
//
The spool and the guiding devices axis
must be aligned: ± 5 mm
Fixation with 4 bolts
FITTING
OVER-PULL ARM ADJUSTMENT
If the arm is not fitted, place it with the screw item
• Unscrew the screw item
• Remove the bolt item according to the figure A.
• Position the arm item according to the figure B.
• Place the bolt item in the suitable opening (figures C&D)
• Tight the screw item and block the bolt item
• Screw the proximity switch connector (in case of connecting box).
- -
2
1
3
Fig A
1
Fig C
Fig D
1
2 1
2
3
1
2
1
MAX POSITION Detected during normal jerks
~15
mm
1 Fig B
Page 52 of 79
4 40N033 2/3
LY R E S DE GU I D A G E LS - LD - LDD GU I D I N G DE V I C ES LS - LD - LDD
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
09/09
CONNECTION UNDER-PULL / OVER-PULL / POSITION ON TERMINAL BOX
• Proximity switch 20/250V-AC/DC with a 2 wires cable.
• The proximity switches are connected in our factory in the connecting box R.
Customer connection: • Cable with 8 active cores or 5 cores.
- -
L1 L+
N L-
FC6 FC7
FC3 FC5
R
21 22 23 24 25 26 27 28
+ + + +ITEM + DETECTION
FC3 21 22 LEFT OVER-PULL
FC5 23 24 RIGHT OVER-PULL
FC6 25 26 UNDER-PULL
FC7 27 28 POSITION
Customer cable Cable gland ISO25
Connecting box R
BN (Brown)
BU (Blue)
Page 53 of 79
4 40N033 3/3
LY R E S DE GU I D A G E LS - LD - LDD GU I D I N G DE V I C ES LS - LD - LDD
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
09/09 - -
MAINTENANCE • Check the free rotation of guide rollers.If options: • Check the free rotation of under-pull arm rollers.• Check the over-pull arms(position and pull).• Check the good working of the proximity switches.
RECOMMANDED SPARE PARTS
Guiding devices R350 - R500
Guiding devices R750 - R1000 - R1300
ITEM DESCRIPTION REFERENCE
A Guide roller Ø38 4 R75063
B Guide roller Ø38 (with flanges) 4 5R0039
C Roller (under-pull) 4 R75064
D Elastic hub (over-pull) 4 20F082
ITEM DESCRIPTION REFERENCE
A Guide roller Ø55 4 R75062
B Guide roller Ø55 (with flanges) 4 R75059
C Roller (under-pull) 4 R75066
D Elastic hub (over-pull) 4 20F083
ITEM DESCRIPTION REFERENCE
E Proximity switch (option) 4 20F124
C
E
A
E
D
B
Page 54 of 79
MAIN GEARBOX TYPE BNA700710
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul
NUTS and BOLTS are assembled using LOCTITE thread-locking product 243
MAINTENANCE
� Original equipme nt is supplied greased for 15.000 operating hours or 5 years.� Every 2000 hours or every year, check the state of the gears by opening a closing plate.
LUBRICATION
* With grease (See folio 2).
CHANGE OF GREASE
* Open one of the apertures by removing a cover or a drive-unit.* Remove the grease, using a syringe or a rag.
CHANGE OF THE GEAR-WHEEL
∗ Remove the spool, slipring, drive-units and secondary gearboxes.∗ Remove the grease∗ WARNING: Hold in position the shaft with the lifting point of the main frame in order to prevent
misalignment of the bearing item 14 and main frame while operating (Serious risk of escapingthe seals of the bearing if not respected)
∗ Take off the closing flange item 6, fixed by 12 bolts HM 12 x 30.∗ Take off the assembly item 10 and item 11.∗ Fit the new toothed wheel item 11 fixed by 8 bolts CHC 12 x 35 and 2 Mecanindus pins 12 x 20.∗ Refit the assembly item 10 and toothed wheel item 11.∗ Refit 1 or 2 drive units with bevel gear for adjustment reference.∗ Adjust position of the assembly item 10 and toothed wheel item 11 regarding to the conical pinion of the
drive-units with nuts KM 30 item 8 and KM 32 item 12 (access to nuts by one of freed apertures).
NOTICE D'INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
MAIN GEARBOX TYPE BNA700/710
440N153 Folio 1/2 03/12 42R0145 C
Page 56 of 79
PRECAUTIONS WHEN RE-ASSEMBLING
∗ Once closing flange item 6 is in place, check GAP between teeth (0.3 to 0.4 mm).∗ Be careful not to turn over the lip on the joint item 1.∗ Make sure that the joint (JO1) between flange item 6 and main frame is continuous and compatible with
the grease (ORAPI 333).∗ Replace the joints.∗ Respect the position of the respiration screw item 21.∗ When replacing the bearing item 4, grease the bearing and fill the nylos flanges with grease 420F061
before mounting.
SPARE PARTS (Please indicate cable reel reference number when order ing spare parts)
Rep1 450N063 Replacement kit (grease, joints, gear box, technical leaflet) JO3 LOCTITE 5375 Slipring housing joint JO2 4J10033 Additional gear box / Coupler joint JO1 ORAPI 333 Closing flange joint GR According to 410N026 Grease-Quantity : 10 kg 16 175 x 200 x 17 Seal oil ring C 14 420F305/1 Bearing 24032 with contact seal 11 4P28065 Gear wheel 150 teeth M4 10 2333715 Hub 4 FT 129695 Bearing 6226 1 130 x 160 x 15 Seal oil ring C Rep Référence Désignation
NOTICE D'INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
MAIN GEARBOX TYPE BNA700/710
440N153 Folio 2/2 03/12 42R0145 C
Page 57 of 79
NOTES
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
10/12
MAINTENANCE Every 6 months or 2 000 hours: • Remove the cover of the slipring.
• Check the connections.• Check that the screws and threaded rods of the slipring are well tightened.• Check that the hub slipring is well tightened on the driving shaft.• If the rings are marked, slightly pitted or with large carbon deposit, polish with emerie cloth 320 grade.
• Clean the insulators.
• Remove all dust.
• Check:
⇒ the brushes wear (replacement if X ≤ 2 mm),
⇒ the position of the brushes on the rings,
⇒ the quality of the contact of the brushes on the rings.
• Refit the cover using a new seal.
• Change the joints if they are showing signs of wear.
• Check the wear of the rubber driving fingers Item 5. If necessary, change them (according to type for H7).
Core H7 : 120 mm² max
H12 : 240 mm² max H24 : 240 mm² max
Marking L1 - L2 - L3 - … -
Connections
Round connection for
ØM12 screw
Tightening torque : 25 Nm
H7 - H12 - H24 RINGS CONNECTION
Core H12 : 240 mm² max H24 : 240 mm² max
Connections
Round connection for
ØM12 screw
Tightening torque : 30 Nm
H12 - H24 - BRUSH HOLDERS CONNECTION
Core H7 : 120 mm² max
Connections
Round connection for
ØM12 screw
Tightening torque : 30 Nm
H7 - BRUSH HOLDERS CONNECTION
H7 S l ipr ing H12 S l ipr ing H24 S l ipr ing
BEFORE OPENING THE COVER, BE SURE THAT THE HIGH VOLTAGE INSTALLATION IS PROTECTED
(POWER OFF - LOCKOUT FEEDING POINT - EARTHING AND SHORT CIRCUITING OF EACH PHASE)
These operations should be carried out by qualified and authorized personal only !
Page 61 of 79
4 40N148 2/2
COLLECTEUR H7 / H12 / H24
SL IP R ING ASSEMBLY H7 / H12 / H24
NOTICE D’INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET
10/12
RECOMMANDED SPARE PARTS (Please indicate the cable reel number.)
DESIGNATION H7 H12 H24
Insulator 4 I40002 FT 128501/1 FT 128501/2
Carbon brushes with shunt 2 8B0004 2 8B0008
Sub-assembly brush holder 2 8P0006 2 8P0031
Earth / phase ring 2 B06010 2 B06020
Complete slipring without hub (Specify the number of rings) Indicate the reel number
Housing / main gear box contacts joint BNA40-50 : 4J10039
Housing / Front reinforcing plate Joint BNA30: 4J10039 -----
Instructions and Maintenance Manual Optical Fiber Transmitter TFO 40
A - GENERAL INFORMATION
A.1 - Responsibilities
The user is responsible for the installation and use of the equipment supplied according to the regulations described
hereafter. CONDUCTIX-wampfler will not be able to guarantee the equipment if these regulations are not adhered to,
except in the case of prior agreement.
All operation of the equipment must be carried out by qualified personnel, in accordance with current norms and regulations.
A.2 - Data and modifications
This document provides the information required for the start up, use and maintenance of the cable reel.
CONDUCTIX-wampfler reserves the right to modify the characteristics of its products at any time in order to include the
most recent technological developments. The information contained in this document may, therefore, be modified at any
moment without prior notice.
A.3 - Safety
A.3.1 - General information
During all maintenance and adjustment work and whenever the equipment is being operated with the protective covers
open basic safety rules must be respected.
During normal working all the covers must be in place and the safety systems must be operational.
It is equally important to pay attention to parts which may move, for example the cable and the reel.
A.3.2 - Slip ring
The protective cover should never be removed unless power is off.
DO NOT REMOVE THE SLIP-RING COVER WHILE POWER IS ON
DANGER of DEATHDANGER of DEATH
This equipment is designed for an industrial use.
Ensure that the operators are trained in the use of this material.
This equipment could be used in Explosive Atmospheres ATEX
(in accordance with the definition in directive 1999/92/CE dated 16 December 1999)
only if it is equipped with a specific cover,
supplied and certified by CONDUCTIX-WAMPFLER .
In this case, an ATEX marking, which defines the product category,
is fixed on the equipment.
Page 67 of 79
Instructions and Maintenance Manual Optical Fiber Transmitter TFO 40
B - INSTALLING AN OPTICAL TRANSMITTER ON TO A CABLE REEL
♦ The TFO 40 can be started up at every point of the engine travel.
♦ The cable of the reel must be connected to the fixed point.
B.1 - Preparing the cable reel
Before installing the transmitter, check that the following operations have been carried out on the cable reel:
• Power is off,• The cable is wound on to the spool and the cores of the cable are connected to the slip ring of the cable reel,• The other end of the cable is fixed and connected,• A minimum length of 1 m of optical fiber is available between the end of the slip ring and the transmitter. If the reel isdelivered with fitted cable, this length is fixed on the slip ring side disc #2 (see fig 4/4).
B.2 - Reading of the position and winding direction indicator
The type of the transmitter is indicated on the identification plates.
TFO 40 : Use for a cable reel, which the spool travels less than 40 turns between the feeding point and the end
of the travel.
Be careful not to damage the fiber optic cores - Handle with care !!!
Reading window
Indicator for
winding
according to
Direction 2
Indicator for
winding
according to
Direction 1
Winding level
Range of use
The label ‘Start’ indicates the winding
level of the ribbon when the spool is
full. N
P
N
P
NEVER EXCEED THE RANGE OF USE !
Page 68 of 79
Instructions and Maintenance Manual Optical Fiber Transmitter TFO 40
B.2.2 - Mechanical driving of the transmitter
Put back the drive shaft #1 (fig.1a) by fitting in the slip ring side
disc #2 (fig.1b).
B.2.3 - Optical Fiber connections
B.2.3.1 - Rotating part connection (fig.2a)
If the cable reel spool is fitted with cable, the optical fibers will
be fastened on #2, unfasten these optical fibers and connect
them to the rotating junction #3. After connection, the extra
optical fibers cable length shall be fastened on disc #2 with
new cable ties.
B.2.3.2 - Fixed part connection (fig.2b) A removable circular plate #4 (fig.2b) is used to fit the entry cable gland. Plug the connectors onto the fix box #5 and fasten the optical fiber cable with cable ties using the holes on the flange #6.
B.2.4 - Electrical Connection of the transmitter
• The Optical Fiber Transmitter must not work withouttemperature control.
• The connection of the heating strip must be done beforethe start up.
• The working authorization is given by the thermostat T2,which is connected to the terminals 41 and 42.
• The heating resistance must be continuously feed withpower, even during the machine stop phases.
See the attached electrical diagram # 440N111.
Attach the supply cable with ties using the holes on the
Before connection, the connectors and the bulkhead unions must be cleaned with isopropyl alcohol, using a rifle-type brush and/or a microfibre rag (lint-free cloth).
Page 69 of 79
ELECTRICAL DIAGRAM
GENERAL CONTRACTING INDUSTRIAL CONSTRUCTION AND TRADING CO. Adres: Sümko Sitesi Işıl Apt. M7 A Blok Kat: 4 No: 17 Kozyatağı – Istanbul