INSTRUCTION MANUAL

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

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 GENERAL WARNINGS AND SAFETY GUIDELINES

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.

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 STORAGE INSTRUCTIONS
For correct storage of Cavotec cable/hose reels, maintain the goods in the original packing
in a closed warehouse, protected from the rain and in an ambient that prevents the
formation of condensation.

INSTRUCTIONS FOR LONG TIME STORAGE (MORE THAN 6-9 MONTHS)

The equipment should be stored in accordance with its working position.

The equipment should be stored:

• away from humidity (less than 80%),
• in an enclosed building, protect from the rain and water sprays (temperature from -
15°C to +45°C).
• away from frequent significant variations in temperature, to avoid the risk of
condensation.
• away from vibrations.
• away from aggressive vapours or fumes.

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.

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During the commissioning:
• Bearings
* Sealed bearings: Replace them if the storage period is more than 3 years.
* Bearings, which can be regreased:

* Regrease the bearings, which are equipped with lubricators.

• Grease: Change the grease if the storage period is more than 3 years.
• Check the good conditions of the joints of mechanical and electric parts. Change them
if necessary.
• Open the bleed nipples of the motor to evacuate moisture. Put them back in place.

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CONTENTS
SECTION 1 – SPECIFICATIONS ..................................................................................................... 1
SECTION 2 – REELING SYSTEM OVERVIEW ............................................................................... 3
2.1 DRUM ........................................................................................................................ 3
2.2 TORQUE UNIT .......................................................................................................... 4
2.3 MOTOR ..................................................................................................................... 4
2.4 COLLECTOR ............................................................................................................. 4
2.5 ROTARY LIMIT SWITCH ........................................................................................... 4
SECTION 3 - DRIVE MODULE ........................................................................................................ 5
3.1 DELIVERY ................................................................................................................. 5
3.2 INSTALLATION ......................................................................................................... 5
3.3 ELECTRICAL INSTALLATION................................................................................... 5
SECTION 4 – DRUM ........................................................................................................................ 6
4.1 DELIVERY ................................................................................................................. 6
4.2 REQUIRED TOOLS & ACCESSORIES ..................................................................... 6
4.3 DRUM ASSEMBLY .................................................................................................... 7
4.4 DRUM INSTALLATION .............................................................................................. 7
4.5 SPACING ADJUSTMENT .......................................................................................... 9
4.6 PERIODIC MAINTENANCE..................................................................................... 10
SECTION 5 - CABLE ..................................................................................................................... 11
5.1 CABLE PREPARATION........................................................................................... 11
5.2 CABLE INSTALLATION ........................................................................................... 12
5.3 PERIODIC MAINTENANCE..................................................................................... 14
SECTION 6 - COLLECTOR ........................................................................................................... 15
6.1 REELING CABLE CONNECTION............................................................................ 15
6.2 FIXED CABLE CONNECTION ................................................................................. 15
6.3 ANTI-CONDENSATION HEATER ........................................................................... 15
6.4 FINAL CHECKS ....................................................................................................... 15
6.5 PERIODIC MAINTENANCE..................................................................................... 16
SECTION 7 – STROMAG ROTARY LIMIT SWITCH...................................................................... 17
7.1 GENERAL ............................................................................................................... 17
7.2 ELECTRICAL CONNECTION .................................................................................. 17
7.3 SETTING ................................................................................................................. 18
7.4 PERIODIC MAINTENANCE..................................................................................... 18
SECTION 8 - TORQUE UNIT ......................................................................................................... 19
8.1 GENERAL ............................................................................................................... 19
8.2 TORQUE ADJUSTMENT......................................................................................... 19
8.3 PERIODIC MAINTENANCE..................................................................................... 20
SECTION 9 - MOTOR .................................................................................................................... 21
9.1 ELECTRICAL CONNECTION .................................................................................. 21
9.2 PERIODIC MAINTENANCE..................................................................................... 21
SECTION 10 – OPERATING INSTRUCTIONS .............................................................................. 22
10.1 MOTOR OPERATION ............................................................................................. 22
10.2 COMMISSIONING ................................................................................................... 22
SECTION 11 - TROUBLESHOOTING............................................................................................ 24
SECTION 12 - RECOMMENDED SPARES ................................................................................... 25
SECTION 13 - MECHANICAL DOCUMENTATION ....................................................................... 26
SECTION 14 - ELECTRICAL DOCUMENTATION ......................................................................... 27

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SECTION 1 – SPECIFICATIONS
Client Mantsinen Group
Project Mantsinen Montes del Platas
Works Order 1800633
Reel Type 300.4 DM1935-50G K4121/FC/R
Delivery Drive module Type 300.4……K4121/FC/R
Fixing with 4 off M24 high tensile bolts
Weight 813kg
Drum Type DM1935-50G
Double Monospiral
Weight 600kg
Special instructions None
Drawings Reel installation SC-1800633-IS1
Schematic STD-SE-018
Cable Manufacturer Nexans
Type Buflex M
Voltage rating 0.6/1kV
Composition ……..
Dimensions φ47mm, 4.90kg/m
Allowable tension 7200N
Duty Reeling length 110m
Dead turns 2
Installation type Horizontal
Feed point Centre
Installation height 3m
Speed 40m/min
Acceleration 0.13m/s2
Duty cycle 40% ED
Ambient temp. -8°C to +40°C
Drum Manufacturer Cavotec Specimas S.p.A.
Type Double Monospiral
Model DM1935-50G with front box
Inner diameter 1900mm
Outer diameter 3500mm
Width 2x50mm
Construction Half-wheel
Main spokes 12 off 80x40x3 per side
Material Mild steel
Treatment Hot-dip galvanised
Fasteners AISI 304
Weight 600kg
Torque Unit Manufacturer Cavotec Specimas S.p.A.
Type 1-stage worm-wheel with friction clutch
Model 300.0
Ratio 1:237
Setting torque 1400Nm
Maximum torque 2700Nm
Main shaft ID 118mm
Lubricant Mobil Mobilube HD 80W 90
Quantity 67 litres

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 Finish Painted RAL 1004 (Yellow)
Weight 610kg
Motor Manufacturer Cavotec Specimas S.p.A.
Type Totally enclosed, fan cooled (TEFC) 4 pole motor with
heater
Model V132M4/I
Power 7.5kW, 400V, 50Hz
Insulation Class F, tropicalised
Nominal speed 1441rpm
Nominal current 14.21A @ 400V
Protection rating IP55
Heater 230V, 25W
Finish Painted RAL 5009 (Light Blue)
Weight 52kg
Collector Manufacturer Cavotec Specimas SpA
Type 3 phase + earth, multi-contact copper-graphite brushes on
brass rings
Model K4121/R
Earth 1 off 1200A nominal Ø270 standard ring with 1 off KP20
brushes per ring, 600A current rating @ 100% ED
Power 3 off 1200A nominal Ø270 standard rings with 2 off KP20
brushes per ring, 600A current rating @ 100% ED
Fixtures Ring side - 2 x M12, tighten 30Nm
Brush side - 2 x M12 on connection bar, tighten 30Nm
Insulation material Glass fibre
Rated voltage 1000 VAC
Test voltage 3000VAC
Housing material AISI 304
Protection IP65
Heater Watlow 50W - 220-240V
Weight 42.5kg
Reeling Cable Slipring core lengths Earth 1250mm
Terminations Phase 1 1300mm
Phase 2 1465mm
Phase 3 1515mm
Special instructions The outer sheath of the cable needs to be removed, starting from the point
directly after the gland in the front-entry box, so that the individual cores can pass
through the shaft of the drive
Limit Switch Manufacturer Stromag AG
Type 29 turn geared rotary limit switch with 1+4 switches
Model 51/2D 29MB 192/492
Contacts 5 x silver, changeover
AC-15 contact rating 1.5A, 230VAC in accordance with IEC 60947-5-1
DC-13 contact rating 0.5A, 60VDC in accordance with IEC 60947-5-1
Thermal current 10A
Insulation voltage 250V
Switch life 1x107 operations
Connections Screw-type terminals with self-lifting pads
Gear ratio 1:30.35
Cams 1-2 15º (29.5 revs off, 1 rev on)
3-4 40º (27 revs off, 3.5 revs on)
Protection rating IP20
Driven by Coupling to ring-pack
Other None
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SECTION 2 – REELING SYSTEM OVERVIEW
Large mobile machines such as cranes, stackers and ship loaders rely on an external electrical
power source to operate. In many cases, these machines also require analogue and/or digital data
conduits for control and feedback. This power and data is typically transmitted through a composite
flexible cable comprising of copper conductors for power and hard wire control circuits, and optical
fibres for digital data. Since these machines can travel over relatively long distances, this cable
needs to be quite long, and a means of handling the cable in a controlled manner is required. A
Cable Reeling System typically carries out this function.

Motor with brake

and encoder

Prereducer

Torque unit Drum

Collector with internal

rotary limit switch

Motor

Figure 1 – Typical cable reeling system

2.1 DRUM
2.1.1 A drum stores cable by rotating in the appropriate direction as the machine travels
towards the feedpoint. The internal diameter of the drum is selected to meet the minimum
bend radius requirements of the cable and to ensure an optimal relationship between
reeling torque and cable tension. The external diameter of the drum is selected to ensure
that the full cable length can be accommodated. The compartment width of the drum

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 depends on the cable diameter and the type of lay selected (eg. monospiral, 3-2-3,
random).
2.1.2 Drums are typically fabricated from mild steel RHS, and can be painted or hot-dip
galvanised. The drum sides can be either fully welded (for smaller drums) or composite
designs. All fasteners are stainless steel.
2.2 TORQUE UNIT
2.2.1 A torque unit is typically a specially designed reduction gearbox with a large bore main
shaft through which the cable can be fed, and a high overhung load capacity. The torque
output of this unit is regulated by mechanical or electrical means. An example of a
mechanical torque regulator is the Hydrodynamic oil immersed friction drive. Electrical
torque regulators include torque motors, permanent magnet clutches and flux vector
controlled AC motors.
2.2.2 The optimum torque output of a torque unit is just sufficient to recover and pay out cable
in all modes of operation without placing undesirable stress into the typically fragile
conductors. The speed output of the torque unit can vary greatly in relation to the machine
speed because of the changing winding diameter, and the differences are generally taken
up by mechanical or electrical slippage.
2.3 MOTOR
2.3.1 Motors are typically Totally Enclosed Fan Cooled (TEFC) type, are fitted with sealed for
life bearings, and have IP55 protection ratings. When used with flux vector drives, the
motors are oversized to preclude the need for forced cooling.
2.3.2 Cavotec motors are supplied with class F insulation. Optional Klixon switches or
thermistors are embedded in the windings to provide a means of protecting the motor from
over-temperature conditions.
2.4 COLLECTOR
2.4.1 The collector facilitates the transmission of power and data between the rotating reeling
cable and the fixed machine cables.
2.4.2 The collector consists of a number of rotating brass sliprings (typically 4 for power
applications) against which a number of fixed copper-graphite brush tips rub. Insulators
and air separate each phase.
2.4.3 The collector may also include a fibre optic rotary joint used to transmit optical data across
the rotating interface.
2.4.4 Collectors are typically housed in stainless steel enclosures with anti-condensation
heaters.
2.5 ROTARY LIMIT SWITCH
2.5.1 A geared rotary limit switch for reel full and reel empty detection is typically supplied with
the collector, mounted either internally or externally of the collector enclosure.
2.5.2 The rotary limit switch can be fitted with a potentiometer or rotary transducer to give a
precise indication of the amount of cable on the drum at any time.

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SECTION 3 - DRIVE MODULE
3.1 DELIVERY
3.1.1 The torque unit, base frame (if supplied), collector, prereducer/s (if supplied) and motor/s
are supplied pre-assembled as a completed drive module. Check that this module has
arrived in good condition.
3.1.2 Note any special instructions in the Delivery subsection of SECTION 1.
3.2 INSTALLATION
3.2.1 Check that the structure onto which the drive module is to be mounted is flat and free from
distortion.
3.2.2 Lift the drive module using the lifting points provided. The total weight of the module is
indicated in the Delivery subsection of SECTION 1.
3.2.3 Bolt the drive module to the mounting structure using high tensile bolts of appropriate
length with the dimensions indicated in the Delivery subsection of SECTION 1, ensuring
that it is level by using a spirit level. Ensure that the face of the drum mounting flange is
parallel to the direction of machine travel. Use shims or packing pieces as necessary and
bolt down securely.
3.3 ELECTRICAL INSTALLATION
3.3.1 Referring to the electrical schematics located in SECTION 14, run, gland and terminate
appropriate cables between the reeler control centre and the various components
supplied.
3.3.2 Run, gland and terminate an appropriate cable/s between the collector brushgear and the
machine’s power/control inlet.

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SECTION 4 – DRUM
4.1 DELIVERY
4.1.1 Check that the following separate items have arrived and are in good condition:
• 2 off pre-assembled drum halves
• 12 off M20x160 bolts complete with 12 off full-nuts, 12 off Pal nuts and 24 off
washers
• 16 off M12x90 bolts complete with 12 off Nyloc nuts and 24 off extra-large washers
4.1.2 Note any special instructions in the Delivery subsection of SECTION 1.

Pos. Description Qty Pos. Description Qty

1 Half wheel internal, 80x40x3 spokes 2 10 Hex head bolt M20x160 12
2 Half wheel central, 60x40x3 spokes 2 11 Plain washer M20 216
3 Half wheel external 80x40x3 spokes 2 12 Lock nut M20 108
4 Inner ring in two halves 2 13 Counter-nut self-locking M20 (Palmutter) 60
5 Flange intermediate type F dia. 790, 15t 1 14 Hex head screw M12x90 full thread 16
6 Hex head screw M12x50 full thread 12 15 Washer plain extra large M12xØ36 36
7 Plain washer M12 12 16 Lock nut M12 20
Front box L=320, M63x1,5 cable gland,
8 Tie rod M20x405 12 17 1
drumDM-SS316
9 Tie rod M20x390 12

Figure 2 – Drum assembly

4.2 REQUIRED TOOLS & ACCESSORIES
4.2.1 The following tools and accessories will be required to carry out the drum assembly:
• 2 off wooden blocks 100x100, length = drum OD
• 2 off 19mm open ended spanners
• 2 off 30mm open ended spanners
• 1 off dynamometric key
• 500kg lifting sling, 10m long

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4.3 DRUM ASSEMBLY
4.3.1 Lay the two pre-assembled drum halves on a pair of supports with the small internal
diameter side facing upwards as shown in Figure 3.
4.3.2 Loosely join the two halves together using the supplied M12 fasteners (items 14, 15 & 16).
4.3.3 Ensure that the inner faces (cable compartment) of the mating halves are flush, and then
tighten the M12 fasteners to 30Nm.

Figure 3 – Assembly preparation

4.3.4 Join the three wheels (internal, central and external) using the supplied M20 tie rods,
washers and nuts on diameters 740 and 1484 as shown in Figure 2. Tighten to 155Nm.
4.4 DRUM INSTALLATION
4.4.1 Remove the twelve M20 Pal nuts, hex nuts and washers from the upper side of the
740mm PCD (positions 11a, 12a and 13a in Figure 4).
4.4.2 Lift the drum by using an appropriately rated sling wrapped around the inner ring. The
drum weight is indicated in the Drum subsection of SECTION 1.
4.4.3 Present the drum to the drive flange as shown in Figure 4 and guide the exposed tie-rod
ends on the 740mm PCD into the appropriate holes in the flange.
4.4.4 Fit the washers 11a and nuts 12a, and tighten to 155Nm. Fit the Pal nuts 13a, placing the
flat side against the full-nut as shown in Figure 5.

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4.4.5 Fit the washers 11b and nuts 12b, and tighten to 155Nm. Fit the Pal nuts 13b, placing the
flat side against the full-nut as shown in Figure 5.

Figure 4 – Drum installation

Figure 5 – Pal nut installation

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4.5 SPACING ADJUSTMENT
4.5.1 In order to ensure reliable performance of the reel, it is very important that the spacing
between the spokes is accurately set.
4.5.2 Measure the exact diameter of the cable at a minimum of 3 points along its length and
calculate the average value D.
4.5.3 Referring to Figure 6, remove all Pal nuts from (b) then loosen all nuts (a) and (b) on the
external main spokes.
4.5.4 If the drum width S1 is greater than D+3mm, or less than D+1mm, partially remove each
tie-rod (c) one at a time, and remove or insert washers (w) to bring the width to within the
correct range.
4.5.5 Re-insert each tie-rod, refit each washer and loosely refit each full-nut.
4.5.6 Once the adjustment has been completed, tighten all the full-nuts to 155Nm. Refit the Pal
nuts, placing the flat side against the full-nut as shown in Figure 5.
4.5.7 Adjust the parallelism of every main spoke pair (internal and external) so that S2 is
between D+2mm and D+3 mm.
4.5.8 To increase S2, loosen nut (a) and tighten nut (b). To decrease S2, loosen nut (b) and
tighten nut (a).
4.5.9 Tighten all the full-nuts to 155Nm, and check the spacing again. If no changes need to be
made, refit the Pal nuts, placing the flat side against the full-nut as shown in Figure 5.

S2

S1
D c

a b

Figure 6 – Spacing adjustment

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4.6 PERIODIC MAINTENANCE
4.6.1 Verify the tightness of all fasteners.
4.6.2 Check the drum width, and adjust as necessary following the procedures described in
section 4.5.
4.6.3 Verify the fixing of the first turn of cable on the drum.
4.6.4 Verify that the cable entry gland is properly fitted.

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SECTION 5 - CABLE
5.1 CABLE PREPARATION
5.1.1 Check that the cable diameter and weight are as originally specified (see Cable
subsection of SECTION 1 for cable details) and ensure that the cable length does not
exceed that for which the reel was designed.
5.1.2 Generally, reputable manufactures will supply their cables free of induced twist on storage
drums. If, however, the cable on the storage drum is second hand, or the supplier cannot
guarantee the cable to be free of induced twist, the cable should be prepared in
accordance with the following.
5.1.3 The transport drum should be supported on stands or rollers to allow free rotation. The
cable must always be pulled from the top of the drum. Refer to Figure 7.
CABLE
TRANSPO RT
DRUM

DRUM JACKS

Figure 7 – Cable Transport Drum

5.1.4 Lay out the full length of the cable as it is pulled off the drum, either by manhandling with
one person every 5m approximately or by pulling over cable rollers. On no account
should the full length of the cable be dragged over the ground, nor should a dozer,
tractor or any other powered machine be used to pull or drag the cable.
5.1.5 There may be some twist evident in the cable, which is due to the manufacturing process,
and this should now be removed. Leave one end of the cable fixed (eg. still attached to
the transport drum) and working from this end, run the twist out of the cable by either (a)
placing a suitable bar under the cable and walking towards the free end while gently
moving the bar up and down (Figure 8), or (b) forming a coil of cable as near as possible
to the fixed end and rolling it along to the free end (Figure 9). If there is a lot of twist in the
cable, the process described above may need to be repeated several times.
C ABLE
TRAN SPOR T
D RU M

CABL E

ROUN D BAR

DRU M JAC KS

Figure 8 – Removal of Cable Twist Using Round Bar

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 CABLE
TRANSPORT
DRUM

DRUM JACKS

CABLE LOOP CABLE

Figure 9 – Removal of Cable Twist Using Cable Coil Method

5.2 CABLE INSTALLATION
5.2.1 In order to ensure satisfactory performance of a reeling cable, the following installation
procedure should be adopted. If the cable has been layed out according to the instructions
in Section 5.1, then it should be rewound onto the storage drum before being transferred
to the reeler using the method described below.
5.2.2 Manually rotate the reeler drum so that the opening in the inner ring is pointing vertically
upwards.
5.2.3 With the machine located as close to the feed point as possible, feed the cable from the
top of the cable transport drums directly onto the top of the reeler drum (refer to Figure
12).
5.2.4 Continue feeding it through the opening of the inner ring of the drum, out through the
space between the spokes and then through the cable gland as shown in Figure 10

OPENING
INNER RING

CABLE

FRONT BOX

Figure 10 – Cable entry

5.2.5 Once the cable has been terminated to the sliprings in the collector, tighten the cable
gland to exclude moisture and dirt. and tighten to 8Nm the bolts for closed the cover of
front entry box see Figure 11.

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 Figure 11 - Tighten front entry box (example)
5.2.6 Secure the cable onto the drum inner band with a number of heavy duty cable ties.

CABLE REELER

CABLE

CABLE TRANSPORT DRUM

CABLE GUIDE

DRUM JACKS

Figure 12 – Correct Method of Cable Installation

5.2.7 The drive unit needs to be energised to rotate the reel for cable fitting.
Ensure that an operator is available to immediately switch off the motor in the event
of a problem.

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.

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5.2.9 The ends of the cable can now be passed down through the cable guide (if fitted) and
manually pulled along the ground or cable tray to the nearby feedpoint.
5.2.10 Lay out the cable as it is pulled off the reel, either by manhandling with one person
approximately every 5 m or by pulling over cable rollers. On no account should the
cable be dragged over the ground, nor should a dozer, tractor or any other powered
machine be used to pull or drag the cable.
5.3 PERIODIC MAINTENANCE
5.3.1 The cables should be inspected after a short time in operation. Twisting may occur as the
cable runs in due to the lay of the cable relaxing slightly under operation. This twisting will
tend to move towards the feed point over time, and can eventually cause damage to the
cable. If twisting is apparent at any time, the cable should be freed at the feed point with
the reel at the furthest point of travel (ie. with all the cable paid out), and the twist should
be removed by following the instructions in Section 5.1. Due to variations in operating
conditions, it is impossible to state an exact number of cycles which need to be carried
out, or period of time after which twisting will cease, and in some cases it may be several
weeks. Periodic inspections are advisable after the machine has begun operation.

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SECTION 6 - COLLECTOR
Ensure that all circuits are isolated by an authorised person prior to removing the
cover of the collector housing. Electrical connections should only be carried out
by qualified persons.

6.1 REELING CABLE CONNECTION

6.1.1 Reeling cable termination is best done before feeding the cable through the torque unit
shaft into the collector.
6.1.2 Strip the outer sheath in order to expose sufficient core length to respect the core
dimensions specified in the Reeling Cable Terminations subsection of SECTION 1.
6.1.3 Terminate each core with an appropriately sized terminal to suit the ring side fixtures
specified in the Collector subsection of SECTION 1.
6.1.4 Feed the cable through entry box, torque unit shaft and into the collector; connect each
core to the corresponding slipring terminal.
6.1.5 Tighten the cable gland on the drum side of the torque unit.
6.2 FIXED CABLE CONNECTION
6.2.1 Feed the fixed cable through the gland mounted on the side of the collector housing,
ensuring that it is well supported so as not to put any bending force on the gland.
6.2.2 Strip the outer sheath in order to expose sufficient core length to neatly arrive at the
brushgear connection points, and shorten individual cores as necessary.
6.2.3 Terminate each core with an appropriately sized fitting to suit the brush side fixtures
specified in the Collector subsection of SECTION 1.
6.2.4 Ensure that the cores are neatly arranged and properly supported inside the collector
housing, and ensure that the cores are not in contact with live metal parts.
6.2.5 Tighten the cable gland.
6.3 ANTI-CONDENSATION HEATER
6.3.1 Fit a suitably sized cable gland to the removable blanking plate located on the side of the
collector housing for the heater cable.
6.3.2 Pass the heater connection cable through this gland up to the heater terminal block. Fix
the cable well along the path selected, and ensure that it does not come any closer than
50mm to live metal parts.
6.3.3 Strip the cable cores to the correct length, and terminate using appropriately sized blade
terminals.
6.3.4 Connect the cable cores to the appropriate terminals as indicated by the schematic
referenced in the Drawings subsection of SECTION 1. Tighten the screws to 0.8Nm.
6.3.5 The heater should remain energised at all times in order to prevent the formation of
condensation.
6.4 FINAL CHECKS
6.4.1 Before closing the housing and applying current to the collector for the first time, ensure
that:
• all the carbon brushes are correctly aligned in the slipring grooves.
• all the brush arms are correctly aligned with the sliprings.
• all the electrical connections are correctly tightened.

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 • all cores are sufficiently clear of each other and rotating and live metal parts.
6.5 PERIODIC MAINTENANCE
6.5.1 The sliprings and brushgear should be inspected to ensure good contact and alignment is
maintained between the sliprings and brushes. Worn brushes should be replaced.
6.5.2 Verify tightness of all electrical connections.
6.5.3 If necessary, the sliprings can be lightly cleaned with glass paper, and then wiped clean
with a cloth dampened with methylated spirit.
6.5.4 Vacuum the carbon dust from the insulators, cable terminations and floor of the collector
housing. Alternatively, use a brush or a lint free cloth. Never use water or solvents for
cleaning.
6.5.5 The housing cover seal should be checked and replaced if necessary.

Alignment Check

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SECTION 7 – STROMAG ROTARY LIMIT SWITCH
Ensure that all circuits are isolated by an authorised person prior to removing any
covers. Electrical connections should only be carried out by qualified persons.

7.1 GENERAL

Figure 13 – Stromag rotary limit switch

7.1.1 The geared rotary limit switch (GRLS) consists of a number of cam activated switches
used for drum full/drum empty detection. These cams rotate via a gear reduction
connected to the input shaft, with one turn of the input shaft resulting in a partial rotation of
the cams that is proportional to this gear reduction.
7.1.2 Drum full detection is carried out using two switches in order to minimise the effects of
hysteresis. The resulting closed contacts are used to bypass the undertension switch as
the machine moves over the feedpoint.
7.1.3 Additional cam operated switches are available for other functions if required.
7.1.4 The technical specification of this limit switch can be found in the Limit Switch subsection
of SECTION 1.
7.2 ELECTRICAL CONNECTION
7.2.1 Remove the metallic limit switch cover at the rear end of the collector housing.
7.2.2 Remove the plastic limit switch cover.
7.2.3 Pass the limit switch connection cable through the gland on the side of the limit switch
housing and up to the limit switch. Fix the cable well along the path selected.
7.2.4 Strip the cable cores to the correct length, and terminate using appropriately sized forked
lugs.
7.2.5 Connect the cable cores to the appropriate terminals as indicated by the schematic
referenced in the Drawings subsection of SECTION 1. Tighten the screws to 0.8Nm.
7.2.6 Tighten the cable gland and refit covers.

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7.3 SETTING
7.3.1 Travel the machine towards the feedpoint and note the rotation direction of the limit switch
shaft when viewed from the rear.
7.3.2 Position the machine so that the roller guide is about 2 m from the feedpoint, and set the
anti-hysteresis BF0 and drum full BF1 switches as follows:
• If the GRLS shaft was turning clockwise during recovery, turn the black adjustment
screw (BF0) in the clockwise direction until the first cam just activates the switch (there
will be an audible click). Turn the first white adjustment screw (BF1) in the same
direction until the first cam just activates the switch.
• If the GRLS shaft was turning anti-clockwise during recovery, turn the black adjustment
screw (BF0) in the anti-clockwise direction until the first cam just activates the switch
(there will be an audible click). Turn the first white adjustment screw (BF1) in the same
direction until the first cam just activates the switch.
• Ensure that the incoming wires on switches 1 and 2 are connected to the normally
open terminals marked 1 and 4.
7.3.3 Travel the machine over the cable feedpoint. Note that as the machine passes the feed
point, the rotation direction of the cams will change. Ensure that the cams do not over-run
the switch before this direction change occurs. Ensure that no fault occurs as the
cable/hose passes through the undertension sensor.
7.3.4 Repeat step 7.3.3 from the other side of the feedpoint.
7.3.5 Move the machine to the longest extremity of travel from the feedpoint. Note that if the
feedpoint is not in the centre of travel, or if the reeler is not positioned in the centre of the
machine, the amount of cable/hose payed out will differ in each travel direction. Set the
drum empty BF2 switch to trip at this point by following the instructions below:
• If the GRLS shaft was turning clockwise during recovery, turn the second white
adjustment screw (BF2) in the anti-clockwise direction until the third cam just activates
the switch (there will be an audible click).
• If the GRLS shaft was turning anti-clockwise during recovery, turn the second white
adjustment screw (BF2) in the clockwise direction until the third cam just activates the
switch (there will be an audible click).
• Ensure that the incoming wires on switch 3 are connected to the normally closed
terminals marked 1 and 2.
7.3.6 Travel the machine back towards the feedpoint, then back to the end of travel. Ensure that
the drum empty switch does not trip within the normal travel limits. Travel the machine to
the other end of travel to prove the operation.
7.3.7 Note that if the anti-hysteresis adjustment screw is turned after the switches have been
set, it will be necessary to re-set the switches.
7.3.8 The spare switches BF3 and BF4, if used, should be set using the procedures described
above.
7.4 PERIODIC MAINTENANCE

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.

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SECTION 8 - TORQUE UNIT
8.1 GENERAL
8.1.1 The Hydrodynamic torque unit is the primary support for all the components of the cable
reel.
8.1.2 It consists of an oil immersed clutch driven via a non-reversible worm reduction gear set
by a conventional electric motor, or alternate power sources including hydraulic and
pneumatic motors. The clutch has an oil lubricated bronze/steel friction interface, and
torque is created as a result of shearing of the oil.
8.1.3 Generally, the drive motor runs at a constant speed, and any variation in reel speed is
taken up as slip in the clutch. The output torque of the clutch is virtually independent of the
rotating speeds of the input and output shafts. The faces of the clutch have been specially
machined, so that the static torque is typically no more than 3% – 10% higher than the
normal dynamic operating torque.
8.1.4 The non-reversible worm prevents unwinding of the cable/hose when the machine on
which the reel is mounted is stationary and the drive motor is de-energised.
8.2 TORQUE ADJUSTMENT

Figure 14 – Torque Adjustment

8.2.1 Referring to Figure 14, unscrew the torque adjustment key (position 1), turn the torque
adjustment key upside down (position 2) and replace it into the torque unit.
8.2.2 Turn drum slowly until key enters completely in the hole into locked position.
8.2.3 Looking from the cable/hose drum towards the drive, turn the cable/hose drum anti-
clockwise to increase the torque output and clockwise to decrease the torque output.
8.2.4 Do not rotate the drum more than ¼ of a turn at a time, and do not exceed the adjustment
range noted in the Torque Unit subsection of SECTION 1. Note that there is no protection
against over-adjustment. Over-adjustment can cause damage to the worm screw and
crown gear.

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8.2.5 After adjustment, withdraw the torque adjustment key, turn it upside down and screw it
back into the drive. Note that operating the reeler drive with the torque adjustment nut
locked will cause damage to the gearbox and should be avoided.
8.3 PERIODIC MAINTENANCE
8.3.1 After the first 100 hours of operation, and every 500 hours or 12 months thereafter
(whichever occurs first), drain the oil from the torque unit and replace it with the type and
quantity specified in the Torque Unit subsection of SECTION 1. Note that no equivalent
oils from other manufacturers must be used without explicit approval from Cavotec.
8.3.2 Under extreme operating conditions, the lubricant should be changed more frequently.
Degradation of the oil can cause a drop in torque output and leads to faster wear of the
clutch surfaces and the worm gears.
8.3.3 Between oil change intervals, perform bi-monthly checks on the oil level using the level
gauge and top up as necessary with the oil specified.
8.3.4 Check for oil leakage or unusual noises, and rectify as necessary.
8.3.5 Check for water ingress and replace oil if necessary.
8.3.6 Ensure that the breather, which is incorporated into the Torque Adjustment Key, is clean
and not blocked.
8.3.7 After a period of operation, the torque unit may need adjustment as per section 8.2.

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SECTION 9 - MOTOR
Ensure that all circuits are isolated by an authorised person prior to removing any
covers. Electrical connections and motor maintenance should only be carried out
by qualified persons.

9.1 ELECTRICAL CONNECTION

9.1.1 Ensure nameplate data matches the available power supply.
9.1.2 Remove the cover of the motor terminal box, ensuring beforehand that all live electrical
circuits have been isolated.
9.1.3 Measure the winding resistances between each phase and earth, and between individual
phases, and ensure that they are greater than 5 MΩ.
9.1.4 Run and gland an appropriate power cable, and connect the cable cores to the
appropriate terminals as indicated by the schematic referenced in the Drawings
subsection of SECTION 1 and the motor datasheets referenced in the Motor subsection/s
of SECTION 1. Ensure that sufficient air-gap exists between the connections.
9.1.5 If a heater has been fitted, run and gland an appropriate cable, and connect the cable
cores to the appropriate terminals as indicated by the schematic referenced in the
Drawings subsection of SECTION 1 and the motor datasheets referenced in the Motor
subsection/s of SECTION 1.
9.1.6 If a thermal sensor has been fitted, run and gland an appropriate cable, and connect the
cable cores to the appropriate terminals as indicated by the schematic referenced in the
Drawings subsection of SECTION 1 and the motor datasheets referenced in the Motor
subsection/s of SECTION 1.
9.1.7 If a brake has been fitted, run and gland an appropriate cable, and connect the cable
cores to the appropriate terminals on the rectifier as indicated by the schematic
referenced in the Drawings subsection of SECTION 1 and the motor datasheets
referenced in the Motor subsection/s of SECTION 1.
9.1.8 If an encoder has been fitted, open the encoder terminal box located on the fan cowling,
run and gland an appropriate cable, and connect the cable cores to the appropriate
terminals as indicated by the schematic referenced in the Drawings subsection of
SECTION 1 and the motor datasheets referenced in the Motor subsection/s of SECTION
1.
9.1.9 Prior to closing the terminal boxes, ensure that all connections have been properly
tightened.
9.2 PERIODIC MAINTENANCE
9.2.1 Clean cooling air passages using low-pressure water spray.
9.2.2 Ensure that all electrical connections are properly tightened.
9.2.3 Ensure that all glands are correctly tightened and sealing correctly.
9.2.4 Ensure that the encoder (if fitted) is properly fixed to the motor shaft.
9.2.5 Ensure that the brake (if fitted) is functioning correctly.
9.2.6 The ball bearings are sealed for life, and therefore maintenance free.

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SECTION 10 – OPERATING INSTRUCTIONS
10.1 MOTOR OPERATION
10.1.1 The travel direction of the machine relative to the cable/hose feedpoint determines how
the reeler drive motor/s should operate:
• When the machine is travelling towards the feed point, the reel needs to recover
cable/hose. The motor/s must therefore be energised in the reeling in direction.
• At the end of any recovery cycle, the 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/hose as the machine coasts to a complete stop. The
duration of the coasting timer is typically between 3-5 seconds.
• When the machine is travelling away from the feed point, the cable/hose will be pulled
off the reel against the clutch. The motor/s must be de-energised. Note that keeping
the motor energised in this phase will increase the clutch slippage and the amount of
heat generated, leading to a greatly reduced usable life of the clutch.
• When the machine is stopped, the motor/s must be de-energised.
10.1.2 The motor heater/s, if fitted, should be energised whenever the motor/s is/are not running.
10.1.3 A typical electrical schematic and functional description can be found in SECTION 14.
10.1.4 With reference to the electrical schematic in SECTION 14, note that:
• KFP is to be closed whenever the machine travels towards the feedpoint, and should
be open when the machine travels away from the feedpoint.
• Motor overload Q1, motor contactor QC1, and delay-off timer KT are to be supplied by
others.
• All dashed interconnecting wiring is to be supplied by others.

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.

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Revision A
 • Do not set the torque higher than necessary as this will reduce the life of the clutch and
the cable/hose.
10.2.3 Other Checks
• Perform an amp test on the reeler motor to confirm the current consumption is within
the motor ratings.
• Perform a visual check on the reel to ensure that all components are operating
correctly and that no components are missing. Replace all covers and guards after
completion of commissioning tests.

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Revision A
SECTION 11 - TROUBLESHOOTING
Note that the majority of operating problems experienced with the Compact Drive torque unit are
caused by overheating. It is important that the unit is operated within the recommended duty
cycle/torque output limits and that the motor is switched off when not required.
FAULT POSSIBLE CAUSE
Blown motor fuse.
Circuit breaker has tripped.
Reeler motor fails Control circuit incorrect.
to start. Motor contactor damaged or faulty.
Motor burnt out.
No power supply available.
Torque unit setting too low.
Motor key not fitted or worn.
Motor starts but
Oil degraded or contaminated, or
reeler fails to
wrong oil used.
recover cable/hose.
Motor is running backwards.
Cable/hose size/length excessive.
Clutch surfaces worn or damaged.
Oil degraded or contaminated, or
Vibration or noise wrong oil used.
during operation.
Torque setting too high.
Crown wheel teeth worn.
Cable/hose drops
when reel is at Oil degraded or contaminated, or
standstill. wrong oil used.
Machine vibration causing the
worm gears to slowly backwind.
Cable/hose is snagged.
Excessive
cable/hose tension. Motor operates during payout.
Torque unit setting too low.
Instruction Manual Page 24
Revision A
REMEDY
Check and replace if necessary.
Check for an obvious cause, reset.
Check against circuit diagram.
Check and replace.
Investigate cause, then replace.
Confirm power.
Commission the reel as per section
10.2.
Check that key is fitted and ok.
Check oil type and quality and
change if necessary with the type
and quantity specified in the
Torque Unit subsection of
SECTION 1.
Correct motor direction.
Check data, contact Cavotec.
Contact Cavotec.
Check oil type and quality and
change if necessary with the type
and quantity specified in the
Torque Unit subsection of
SECTION 1.
Commission the reel as per section
10.2.
Check reel duty cycle/torque
output for overload. Contact
Cavotec.
Check oil type and quality and
change if necessary with the type
and quantity specified in the
Torque Unit subsection of
SECTION 1.
Fit a brake motor to drive. Contact
Cavotec.
Check cable/hose path through
cable/hose guide if fitted. Ensure
that rollers run freely.
Check control circuit and correct as
necessary.
Commission the reel as per section
10.2.
Printed 9 May 2018
SECTION 12 - RECOMMENDED SPARES
Drive System Spares
Qty
Part Number Part Description
Inst’d Spares
S01-H3000-001 300.0 torque unit 1 1
SC-1800633-MC1 Motor 4p 7.5KW 400 V 50 Hz IP55 +heater 230V-25W 1 1
SR1-S0188-000 Gasket kit 1 1
S64-20090-000 Mineral Oil Mobilube HD 80W-90 67l 150l

Collector Assembly Spares

Qty
Part Number Part Description
Inst’d Spares
S22-04121-010 Ring assembly F 4121 - 1 kV 1 1
SR2-01267-000 Slipring Ø270 for KP brushgear 1 1
SR2-07507-000 Slipring Ø270 for KP brushgear 3 3
SR2-S0163-000 Brushgear KP20/270 (600A) 7 7
S99-SG025-400 Limit switch Stromag 1:29/4 IP 20 1 1

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Revision A
SECTION 13 - MECHANICAL DOCUMENTATION
Drawing No. Description
SC-1800633-IS1 Reel assembly

Instruction Manual Page 26 Printed 9 May 2018

Revision A
 60
80 80
50
50

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

Heater cable gland M20x1.5

cable range ∅7 - ∅16mm

TITLE
Cable Reel
300.4 DM1935-50G K4121-FCi-R
CLIENT PROJECT

Mantsinen Mantsinen Montes del Platas

THIS DESIGN IS THE DRWN FN
PROPERTY OF CAVOTEC
SPECIMAS SPA AND IS DATE 05-03-18
C REVISED AS CUSTOMER REQUIRED GDS 03-05-18 ONLY TO BE USED WITH CHKD APPD
EXPRESS PERMISSION FROM
B UPDATED MOTOR LENGTH FN 12-03-18 CAVOTEC SPECIMAS SPA
ALL DIMENSIONS A ISSUED FOR APPROVAL FN 05-03-18 MAT'L DWG
IN MM UNLESS
OTHERWISE NOTED No. REVISION BY DATE
SCALE 1 : 20 ON A3 WGHT ~ 1400 kg No SC-1800633-IS1 C
SECTION 14 - ELECTRICAL DOCUMENTATION
Drawing No. Description
STD-SE-018 Power & control schematic
Hydrodynamic centre-fed functional
STD-TD-042
description

Instruction Manual Page 27 Printed 9 May 2018

Revision A
 Functional Description for Hydrodynamic
Centre-Feed Reeling System
Document No: STD-TD-042 Revision: A Date: 02 April 2010

REVISION STATUS

B Changed document number from STD-TD-034 PR 20/05/10

A Issued for information ER 02/04/10
Rev Description By Date

GEARED ROTARY LIMIT SWITCH (OPTIONAL)

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.

Cavotec Specimas SpA Page 1 of 1

Via Galvani, 1
I-20054 Nova Milanese (MI), Italy