expansion of the raw material handling system cable reel data sheet-(conductix)

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 - TurkeyTel: +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 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

of 79

Quote No.D-E-2013-50220-371-C-134413UE

30, avenue Brillat Savarin - 01300 Belley - France

Tél. +33 (0)4 79 42 50 00 - Fax +33 (0)4 79 42 50 05

SIRET : En cours de création – APE : 2712Z - N° TVA : FR 74 752 765 255

CONDUCTIX WAMPFLER France SAS au capital de 4 501 000 Euros - SIREN : 752 765 255 RCS NANTERRE

Siège Social - 119, avenue Louis Roche – B.P. 152 - 92231 Gennevilliers Cedex - France

Tél. +33 (0)1 46 88 15 00 - Fax +33 (0)1 46 88 15 01 - www.conductix.com

Ordering Summary

96N6319401 Replacement / Central-feeding

part number description quantity

0440217 BNA700.3CN55.M2575VS 3TH12+TFO40.6FO62.5 2

WGD89552 cable WG-D 3x95 + 2x50/2 + 12FO - 8.7/15(18)KV - O.D. = 58,0 to 62,0 mm - weight = 6,05 kg/m

1078

copper surcharge 1078

420F093 cable termination 24kV + 12FO 1

0486116 2 ways guiding device LD1000 2

0484945 anchoring drum TA800 2

0484940 entry funnel RE800 2

0486221 3TH12+FO (+LV) connection box - 930x600x350 - 304 stainless steel

2

1-a

http://www.kme.com/en/metal_prices

Quote No.D-E-2013-50220-371-C-134413UE


Tél. +33 (0)4 79 42 50 00 - Fax +33 (0)4 79 42 50 05





96N6319401 Replacement / Central-feeding

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


Tél. +33 (0)4 79 42 50 00 - Fax +33 (0)4 79 42 50 05





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

Protection IP66 316L stainless steel square housing Cable gland 6 Nickel plated brass cable gland(s) heating resistance 500W/220-240V AC

Fiber Optic transmitter Model TFO40-6FO Number of channels 6 Fiber type 62.5/125 µm Multimode Number of turns 40 Housing 316L stainless steel

Rotary switch limit switch fitted on to one gear box entry STROMAG - 4 contacts - 540 turns

Electrical diagram F-E-410N008

Empty reel weight 3884 kg

Cable WG-D 3x95 + 2x50/2 + 12FO - 8.7/15(18)KV - O.D. = 58,0 to 62,0 mm - weight = 6,05 kg/m

Voltage rating 8.7/15 kV Outer diameter (min/max) 58 / 62 mm Temperature range -25°C / 80°C Weight 6,05 kg/m Maximum pull 570 daN

1-c

Quote No.D-E-2013-50220-371-C-134413UE


Tél. +33 (0)4 79 42 50 00 - Fax +33 (0)4 79 42 50 05





2 ways guiding device LD1000

Radius 1000 mm Sensor functions Slack detection

Over tension detection Position detection Switches pre-wired to a terminal box

Sensor type Inductive proximity sensor 20-250 V AC/DC Treatment and paint Flanges : galvanized steel

rollers : painted

Anchoring drum TA800

Installation as per drawings 420N113 / 420N093

Entry funnel RE800

Installation as per drawings 420N113 / 420N089

1-d

INDEX

05-17 19-31

33-35 37-39 41 43 45 47 49 52-54 56-57 59 61-62 64 66-69 71-73 75 77

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

Tel: +90 216 361 42 05; Fax: +90 216 372 64 87; E-mail:[email protected]

Page 2 of 79

INSTALLATION INSTRUCTIONS



Page 3 of 79

Energy & Data Transmission S.A.S. Conductix-Wampfler France Parc des Chanteraines Phone: +33 (1) 46 88 16 00 8 rue du Commandant Estienne Fax: +33 (1) 46 88 16 10 d’Orves E-Mail: [email protected] 92390 Villeneuve la GarenneFrance

Page 4 of 79

Installation Instructions

MMMOOOTTTOOORRR DDDRRRIIIVVVEEENNN CCCAAABBBLLLEEE RRREEEEEELLL

WWWIIITTTHHH MMMAAAGGGNNNEEETTTIIICCC CCCOOOUUUPPPLLLEEERRR

IINNSSTTAALLLLAATT IIOONN

SSTTAARRTT--UUPP

MMAAIINNTTEENNAANNCCEE

SSPPAARREE PPAARRTTSS

EELLEECCTTRRIICCAALL DDIIAAGGRRAAMM

CONDUCTIX - WAMPFLER

DELACHAUX S.A.

30 avenue Brillat Savarin - BP 39

01300 Belley - France

tel.: +33 (0)4 79 42 50 00

fax: +33 (0)4 79 42 50 05

email: [email protected]

internet: www.conductix.com

Page 5 of 79

INSTALLATION INSTRUCTIONS MOTOR DRIVEN CABLE REEL WITH MAGNETIC COUPLER

SUMMARY Page(s)

A - GENERAL INFORMATION

A.1. Responsabilities

A.2. Data and modifications

A.3. Security

A.3.1. General information

A.3.2. Slipring

A.4. Restrictions of use

A.4.1. Wind

7-8

B - INSTALLATION

B.1. Shipment

B.2. Erection of the cable reel

B.2.1. Handling

B.2.2. Installation of the reel

B.2.3. Spools not mounted on the gear box

B.3. Fitting of accessories

B.4. Installation of the cable on the spool

B.4.1. Preparation

B.4.2. Installing the cable on the spool

B.4.3. Fixation of the cable to the moving part

B.4.4. Winding on of the cable

B.5. Connection of the cable to the motor reel

B.5.1. Low Voltage Sliprings

B.5.2. High Voltage Sliprings

B.5.3. Option / TFO (Optic Fibre Transmitter)

B.6. Connection of the cable at the feed point

B.7. Electrical connection of the motor(s)

B.8. Electrical connection of the accessories

9-13

C - COMMISSIONING

C.1. Energizing the drive motor(s)

C.2. Limit switch adjustment (option)

C.3. Over Pull adjustment onto guiding device (Option)

C.4. Various adjustments

C.4.1. Change of the cable winding direction

C.4.2. Cable of different diametre

C.4.3. Adjustment of W and C couplers

C.5. Troubles shooting list

13-15

D - MAINTENANCE 16-17

Page 6 of 79


MAGNETIC COUPLERS

SPOOLS

► C080 - C120 - C180► P050► P080 - P120 - P180► P270

LOW VOLTAGE SLIPRINGS

► BNA0► BNA1► BNA2► BNA3► BNA4► BNA5► BNA7

MAIN GEARBOXES

ADDITIONAL GEARBOXES

►Monospiral spools►XM spools (multi-monospirals)►Trispiral spools►Semi-wide spools

►One-layer spools

: for some reel configurations only.

► BNA1x► BNA2x► BNA36 - 47 - 59 only► BNA38

► BNA710

► Coupler V► Coupler W► Coupler CN► Coupler D

SECONDARY GEARBOXES

► H7, H12, H24

HIGH VOLTAGE SLIPRINGS

Page 7 of 79



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


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 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).





L'AXE DE LA BOBINE.


L'AXE DE LA BOBINE.

Page 10 of 79


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).


L'AXE DE LA BOBINE.

Page 11 of 79


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


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.


L'AXE DE LA BOBINE.






(voir notices spécifiques de montage des bobines). Tous ces accessoires doivent être MONTES DANS


L'AXE DE LA BOBINE.

Page 13 of 79


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


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.

Optical Fiber transmitter failure Replace Optical Fiber transmitter.

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


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



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


Frequency

1 Every 2 000 working hours / 6 months

2 Every 2 000 working hours / 1 year




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

B Rotation of the guide rollers. 2

C Wear of the rollers. 2

D Position switch. 2

OPTIC FIBER TRANSMITTER

A Visual aspect and connections. 2

B Heating resistance. 2

NOTES

..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... .....................................................................................................................................................................................

Page 17 of 79

MONOSPIRAL SPOOL IN KIT FORM



Page 18 of 79


DELACHAUX S.A.



tel.: +33 (0)4 79 42 50 00

fax: +33 (0)4 79 42 50 05



Notice de Montage & Installation

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

TYPE* 1 2a 2b 3 4 5 6 7 8 9 10 11

Ι × 1 × 27 × 28 × 1 × 56 × 1 × 8 × 8 × 1 × 28 × 1 × 1

ΙΙ × 1 × 29 × 30 × 1 × 60 × 1 × 10 × 10 × 1 × 30 × 1 × 1

* Types Ι, ΙΙ: p13-13

AXE EPAULE / SHOULDERED STUD

RENFORT / SPOKE REINFORCEMENT

1 4

2a

2b

3

8

9 5

6

7

10

VISSERIE / BOLTS & NUTS (� p.13-13)

11

CALE DE REGLAGE / GAUGE BLOCK

DISQUE CENTRAL CENTRAL DISC

BRAS (Face Avant)/SPOKE (Front Side)

BRAS RECOUPE / CABLE ENTRY SPOKE

VIROLE SPIRALEE / INNER DRUM BAND

a

b

a

b

COLLIER / CABLE CLAMP

VIROLE EXTERIEURE (secteurs)OUTSIDE RIM (sections) BRAS (Face Arrière) / SPOKE (Back Side)

Étape 8 Étape 8 -- Step 8Step 8 Virole extérieure arrière Back outside rim

Étape 2 Étape 2 -- Step 2Step 2 Bras recoupé Cable entry spoke

Étape 1 Étape 1 -- Step 1Step 1 Disque central + axes épaulés

Central disc + Shouldered studs

Étape 7 Étape 7 -- Step 7Step 7 Virole spiralée Inner drum band

Étapes 3Étapes 3--44--5 5 -- Steps 3Steps 3--44--55 Bras (Face Arrière) Spokes (Back Side)

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


�� 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


�� 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


Répéter pour chaque bras 2b. Repeat for every spoke 2b.


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



Répéter pour chaque bras 2a. Ordre de montage suivant Étape 4.Repeat for every spoke 2a.

Mounting sequence order identical to Step 4.


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


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


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


�� 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


V4 CHcM12-30 × 80 × 90

E2 H M12 × 96 × 110

RF2 CS 12 × 96 × 110


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


�� 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


Ne pas serrer la visserie à ce moment. Do not fully tighten the nuts at this time.


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



Réglage et blocage de la virole extérieure avant suivant Étape 1.Adjustment and tightening of the front outside rim identical to Step 1.


Répéter pour chaque axe épaulé 4.

Repeat for every shouldered stud 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



E2 69 N.m 51 lb.ft

E2

E2

5


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


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


�� ☺☺☺☺

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



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


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.


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



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


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.

NOTES ..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................

Page 30 of 79


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



Page 32 of 79

D-03/IT-12281 - Rév.3 - E

MMAA 33 "SEASIDE" ENVIRONMENT

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.

Lubrication by GREASE.

SPOOL

Semi wide spool: Delivered mounted on the reel.

Monospiral spool - Diameter 3,1m: Delivered mounted onthe reel.

Monospiral spool - 3,1m > diameter 4,7m:Delivered in 3 assembled parts, not mounted on the reel.

Monospiral spool - 4,7m > diameter 5,5m:Delivered in 5 assembled parts.

Monospiral spool - Diameter > 5,5m:Delivered in kit on pallet (assembling fasteners).

Large (Level wind): Delivered assembled or in kit, depending on the overall dimensions.

ACCESSORIES

Connection box with heating resistance.

Page 33 of 79

MA 3 - "Seaside" Environment

D-03/IT-12281 - Rév.3 - E

GENERAL ASPECT

SP 200 paint, according to technical leaflet.

Galvanization, according to NF EN ISO 1461.

A2 Stainless steel external fasteners.

Screw locking (Thread-locking product + Stainless steel washer or Stainless steel washer type "contact").

Identification by sticker on the slipring housing of the reel and on the accessories.

Reels

Motors ......................................................................... Paint as supplied by the motor manufacturer.

Couplers :

- Support ................................................................ Cataphoresis + black paint

- Coupler W / Vn .................................................... Anode oxidization

- Coupler Cn / D ...................................................... Stainless steel

Gear boxes P1/BNA0/BNA10/20/30 ............................ Cataphoresis + SP 200 paint

Others gear boxes ....................................................... SP200 paint

Additional gear boxes .................................................. Cataphoresis + SP 200 paint

Spool - Fixation by SAFETY NUTS:

- Monospiral / Trispiral ............................................ Galvanization

- SL 3 ...................................................................... SP 200 paint

- SL 4/5/6/7 ............................................................. Galvanization

- SL 8 ...................................................................... SP 200 paint

- SL (special) .......................................................... SP 200 paint or galvanization (according to construction)

Level wind .................................................................... Galvanization or SP 200 paint, depending on overall dimensions.

Slipring housings:

- Low Voltage

Round housing .................................... Galvanization

except P1 SL3 - BNA0 ........ SP 200 paint

Square housing (P270): ....................... 304L Stainless steel

- High Voltage .................................................... 304L STAINLESS STEEL + A2 Stainless steel fasteners.

Accessories

Entry device ................................................................ Galvanization

Shock absorber spring ............................................... Passivated zinc steel

Cable sleeve .............................................................. Galvanized steel

Cable guide / Diverting device .................................... Galvanization / Rollers on ball bearings with protection joint.

Anchoring device ........................................................ Galvanization

Connecting device

- Low Voltage ..................................................... Paint as per manufacturer's specification

- High Voltage .................................................... Stainless steel

Others accessories generally available ...................... Paint as per manufacturer's specification

Page 34 of 79

MA 3 - "Seaside" Environment

D-03/IT-12281 - Rév.3 - E

OPTIONS on request

Motor: - Reinforced tropicalization (T° -20°C to +40°C / HR > 95%).

- Low temperature (up to -40°C)

- Special voltage (max 690 V TRI star).

- Heating resistance.

- CTP sensor.

- PTO thermostatic sensor.

- Canopy.

- IP65.

- Brake with manual releasing.

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



Page 36 of 79

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


Cn Moto coupler


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


Cn Moto coupler


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



Page 40 of 79

CONNECTIONS TABLE



Page 42 of 79

C8 / C080 / C120 / C180 Type connection

Maximum cable size

Terminal with Screws (Weidmuller) + End for 2,5²

2,5² RINGS

Option 6² with 6² special end (This option is restricted to 5 rings (4TC8) for C8 sliprings)

Type connection

Maximum cable size

FASTON Type 6,35 (not insulated)

2,5²

Slipring Type C

Low Voltage

BRUSH

HOLDER

Option 6² with FASTON Type 6,35 spécial 6²

P050 P080 P120 P180

RINGS

Type connection

Maximum cable size

Ring terminal insulated* Ø M5

10²


25²


50²


95²

Slipring Type P

Low Voltage

BRUSH

HOLDER Type connection

Maximum cable size

Ring terminal Ø M4

10²

Ring terminal Ø M8

25²

Ring terminal Ø M8

50²

Ring terminal Ø M12

95²

* Rings terminal should be protected by using heat-shrink sleeving or insulated terminal.

P270/1 - /2 - /4 P400/1 - /2 - /4

RINGS

Type connection

Maximum cable size

Ring Terminal Ø M12

P270/1 & /2 � 2 screws

P270/4 � 4 screws

300²

Ring Terminal Ø M12

P400/1 & /2 � 2 screws

P400/4 � 4 screws

300²

Slipring Type P

Low Voltage

BRUSH HOLDER Type connection

Maximum cable size


P270/1 � 1 screw

P270/2 � 2 screws

P270/4 � 4 screws

300²


P400/1 � 1 screw

P400/2 � 2 screws

P400/4 � 4 screws

300²

H7 H12 H24

RINGS

Type connection

Maximum cable size


120²


240²


240²

Slipring Type H

High Voltage

BRUSH

HOLDER Type connection

Maximum cable size


120²


240²


240²

Fiber Optic Transmitter (TFO)

Standard : Connector : ST On request : FC

NOTICE D'INFORMATION TECHNIQUE TECHNICAL INFORMATION LEAFLET

CONNECTIONS TABLE

4 10N108 Folio 1/1 03/10

Page 43 of 79

D-E-2013-50220-0371-C-Drawing



Page 44 of 79

970

448

Ø25

00

Ø75

00

150

150

217 66

~1758

BNA700.3CN55.M2575VS 3TH12+TFO40.6FO62.5

SAVOYE 29/07/13

350

1000

134413UE

500

Empty reel weight : 3884kg

Measurements in mm

885

850

305

350

15

240

15

400

250

325

240

620

220

540

535

Page 45 of 79

Data sheet-Cable WG-D-WG-D 8.715-3x95+2x502 +12FO (539m)



Page 46 of 79

Data sheet-D-E-2013-50220-371-C

BNA700.3CN55.M2575VS 3TH12+TFO40.6FO62.5

Cable WG-D - WG-D 8.7/15 - 3x95 + 2x50/2 + 12FO (539m)

Installation

Frequency..................... : 50Hz

Motor voltage................. : 400V

Motor voltage................. : Three phase

Motor voltages (Δ/Y).......... : 230/400 V

Yearly use.................... : 2000h

Slip ring service factor...... : 100%

Minimum ambient temperature... : 5°C

Maximum ambient temperature... : 45°C

Environment................... : MA3 - seaside

Wind speed.................... : 20m/s

Reel travel length..........Ce : 510m

Installation height..........H : 6.5m

Deflection distance.........e0 : 0m

Traveling speed............... : 30m/min

Working speed................. : 30m/min

Acceleration time............. : 5s

Acceleration.................. : 0,1m/s²

Length after anchor point..... : 5m

Electrical settings Conductor type................ : Power

Network type.................. : Three phase

Mains voltage................. : 10000V

Tolerance..................... : 5%

Number of conductors.......... : 4

Including ground.............. : Yes

Shielded conductors........... : No

Nominal current............... : 177,74A

Power......................... : 3078,55kVA

Power......................... : 2616,77kW

Cosines phi................... : 0,85

Maximum voltage drop.......... : 5%

Cable derating coefficient.... : 0,85

Conductor type................ : Optical fiber

Number of conductors.......... : 6

Fiber diameter................ : 62.5µm

Cable WG-D - WG-D 8.7/15 - 3x95 + 2x50/2 + 12FO (539m) Minimum diameter.............. : 58mm

Maximum diameter.............. : 62mm

Weight........................ : 6,05kg/m

Copper weight................. : 3,216kg/m

Max pull with guiding devices. : 570daN

Maximum speed................. : 120m/min

Minimum ambient temperature... : -25°C

Maximum ambient temperature... : 80°C

Nominal current............... : 298A

Maximum voltage drop.......... : 0,44V/A/km

Spool M2575VS Spool type.................... : Monospiral spool

Inner diameter................ : 2,5m

Outer diameter................ : 7,5m

Spool width................... : 0,066m

Spokes quantity............... : 30

Safety factor................. : 1

Number of dead turns.......... : 2

Results Workshop settings : C0=0,56 - Te=217 - Td=269

Rotary limit switch : STROMAG 4c/540tr (361) mounted on the main

gearbox

Motor(s) with brakes : 3

Empty reel weight : 3884kg

Wound element weight : 3260,95kg (539m x 6,05kg/m)

Guiding device : R1000

Cable guide recommended height : 0,74m

Reeling direction : to be defined

Performance Wound element Max pull on duty : 45%(254,03daN/570daN)

Max slipping pull : 23%(132,86daN/570daN)

Spool Filling ratio : 83%(526,73m/633,6m)

Maximum pull : 32%(254,03daN/800daN)

Gearbox Generated torque : 94%(271,21daN.m/288,93daN.m)

Maximum load : 69%(6227,69daN/9000daN)

Page 47 of 79

GEAR BOX LUBRICATION



Page 48 of 79

LUBRIFICATION DES ENGRENAGES SOUS CARTER ETANCHE A LA GRAISSE PAR BARBOTAGE

D'origine, le matériel est lubrifié avec de la graisse "…." (Référence suivant repère).

� Rep. 1 : CONDAT 31028 Redugraisse suivant fiche technique 4 4 20F311Matériels concernés : - P1 - BNA0 - BNA1 - BNA2 - BNA3 - BNA4 - BNA5 - BNA7-

A3X - NCR - XO73 - XO74 - XO75 - XO77 - Réducteurs additionnels R1-R2-R3-R4-R5-R6-R7-R8-R9-

R10 - Cellules additionnelles 11-22-33-44-55-66-77-88-99

� Rep. 2 : CONDAT type REDUSYNTH suivant fiche technique 4 4 20F322Matériels concernés : - Tous réducteurs et cellules en option basse et

haute température

Nota : Ne pas mélanger les graisses.

Utiliser impérativement une graisse de même nature que celle d'origine.

� � �

LUBRIFICATION OF GEARBOXES IN SEALED HOUSING BY GREASE SOAKING

Original equipment is supplied greased with "…." (reference according to Item)

� Item 1 : CONDAT 31028 Redugraisse according to technical leaflet 4 4 20F311Concerned materials : - P1 - BNA0 - BNA1 - BNA2 - BNA3 - BNA4 - BNA5 - BNA7-

A3X - NCR - XO73 - XO74 - XO75 - XO77 - Secondary gear box R1-R2-R3-R4-R5-R6-R7-R8-R9-R10 - Additionnal gear box 11-22-33-44-55-66-77-88-99

� Item 2 : CONDAT type REDUSYNTH according to technical leaflet 4 4 20F322Concerned materials : - All gear box with option low or high temperature

Note : Do not mix greases

The sort of grease used must be identical to the original grease.

NOTICE TECHNIQUE TECHNICAL LEAFLET

GEAR BOX LUBRICATION

LUBRIFICATION DU REDUCTEUR

410N026 Folio 1/1 10/09

Page 49 of 79

GUIDING DEVICES LS - LD - LDD



Page 51 of 79

4 40N033 1/3

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


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



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



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


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


E Proximity switch (option) 4 20F124

C

E

A

E

D

B

Page 54 of 79

MAIN GEARBOX TYPE BNA700710



Page 55 of 79

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).


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


MAIN GEARBOX TYPE BNA700/710

440N153 Folio 2/2 03/12 42R0145 C

Page 57 of 79

NOTES



Page 58 of 79


DELACHAUX S.A.



tel.: +33 (0)4 79 42 50 00

fax: +33 (0)4 79 42 50 05



Page 59 of 79

SLIPRING ASSEMBLY-H7-H12-H24



Page 60 of 79

4 40N148 1/2

COLLECTEUR H7 / H12 / H24

SL IP R ING ASSEMBLY H7 / H12 / H24


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


ØM12 screw


H12 - H24 - BRUSH HOLDERS CONNECTION

Core H7 : 120 mm² max

Connections


ØM12 screw


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


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 -----

Housing / Main gear box joint BNA30 : 4J10037 BNA40-50 : 4J10038

Cable gland plate joint Indicate the reel number

Housing joint or Housing cover joint Indicate the reel number

External rubber support 0402797

TerreTerreTerreTerre

1111

2222

3333

4444

EarthEarthEarthEarth L1L1L1L1 L2 L2 L2 L2 L3 L3 L3 L3

Tightening torque: 10 N.m10 N.m10 N.m10 N.mH7

1111

2222

3333

4444

H12 - H24

EarthEarthEarthEarth L1L1L1L1 L2L2L2L2 L3L3L3L3

Tightening torque: 10 N.m10 N.m10 N.m10 N.m

1111

2222

3333

4444

Page 62 of 79

SLIPRINGS AND TERMINALS MARKING



Page 63 of 79


ALL OUR SLIPRINGS AND TERMINALS ARE MARKED.

The same stamping appears : - on the brush holder,

- on the connection of the corresponding ring,

- on the terminal.

STAMPING USED

� Low Voltage Type P ..................................................... P1 - P2 - P3...

� Low Voltage Type C...................................................... 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8...

� Low Voltage Type C + Silver plated Rings.................... 1A - 2A - .A - ……..10 - 11…..

� Low Voltage Type C + Paladium Rings ........................ 1ML - 2ML - .ML - ……..10 - 11…..

� Low Voltage Type C + Gold plated Rings ..................... 1D - 2D - .D - ……..10 - 11…..

� High Voltage Type H..................................................... L1 - L2 - L3...

� C Transmitter ................................................................ C1 - C2 - C3 - C4...

� M Transmitter................................................................ M1 - M2 - M3 - M4...

� Explosion proof ............................................................. 1 - 2 - 3 - 4 - 5... Insulated Earth

� Optic Transmitters (TFO) .............................................. F1 - F2 - F3 - F4 - F5 -F6

CABLE MARKING

Except otherwise stipulated :

All the CABLES connected to - the rings,

- the brush-holders,

- the terminals

are marked at the cable ends

either by * a number stamped on the outer sheath,

* a mark attached to the cables.



4 10N107 Folio 1/1 06/09

Page 64 of 79

OPTICAL FIBER TRANSMITTER



Page 65 of 79

Titre Placez votre message ici. Pour renforcer son impact, utilisez deux ou trois phrases.

Instructions and Maintenance Manual

Optical Fiber Transmitter

TFO 40

Conductix-Wampfler France SAS 30 avenue Brillat Savarin - BP 39


tel.: +33 (0)4 79 42 50 00

fax: +33 (0)4 79 42 50 05


www.conductix.com

Page 66 of 79

Instructions and Maintenance Manual Optical Fiber Transmitter TFO 40


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


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


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

bracket #7 (fig.3).

7

fig.3

fig.1b

1 2

fig.2b

3 5

4

6

2

fig.2a

fig.1a

C - SPARE PARTS Description Reference

Heating resistance 100W - 110/250V AC/DC - 50-60Hz 420F151/1

Heating resistance 100W - 250/420V AC/DC - 50-60Hz 420F151/2

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



Page 70 of 79

END LIMIT SWITCH



Page 74 of 79

SPACE HEATER 500 W



Page 76 of 79

MAINTENANCE :

- No maintenance.

SPARE PARTS (Please advice the cable reel number) :

- 1 complete space heater

CONNECTIONS BY USER : On terminal item B. - Power 220/230V, 1 phase 50/60Hz - Other voltage if specified.

ADJUSTMENT OF THERMOSTAT by screwing item A - Environment (from -40°C to +40°C) : 20 °C - Sesaside or tropical environment : 30 °C


SPACE HEATER 500 W

4 10N113 Folio 1/1 04/07

Page 77 of 79

LONG TIME STORAGE



Page 78 of 79


LONG TIME STORAGE (more than 9 months)

4 40N181 Folio 1/1 07/10

INSTRUCTIONS FOR LONG TIME STORAGE (more than 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 gear boxes, 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 gear boxes, lubricate the pinions, the

shafts and the inside of the housings.

� As far as possible, turn the spool axis from 4 to 5 turns, to modify the position of the bearings parts.

During the commissioning:

� Bearings:

∗ Sealed bearings: Replace them if the storage period is more than 3 years.

∗ Bearings, which can be regreased:

Storage period Operations

Less than 1 year No operation on the bearings.

From 1 year to 2 years Regrease the bearing.

From 2 years to 5 years Dismantle the bearing, clean it and regrease it.

More than 5 years Change the bearing. Regrease it.

∗ 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.

Page 79 of 79

expansion of the raw material handling system cable reel data sheet-(conductix)

Documents

belley france tl

cable type wgd

cable reel type bna700

reel travel length

avenue brillat savarin

avenue louis roche

steel comisurata steel

stainless steel