Hubbell MMD21 User Manual

Page 1

INSTALLATION and MAINTENANCE INSTRUCTIONS

MMD21 GEAR DRIVE ELECTRIC CABLE REELS

All units are provided with right hand rotation unless otherwise specified. This means that cable is pulled off spool top left or bottom right (spool rotates clockwise to wind cable) when viewing spring end of reel. See diagram on parts page.

Clock-type springs provide power for automatic cable take-up. Spring must be pretensioned at time of installation to insure that tension is applied to cable at all times. Atension adjustment spanner wrench is provided with each reel.

WARNING

Some reels with large or multiple springs are equipped with a

ratcheted adjustment wrench. Follow separate instructions

for its use. Failure to use ratcheted wrench, on reels so

equipped, could result in serious personal injury.

WARNING

Do not attempt to relieve spring tension using spanner

wrench. Doing so may result in personal injury.

INSTALLATION

1. Insure that machinery to be serviced by reel is at position

closest to reel.

2. Securely mount reel in desired position using 3/8"(M10)

bolts. Be sure spool is aligned with cable run.

3. Position optional cable guide, if reel is so equipped.

See CABLE INSTALLATION DRAWING.

4. Unspool cable from reel, without allowing spool to rotate, so

that desired length of cable extends from reel. Do not pull cable directly off reel as this will apply tension to the spring and may cause overtensioning when the reel is put into service. Connect free end of cable to junction box on

machine or adjust cable stop

5. Remove cover plate on spring housing to expose

shaft and spring hub. (See Figure 1).

6. Insert spanner wrench into holes in spring hub (Fig 2).

Rotate wrench clockwise (for standard rotation). Number of 360 number on serial plate.

reel is reverse rotation and wrench must be rotated counterclockwise.

SPRING

HOUSING

COVER

PLATE

SPRING

Do not exceed number of turns indicated on serial plate.

Over-tensioning can cause a broken spring,

NOTE: If reel is equipped with ratcheted adjustment

wrench, follow instructions on separate sheet.

NOTE: On reels containing more than one spring, the hubs

are connected at the factory. Therefore, by tightening the

outer spring, the inside spring(s) will be tightened.

7. Remove collector cover and connect individual supply

conductors to collector terminals. See ELECTRICAL CONNECTIONS diagram, on parts page.

turns should match last digit in model

If model number includes an “R”,

(See EXPLANATION on parts list page.)

CLOCKWISE

FOR STANDARD

HUB

Figure 1

CAUTION

sheared shaft or other damage.

ROTATION

SPANNER

WRENCH

Figure 2

For reels manufactured after July 1, 1999

MAINTENANCE

Periodically: A. Use compressed air to clean collector

assembly and inside of collector housing. Inspect collector assembly for brush wear and pitted slip rings.

“IN” with 2/3

cable off reel–

SPRING OK

“OUT” with 2/3

cable off reel–

SPRING

BROKEN

BROKEN SPRING

INDICATORS

Figure 3

NOTE: Bearings and springs are prelubricated and require no

periodic maintenance.

Do not attempt to remove spring from its housing. Clock-

type springs can be dangerous to handle. Removal of

spring from housing could result in personal injury.

SPRING REPLACEMENT

The unique SAFETYCHANGE® spring motor consists of a spring and hub sealed within a housing. Areplacement spring is supplied sealed in its housing and the old unit should be discarded completely.

1. Turn off all electric power.

2. Disconnect cable from machine junction box.

3. Wind all cable onto reel to relieve all spring tension.

4. Remove inspection cover from face of spring housing.

5. Rotate spool clockwise and observe spring shaft. Shaft should rotate counterclockwise and hub (with spring attached) should remain stationary.

NOTE: Do not attempt to remove spring if resistance

is met or hub tends to rotate with shaft.

Continue to rotate spool and strike end of shaft with a rubber

mallet until shaft rotates freely and hub remains stationary.

6. Remove (4) nuts which secure spring motor(s) to frame.

7. Slide spring motor(s) off shaft and discard.

NOTE: On multi-spring reels, be sure to remove and save

dowel pins which connect one spring hub with another. Also

remove snap rings on shaft between reel housings.

8. Install replacement spring motor(s), pawls and pawl springs.

NOTE: Pawl springs must be located between the pawls and the deepest section of the shaft grooves. Make sure

that pawls and pawl springs are inserted flush with ends of

shaft and hub or they may rub against inspection cover.

9. Tighten nuts (and extension bolts) securing spring

housing(s) to reel frame.

SPRING

HUB

(Spring not

shown)

SHAFT

GROOVE

END VIEW

10. Connect free end of cable to junction box on machine or

adjust cord stop so that desired length of cord extends from reel.

11. Tension spring with spanner wrench. Refer to

INSTALLATION section.

12. Replace inspection cover.

CONTINUED ON BACK PAGE

B. Inspect cable for wear and check mounting bolts and other hardware for tightness.

C. Check for broken springs by pulling about 2/3 cable off reel and observing “Broken Spring Indicators” on sides of spring canisters. See Fig. 3.

D. Apply grease to gears through grease fitting on side of gear housing.

WARNING

PAWL

SPRING

Install

against flat

SIDE VIEW

SPRING

SHAFT

Page 2

14 15

11 12

28 ref

ILLUSTRATED PARTS LIST

For MMD21 GEAR DRIVE ELECTRIC CABLE REELS manufactured after July 1, 1999

Always specify SERIAL NUMBER &

MODEL NUMBER when ordering parts.

ELECTRICAL CONNECTIONS

SLIP-RING

LEADWIRES ARE

NUMBER TAGGED

SLIP-RING LEAD TO

MOVING CABLE CONNECTIONS

SLIP–RING

COVER

LEADWIRE INPUT FIXED END

(CUSTOMER SUPPLIED)

SLIP–RING ENCLOSURE

• 600 VOLTAC. 250 VOLT DC. WATERTIGHT, DUST TIGHT.

•

DO NOT EXCEED AMPERAGE RATING OF CABLE OR SLIP RING.

•

NUMBER OF CIRCUITS MAY VARY FROM TWO (MINIMUM) TO 36 (MAXIMUM). FOUR CIRCUITS SHOWN.

BRUSH TERMINAL

CONNECTIONS

SLIP–RINGS

TO DETERMINE ROTATION OF REEL

STANDARD REVERSE

ROTATION ROTATION

Cable is payed out and retracted as shown

when viewing reel from spring motor side.

432

FRAME

SET

SCREW

COLLAR

CABLE LEADWIRES

MOVING END

CABLE

WATER–TIGHT

CABLE GRIP

SPOOL

REEL

MAINSHAFT

NOTE:

Wire size, wire connectors, connection sequence, and connection methods must comply with National Electrical code and Local Electrical ordinances. If in doubt, contact a local electrical contractor or electrical inspector.

COLOR SEQUENCE FOR TYPE SO CABLE

THREE CONDUCTOR CABLE # 1 – BLACK # 2 – WHITE # 3 – GREEN (ground)

FOUR THRU TWELVE CONDUCTOR CABLE # 1 – BLACK # 2 – WHITE # 3 – RED # 4 – GREEN (ground) # 5 – ORANGE # 6 – BLUE # 7 – WHITE W/ BLACK TRACER # 8 – RED W/ BLACK TRACER # 9 – GREEN W/ BLACK TRACER #10 – ORANGE W/ BLACK TRACER #11 – BLUE W/ BLACK TRACER #12 – BLACK W/ WHITE TRACER

Page 3

MMD21 GEAR DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST

For reels manufactured after July 1, 1999.

NOTE: Applicable mounting hardware included with each kit.

ITEM KIT NO. DESCRIPTION QTY.

1 012393 Frame Assembly 1 2 012406 Discs (Set of two) 1 3 012397 Main Shaft Assembly 1

4 012402 Bearing Kit–2" Bore 1

5 012401 Bearing Kit–1.75" Bore 1

6 012456 Drive Stud Kit 1 7 017230 Stub Shaft, Gear Ratios ‘A’–‘K’ 1 8 012416 Wrapper Kit–5" Wide, 8" to 14" Dia. 1

8 012417 Wrapper Kit–5" Wide, 15" to 20"Dia. 1

9 012444 Cable Clamp Kit .38–.74 Dia. Cable 1 9 012445 Cable Clamp Kit .75–1.11 Dia. Cable 1

9 012446 Cable Clamp Kit 1.12–1.50 Dia. Cable 1

10 012459 Cable Connector .38–.50 Cable Dia. 1 10 012460 Cable Connector .50–.62 Cable Dia. 1 10 012461 Cable Connector .62–.75 Cable Dia. 1 10 012462 Cable Connector .75–.88 Cable Dia. 1 10 012463 Cable Connector .88–1.00 Cable Dia. 1 10 012464 Cable Connector 1.00–1.12 Cable Dia. 1 10 012465 Cable Connector 1.12–1.25 Cable Dia. 1 10 012466 Cable Connector 1.25–1.38 Cable Dia. 1 10 012467 Cable Connector 1.38–1.50 Cable Dia. 1

11 017052 Spring Motor Kit, Std. Rot.–100 Geared ar 11 017051 Spring Motor Kit, Rev. Rot.–100 Geared ar

12 012427 Pawl Kit (100 Springs) ar 13 017191 Spanner Wrench (100 Springs) 1

14 032804 Ratchet Wrench Kit (100 Springs) 1

15 017055 Extension Bolts (100 Springs) ar

16 016182 Carriage Bolt, .50–13 x 1.5 ar 17 021291 Lockwasher, .56 Med., Z.P. ar 18 100959 Hex Nut, .50–13, Z.P. ar 19 101211 Flat Washer, .50 ar 20 P06-03 ESNA Lock Nut, .50–13, Z.P. ar 21 021762 Hub Lock Pins (100 Springs) ar 22 012285 Collector Assembly, 2 Pole, 35 Amp 1

22 012286 Collector Assembly, 3 Pole, 35 Amp 1 22 012287 Collector Assembly, 4 Pole, 35 Amp 1 22 012288 Collector Assembly, 6 Pole, 35 Amp 1 22 012289 Collector Assembly, 8 Pole, 35 Amp 1 22 012290 Collector Assembly, 10 Pole, 35 Amp 1 22 012291 Collector Assembly, 12 Pole, 35 Amp 1 22 012292 Collector Assembly, 14 Pole, 35 Amp 1 22 012293 Collector Assembly, 16 Pole, 35 Amp 1 22 012294 Collector Assembly, 20 Pole, 35 Amp 1 22 012295 Collector Assembly, 24 Pole, 35 Amp 1 22 012296 Collector Assembly, 30 Pole, 35 Amp 1 22 012297 Collector Assembly, 36 Pole, 35 Amp 1 22 012298 Collector Assembly, 2 Pole, 75 Amp 1 22 012299 Collector Assembly, 3 Pole, 75 Amp 1 22 012300 Collector Assembly, 4 Pole, 75 Amp 1

(Includes pawl, pawl springs, cover, gaskets, and snap ring)

(Includes drive pin and retaining rings)

(Includes housing and gasket)

(Includes 4 wrapper sections)

(Includes 8 wrapper sections)

(U-bolt with lockwashers and hex nuts)

(Includes 2 pawls and springs)

(Includes mounting bolts)

(4 bolts per kit–less hardware)

ITEM KIT NO. DESCRIPTION QTY.

22 012376 Collector Assembly, 6 Pole, 75 Amp 1 22 012377 Collector Assembly, 8 Pole, 75 Amp 1 22 037194 Collector Assembly, 2 Pole, 125 Amp 1 22 037294 Collector Assembly, 3 Pole, 125 Amp 1 22 037295 Collector Assembly, 4 Pole, 125 Amp 1 22 012304 Collector Assembly, 2 Pole, 200 Amp 1 22 012381 Collector Assembly, 3 Pole, 200 Amp 1 22 012382 Collector Assembly, 4 Pole, 200 Amp 1 22 012383 Collector Assembly, 6 Pole, 200 Amp 1 22 012384 Collector Assembly, 8 Pole, 200 Amp 1

23 012440 Brush Kit (35 Amp) ar 23 012441 Brush Kit (75 Amp) ar

23 012443 Brush Kit (125 Amp/200 Amp) ar 24 012409 Collector Cover Kit (8" long) 1

24 012410 Collector Cover Kit (10.5" long) 1 24 012411 Collector Cover Kit (13" long) 1 24 012412 Collector Cover Kit (15.5" long) 1 24 012413 Collector Cover Kit (20.5" long) 1 24 012414 Collector Cover Kit (28.5" long) 1

25 012458 Seal Ring (only) 1 26 045716 Gear Enclosure Kit 1

27 016525 Tensioner Kit 1

28 045717 Gear Kit, Ratio ‘A’(1.22–8 pitch) 1 28 045718 Gear Kit, Ratio ‘B’ (1.50–8 pitch) 1

28 045719 Gear Kit, Ratio ‘C’ (1.86–8 pitch) 1 28 045720 Gear Kit, Ratio ‘D’ (2.07–8 pitch) 1 28 045721 Gear Kit, Ratio ‘E’ (2.33–8 pitch) 1 28 045722 Gear Kit, Ratio ‘F’ (3.00–8 pitch) 1 28 045723 Gear Kit, Ratio ‘G’ (4.00–8 pitch) 1 28 045724 Gear Kit, Ratio ‘H’ (1.22–6 pitch) 1 28 045725 Gear Kit, Ratio ‘I’ (1.50–6 pitch) 1 28 045726 Gear Kit, Ratio ‘J’ (2.00–6 pitch) 1 28 045727 Gear Kit, Ratio ‘K’ (2.33–6 pitch) 1

29 118320 Retaining Ring 1 30 012400 Gearbox Bearing Kit 2

31 012217 Spring Shaft, Gear, Std. Rot. (1001) 1 31 01221701 Spring Shaft, Gear, Rev. Rot. (1001) 1 31 012218 Spring Shaft, Gear, Std. Rot. (1002) 1 31 01221801 Spring Shaft, Gear, Rev. Rot. (1002) 1 31 012219 Spring Shaft, Gear, Std. Rot. (1003) 1 31 01221901 Spring Shaft, Gear, Rev. Rot. (1003) 1 31 012220 Spring Shaft, Gear, Std. Rot. (1004) 1 31 01222001 Spring Shaft, Gear, Rev. Rot. (1004) 1

32 045728 Front Gear Case Cover Kit 1 33 045729 Top Gear Case Cover Kit 1 34 012098 Hoop Kit 1 35 012091 Spool Lock Assembly 1 36 015660 Entrance Assembly Kit–1.50 NPT 1

37 045747 Gear Guard Kit 1

(Each kit includes 4 brushes and 4 fingers)

(Includes seal ring)

(Includes gasket)

(Includes washers, pad and nut)

(Includes 2 gears and key)

(Includes collar, housing and hardware)

(Includes pipe nipple, condulet and dome cover)

NOTE: Please consult factory for optional accessories: roller guides, ratchet lock, limit switch, hoop guides, spool lock , and swivel base

MODEL NUMBER EXPLANATION

SPRING

REEL

FRAME SERIES

SPRING

SERIES

NO. OF

SPRINGS

NO. OF POLES

AMPACITY

CORE

DIAMETER

GEAR RATIO

PRETENSION

TURNS

MMD 21 100 2 R - 12 3 10 - B - 1

INDICATES REVERSE ROTATION.

NO LETTER INDICATES STANDARD ROTATION.

AMPACITY

CODE

7 12 20

AMPS

75 125 200

Page 4

SPRING DETENSIONING

CABLE INSTALLATION

Use the following procedure to relieve spring tension prior to cable or spring replacement..

WARNING

DO NOT insert hands into gearbox until springs are fully

detensioned. Doing so could lead to serious injury.

1. Cycle reel thru normal operating cycle and stop when maximum amount of cable is wound onto reel spool.

2. Set spool lock to prevent spool from turning.

3. Remove access cover from top of gearbox.

4. Using open end wrench, loosen large hex nut slowly to

allow springs to unwind. Fully loosen nut further with wrench until springs are completely unwound.

5. Repair reel or replace springs or cable as necessary.

6. Retighten nut until definite resistance is felt and spring

washers are full compressed (flat). Replace cover.

NOTE: If hex nut is not adequately tightened,

spring unwinding can occur during reel operation.

7. Pretension reel. See INSTALLATION section, front page.

CABLE REMOVAL

CAUTION

Failure to relieve all spring tension prior to removing cable

could result in damage to equipment or personal injury.

Follow instructions carefully.

Use the following procedure to remove worn or damaged cable from reel prior to installation of new cable.

1. Move machine serviced by reel to a position closest to

reel. Springs will still be under pre-tension at this point.

2. Turn off all electric power.

3. Lock spool to prevent turning using spool lock.

4. Disconnect cable from machine junction box.

5. Detension springs as described above.

6. Remove cable from spool. Loosen U-bolt and water-tight

connector and disconnect conductors from slip ring.

Use the following procedure to replace cable or if reel was ordered without cable. Refer to CABLE INSTALLATION

REFERENCE DRAWING, below.

1. Unspool new cable from shipping spool and lay out to eliminate twist.

NOTE: This step is not essential, but will aid in winding

operation of the reel and prolong cable life.

2. Feed one end of the cable through water-tight connector on the main shaft inside the spool and into the slip ring side. (See drawing below).

NOTE: This may require that jacket of cable be stripped

to allow conductors to pass through shaft.

3. Connect individual conductors to appropriate rings on collector using crimp fitting or similar connection method.

4. Tighten water-tight connector and U-bolt provided on drum wrapper segments. Do not over-tighten.

5. Wind the cable onto the reel spool by hand rotating spool in direction it turns free of spring tension.

6. Connect free end of cable to machine junction box.

7. Pretension reel and complete installation as previously described.

COLLECTOR REPLACEMENT

1. Turn off all power to reel.

2. Remove collector cover and gasket.

3. Disconnect electric leads to and from collector.

4. Remove drive stud bolt from bearing housing.

5. Remove pipe plug from hole in side of housing. Insert long 1/8” Allen wrench through hole and loosen two set screws in collector locking collar Set screws are at 90

to one another..

NOTE: Older reels may have lock screws which must be

removed to reach set screws holding collector to shaft.

6. Slide collector off shaft.

7. Install new collector by reversing above steps.

CABLE INSTALLATION REFERENCE DRAWING

TERMINATE THIS END TO MACHINE JUNCTION BOX

ATTACH INDIVIDUAL

CONDUCTORS TO

COLLECTOR LEADS

COLLECTOR

Printed in USA

ATTHIS END

COVER

REMOVE

LINE

ENTRANCE

(NPT)

SLIP RING

ASSEMBLY

HUBBELL

PIPE

PLUG

A Hubbell Company

INSTALLCABLE THIS DIRECTION

CABLE

U-BOLT

WATER- TIGHT CONNECTOR

MAIN SHAFT

POSITION CABLE

GUIDE SO THAT

ROLLER PLATE

FACES CABLE PAY-

OFF DIRECTION.

PAYOFF

DIRECTION

SPRING MOTOR

HOOP GUIDE

SPOOL

GLEASON REEL CORP.

P.O. Box 26 • 600 South Clark St.

Mayville, WI 53050–0026

Phone 920–387–4120

Fax 920–387–4189

SPOOL ROTATION DIRECTION

TO WIND CABLE WHEN

VIEWED FROM SPRING SIDE

(STANDARD ROTATION)

PAYOFF

DIRECTION–

OPTIONAL

GUIDE

LOCATION

PRETENSION

HUB

SPRING MOTOR

PAYOFF

DIRECTION–

OPTIONAL

GUIDE

LOCATION

Bulletin No. 040262.c