Hubbell S-21 User Manual

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“OUT” with 2/3 cable off reel–
SPRING
BROKEN
Figure 3
BROKEN SPRING INDICATORS
“IN” with 2/3 cable off reel– SPRING OK

INSTALLATION and MAINTENANCE INSTRUCTIONS

S-21DIRECT 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-typesprings provide power for automatic cabletake-up.

Spring must be pretensioned at time of installation to insure that tension is applied to cable at all times. A tension 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 counterclockwise (for standard rotation). Number of 360O turns should match last digit in model number on serial plate.If model number includes an “R”, reel is reverse rotation and wrench must be rotated clockwise. (See EXPLANATION on parts list page.)

 

SPRING

 

HOUSING

 

COVER

 

PLATE

 

SPRING

Figure 1

HUB

 

COUNTER-

 

CLOCKWISE

 

FOR STANDARD

 

ROTATION

Figure 2

SPANNER

WRENCH

CAUTION

Do not exceed number of turns indicated on serial plate. Over-tensioningcan 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.

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.

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.

NOTE: Bearings and springs are prelubricated and require no periodic maintenance.

SPRING REPLACEMENT

WARNING

Do not attempt to remove spring from its housing. Clocktype springs can be dangerous to handle. Removal of spring from housing could result in personal injury.

The unique SAFETYCHANGE® spring motor consists of a spring and hub sealed within a housing. A replacement 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 inner shaft. Shaft should rotate clockwise 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: Onmulti-springreels, be sure to remove andsave dowel pins which connect one spring hub with another. Also remove snap rings on shaft between spring 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.

 

PAWL

 

SPRING

SPOOL

 

HUB

 

 

SHAFT

 

 

(Spring not

 

 

 

shown)

 

SPRING

 

SHAFT

 

Install

 

SIDE VIEW

END VIEW

GROOVE

against flat

9.Tighten nuts (and extension bolts) securing spring housing(s) to reel frame.

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

ILLUSTRATED PARTS LIST

 

 

 

S-21DIRECT DRIVE ELECTRIC CABLE REELS

 

Always specify SERIAL NUMBER &

 

 

 

 

MODEL NUMBER when ordering parts.

11

 

 

 

 

 

 

 

12

7

 

 

 

 

21

11

12

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

1

 

 

 

 

 

 

 

 

11

 

 

12

 

 

 

 

 

 

12

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

14

11

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

15

 

 

 

 

 

 

 

 

 

 

 

2

8

3

 

 

 

 

 

 

 

 

 

 

 

15

 

10

 

 

 

 

 

 

 

 

 

 

 

14

8

 

 

 

 

20

 

19

 

 

 

 

 

20

 

 

 

9

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

3

9

 

 

1

 

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

1

3

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

11

7

 

 

 

 

 

 

 

 

 

 

1

 

12

 

 

 

 

 

12

 

 

 

 

 

 

11

 

11

23

 

 

 

 

 

 

 

 

 

 

 

 

12

 

 

 

 

11

 

 

12

 

 

 

17

 

 

 

 

 

 

 

 

 

 

 

 

18

11

 

 

 

11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

19

15

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

 

4

1

1

6

22

13

26

24

25

TO DETERMINE ROTATION OF REEL

STANDARD REVERSE

ROTATION ROTATION

Cable is payed out and retracted as shown when viewing reel from spring motor side.

 

 

 

 

 

CABLE LEADWIRES

ELECTRICAL CONNECTIONS

 

 

 

 

 

 

 

 

MOVING END

 

 

 

 

 

 

CABLE

LEADWIRE INPUT FIXED END (CUSTOMER SUPPLIED)

SLIP-RING

BRUSH TERMINAL

 

 

 

CONNECTIONS

 

 

WATER–TIGHT

LEADWIRES ARE

 

 

 

 

 

 

 

 

 

 

CABLE GRIP

NUMBER TAGGED

 

 

 

 

 

 

 

 

 

 

 

 

1

2

3

4

SET

 

SLIP-RINGLEAD TO

SCREW

REEL

 

 

 

 

MOVING CABLE

 

 

 

 

 

MAINSHAFT

CONNECTIONS

 

 

 

 

 

 

 

1

2

3

4

COLLAR

 

 

 

SLIP–RINGS

 

 

SLIP–RING

 

 

 

 

 

SPOOL

COVER

 

 

 

FRAME

 

 

 

 

 

 

SLIP–RINGENCLOSURE

600 VOLT AC. 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.

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

S-21DIRECT DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST

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

 

 

(Includes drive pin and retaining rings)

 

4

012402

Bearing Kit–2"Bore

1

 

 

(Includes housing and gasket)

 

5

012401

Bearing Kit–1.75"Bore

1

 

 

(Includes housing and gasket)

 

6

012456

Drive Stud Kit

1

7

012208

Stub Shaft, Std. Rotation (351, 601)

1

7

01220801

Stub Shaft, Rev. Rotation (351, 601)

1

7

012209

Stub Shaft, Std. Rot. (621, 751, 801)

1

7

01220901

Stub Shaft, Rev. Rot. (621, 751, 801)

1

7

012210

Stub Shaft, Std. Rot. (622, 752, 802)

1

7

01221001

Stub Shaft, Rev. Rot. (622, 752, 802)

1

7

012211

Stub Shaft, Std. Rot. (623, 753, 803)

1

7

01221101

Stub Shaft, Rev. Rot. (623, 753, 803)

1

7

012212

Stub Shaft, Std. Rot. (624, 754, 804)

1

7

01221201

Stub Shaft, Rev. Rot. (624, 754, 804)

1

7

012213

Stub Shaft, Std. Rotation (1001)

1

7

01221301

Stub Shaft, Rev. Rotation (1001)

1

7

012214

Stub Shaft, Std. Rotation (1002)

1

7

01221401

Stub Shaft, Rev. Rotation (1002)

1

7

012371

Stub Shaft, Std. Rotation (1003)

1

7

01237101

Stub Shaft, Rev. Rotation (1003)

1

7

014619

Stub Shaft, Std. Rotation (1004)

1

7

01461901

Stub Shaft, Rev. Rotation (1004)

1

8

012416

Wrapper Kit–5"Wide, 8" to 14" Dia.

1

 

 

(Includes 4 wrapper sections)

 

8

012417

Wrapper Kit–5"Wide, 15" to 20"Dia.

1

 

 

(Includes 8 wrapper sections)

 

9

012444

Cable Clamp Kit .38–.74Dia. Cable

1

 

 

(U-boltwith lockwashers and hex nuts)

 

9

012445

Cable Clamp Kit .75–1.11Dia. Cable

1

9

012446

Cable Clamp Kit 1.12–1.50Dia. Cable

1

10

012459

Cable Connector .38–.50Cable Dia.

1

10

012460

Cable Connector .50–.62Cable Dia.

1

10

012461

Cable Connector .62–.75Cable Dia.

1

10

012462

Cable Connector .75–.88Cable Dia.

1

10

012463

Cable Connector .88–1.00Cable Dia.

1

10

012464

Cable Connector 1.00–1.12Cable Dia.

1

10

012465

Cable Connector 1.12–1.25Cable Dia.

1

10

012466

Cable Connector 1.25–1.38Cable Dia.

1

10

012467

Cable Connector 1.38–1.50Cable Dia.

1

11

017041

Spring Motor Kit, Std. Rot.–35

ar

 

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

11

017042

Spring Motor Kit, Rev. Rot.–35

ar

11

017043

Spring Motor Kit, Std. Rot.–60

ar

11

017044

Spring Motor Kit, Rev. Rot.–60

ar

11

017045

Spring Motor Kit, Std. Rot.–62

ar

11

017046

Spring Motor Kit, Rev. Rot.–62

ar

11

017047

Spring Motor Kit, Std. Rot.–75

ar

11

017048

Spring Motor Kit, Rev. Rot.–75

ar

11

017049

Spring Motor Kit, Std. Rot.–80

ar

11

017050

Spring Motor Kit, Rev. Rot.–80

ar

11

017051

Spring Motor Kit, Std. Rot.–100

ar

11

017052

Spring Motor Kit, Rev. Rot.–100

ar

12

012425

Pawl Kit

(35, 60 Springs)

ar

 

 

(Includes 2 pawls and springs)

 

12

012426

Pawl Kit

(62, 75, 80 Springs)

ar

12

012427

Pawl Kit

(100 Springs)

ar

 

 

 

 

 

ITEM

KIT NO.

DESCRIPTION

QTY.

13

017190

Spanner Wrench (35 – 80 Springs)

1

13

017191

Spanner Wrench (100 Springs)

1

14

032805

Ratchet Wrench Kit (75, 80 Springs)

1

 

 

(Includes mounting bolts)

 

14

032804

Ratchet Wrench KIt (100 Springs)

1

15

017054

Extension Bolts (35 – 80 Springs)

ar

 

 

(4 bolts per kit–lesshardware)

 

15

017055

Extension Bolts (100 Springs)

ar

16

016182

Carriage Bolt, .50–13x 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

21

021761

Hub Lock Pins (All Other Springs)

ar

22

012457

Button Plug

1

23

012285

Collector Assembly, 2 Pole, 35 Amp

1

23

012286

Collector Assembly, 3 Pole, 35 Amp

1

23

012287

Collector Assembly, 4 Pole, 35 Amp

1

23

012288

Collector Assembly, 6 Pole, 35 Amp

1

23

012289

Collector Assembly, 8 Pole, 35 Amp

1

23

012290

Collector Assembly, 10 Pole, 35 Amp

1

23

012291

Collector Assembly, 12 Pole, 35 Amp

1

23

012292

Collector Assembly, 14 Pole, 35 Amp

1

23

012293

Collector Assembly, 16 Pole, 35 Amp

1

23

012294

Collector Assembly, 20 Pole, 35 Amp

1

23

012295

Collector Assembly, 24 Pole, 35 Amp

1

23

012296

Collector Assembly, 30 Pole, 35 Amp

1

23

012297

Collector Assembly, 36 Pole, 35 Amp

1

23

012298

Collector Assembly, 2 Pole, 75 Amp

1

23

012299

Collector Assembly, 3 Pole, 75 Amp

1

23

012300

Collector Assembly, 4 Pole, 75 Amp

1

23

012376

Collector Assembly, 6 Pole, 75 Amp

1

23

012377

Collector Assembly, 8 Pole, 75 Amp

1

23

037194

Collector Assembly, 2 Pole, 125 Amp

1

23

037294

Collector Assembly, 3 Pole, 125 Amp

1

23

037295

Collector Assembly, 4 Pole, 125 Amp

1

23

012304

Collector Assembly, 2 Pole, 200 Amp

1

23

012381

Collector Assembly, 3 Pole, 200 Amp

1

23

012382

Collector Assembly, 4 Pole, 200 Amp

1

23

012383

Collector Assembly, 6 Pole, 200 Amp

1

23

012384

Collector Assembly, 8 Pole, 200 Amp

1

24

012440

Brush Kit (35 Amp)

ar

 

 

(Each kit includes 4 brushes and 4 fingers)

 

24

012441

Brush Kit (75 Amp)

ar

24

012443

Brush Kit (125 Amp/200 Amp)

ar

25

012409

Collector Cover Kit (8" long)

1

 

 

(Includes seal ring)

 

25

012410

Collector Cover Kit (10.5" long)

1

25

012411

Collector Cover Kit (13" long)

1

25

012412

Collector Cover Kit (15.5" long)

1

25

012413

Collector Cover Kit (20.5" long)

1

25

012414

Collector Cover Kit (28.5" long)

1

26

012458

Seal Ring (only)

1

NOTE:

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

MODEL NUMBER EXPLANATION

AMPACITY

SPRING

 

FRAME

 

SPRING

 

NO. OF

 

NO. OF

 

 

 

 

CORE

 

PRETENSION

 

 

 

 

 

 

 

 

AMPACITY

 

CODE

AMPS

REEL

 

SERIES

 

SERIES

 

SPRINGS

 

POLES

 

 

DIAMETER

 

TURNS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

35

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S 21 80 2 R - 12

3

10 - 1

12

125

 

 

 

 

 

 

7

75

 

 

 

 

 

 

20

200

 

INDICATES REVERSE ROTATION.

 

 

 

 

 

 

 

 

 

 

NO LETTER INDICATES STANDARD ROTATION.

 

 

 

 

 

 

 

 

 

 

 

 

 

CABLE REMOVAL

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

CAUTION

Failure to relieve all spring tension prior to removing cable could result in damage to equipment or personal injury. Follow instructions carefully.

1.Move machine serviced by reel to a position closest to reel. Springs will still be under pre-tensionat this point.

2.Turn off all electric power.

3.Lock spool to prevent turning using either a spool lock mechanism or by tying off.

4.Disconnect cable from machine junction box.

5.Grip spool by hand and carefully release spool lock or tie. Slowly unwind remaining tension.

6.Again lock or tie spool to prevent rotation.

7.Remove cable from spool. Loosen U-boltandwater-tightconnector and disconnect conductors from slip ring.

8.Install new cable following instruction at right.

CABLE INSTALLATION

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-tightconnector 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-tightconnector andU-boltprovided 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 studd bolt from bearing housing.

5.Remove button 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 90O 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

 

 

SPOOL ROTATION DIRECTION

 

 

INSTALL CABLE

 

TO WIND CABLE WHEN

 

TERMINATE THIS END TO

THIS DIRECTION

POSITION CABLE

VIEWED FROM SPRING SIDE

 

 

(STANDARD ROTATION)

 

MACHINE JUNCTION BOX

CABLE

GUIDE (OPTIONAL)

PAYOFF

 

 

 

SO THAT ROLLER

 

 

 

PLATE FACES CABLE

DIRECTION–

ATTACH INDIVIDUAL

BUTTON

U-BOLT

PAYOFF DIRECTION.

OPTIONAL

PLUG

 

GUIDE

CONDUCTORS TO

 

 

LINE

WATERTIGHT

LOCATION

COLLECTOR LEADS

ENTRANCE

CONNECTOR

 

AT THIS END

 

(NPT)

 

 

 

 

 

 

 

 

 

 

 

PRETENSION

 

 

 

 

HUB

COLLECTOR

 

 

PAYOFF

 

COVER

 

 

DIRECTION

 

REMOVE

 

 

 

SPRING

 

 

 

 

 

 

 

 

MOTOR

 

 

SPRING MOTOR

 

 

SLIP RING

 

HOOP GUIDE

 

 

 

(OPTIONAL)

PAYOFF

 

ASSEMBLY

 

 

 

 

SPOOL

DIRECTION–

 

 

 

OPTIONAL

 

 

 

 

 

 

MAIN SHAFT

GUIDE

 

 

LOCATION

 

 

 

 

 

GLEASON REEL CORP.

®

P.O. Box 26 • 600 South Clark St.

 

Mayville, WI 53050–0026

®

Phone 920–387–4120

HUBBELL A Hubbell Company

Fax 920–387–4189

 

Printed in USA

Bulletin No. 040251.a