INSTALLATION and MAINTENANCE INSTRUCTIONS
S-32 DIRECT 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 counterclockwise (for standard rotation).
Number of 360
number on serial plate.
O
turns should match last digit in model
If model number includes an “R”,
reel is reverse rotation and wrench must be rotated
clockwise.
Figure 1
(See EXPLANATION on parts list page.)
SPRING
HOUSING
SPRING
HUB
COVER
PLATE
Figure 2
COUNTER-
CLOCKWISE
FOR STANDARD
ROTATION
SPANNER
WRENCH
CAUTION
Do not exceed number of turns indicated on serial plate.
Over-tensioning can cause a broken spring,
sheared shaft or other damage.
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
“IN” with 2/3
cable off reel–
SPRING OK
BROKEN SPRING
INDICATORS
other hardware for tightness.
C.Check for broken springs
by pulling about 2/3 cable off
reel and observing “Broken
“OUT” with 2/3
cable off reel–
SPRING
BROKEN
Figure 3
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. Clock-
type 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. 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 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: 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 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.
SPOOL
SHAFT
SIDE VIEW
PAWL
SPRING
Install
against flat
END VIEW
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
SPRING
HUB
(Spring not
shown)
SHAFT
GROOVE
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
1
2
3
1
3
1
1
1
11
11
11
11
7
20
14
20
19
15
15
11
12
11
12
11
12
11
12
8
8
TO DETERMINE ROTATION OF REEL
STANDARD REVERSE
ROTATION ROTATION
Cable is payed out and retracted as shown
when viewing reel from spring motor side.
ILLUSTRATED PARTS LIST
S-32 DIRECT DRIVE ELECTRIC CABLE REELS
ELECTRICAL CONNECTIONS
LEADWIRE INPUT FIXED END
(CUSTOMER SUPPLIED)
BRUSH TERMINAL
CONNECTIONS
1
1
SLIP–RINGS
432
32
SLIP-RING
LEADWIRES ARE
NUMBER TAGGED
SLIP-RING LEAD TO
MOVING CABLE
CONNECTIONS
SLIP–RING
COVER
SLIP–RING ENCLOSURE
•
600 VOLTAC. 250 VOLT DC. WATERTIGHT, DUSTTIGHT.
•
DO NOT EXCEED AMPERAGE RATING OF CABLE OR SLIP RING.
• NUMBER OF CIRCUITS MAY VARY FROM TWO (MINIMUM) TO 36 (MAXIMUM). FOUR CIRCUITS SHOWN.
4
FRAME
SCREW
COLLAR
SET
Always specify SERIAL NUMBER &
MODEL NUMBER when ordering parts.
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
S-32 DIRECT DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST
NOTE: Applicable mounting hardware included with each kit.
ITEM KIT NO. DESCRIPTION QTY.
1 041033 Frame Assembly 1
2 041034 Discs (Set of two) 1
3 041035 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 012209 Stub Shaft, Std. Rot. (801) 1
7 01220901 Stub Shaft, Rev. Rot. (801) 1
7 012210 Stub Shaft, Std. Rot. (802) 1
7 01221001 Stub Shaft, Rev. Rot. (802) 1
7 012211 Stub Shaft, Std. Rot. (803) 1
7 01221101 Stub Shaft, Rev. Rot. (803) 1
7 012212 Stub Shaft, Std. Rot. (804) 1
7 01221201 Stub Shaft, Rev. Rot. (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 012418 Wrapper Kit–7" Wide, 8" to 14" Dia. 1
(Includes 4 wrapper sections)
8 012419 Wrapper Kit–7" Wide, 15" to 20"Dia. 1
(Includes 8 wrapper sections)
9 012444 Cable Clamp Kit .38–.74 Dia. Cable 1
(U-bolt with lockwashers and hex nuts)
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 017049 Spring Motor Kit, Std. Rot.–80 ar
(Includes pawl, pawl springs, cover, gaskets, and snap ring)
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 012426 Pawl Kit (80 Springs) ar
(Includes 2 pawls and springs)
12 012427 Pawl Kit (100 Springs) ar
13 012091 Spool Lock Kit 1
ITEM KIT NO. DESCRIPTION QTY.
14 032805 Ratchet Wrench Kit (80 Springs) 1
14 032804 Ratchet Wrench KIt (100 Springs) 1
15 017054 Extension Bolts (80 Springs) ar
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
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
24 012441 Brush Kit (75 Amp) ar
24 012443 Brush Kit (125 Amp/200 Amp) ar
25 012409 Collector Cover Kit (8" long) 1
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
27 Snap Ring 1
(Includes mounting bolts)
(4 bolts per kit–less hardware)
(Each kit includes 4 brushes and 4 fingers)
(Includes seal ring)
Please consult factory for optional accessories: roller guides, ratchet lock, limit
switch, hoop guides, spool lock, and swivel base.
NOTE:
MODEL NUMBER EXPLANATION
SPRING
REEL
FRAME
SERIES
SPRING
SERIES
NO. OF
SPRINGS
NO. OF
POLES
AMPACITY
CORE
DIAMETER
PRETENSION
S 32 80 2 R - 12 3 10 - 1
INDICATES REVERSE ROTATION.
NO LETTER INDICATES STANDARD ROTATION.
TURNS
AMPACITY
CODE
3
7
12
20
AMPS
35
75
125
200
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-tension at 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-bolt and water-tight
connector 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-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 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 90
O
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
ATTHIS END
COLLECTOR
COVER
REMOVE
LINE
ENTRANCE
(NPT)
SLIP RING
ASSEMBLY
HUBBELL
BUTTON
PLUG
®
®
A Hubbell Company
INSTALLCABLE
THIS DIRECTION
CABLE
U-BOLT
WATER- TIGHT
CONNECTOR
MAIN SHAFT
POSITION CABLE
GUIDE (OPTIONAL)
SO THAT ROLLER
PLATE FACES CABLE
PAYOFF DIRECTION.
PAYOFF
DIRECTION
SPRING MOTOR
HOOP GUIDE
(OPTIONAL)
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
Printed in USA
Bulletin No. 041103.a
Loading...