1

General Explanations about Cable Reels.................................................................................................................................... 2

Magnetic Coupling (HMK) ........................................................................................................................................................... 3

Reel body type random-winding, type EB ................................................................................................................................... 7

Reel body spiral-winding type ES.............................................................................................................................................. 10

Reel flange ................................................................................................................................................................................ 18

Slip ring bodies .......................................................................................................................................................................... 20

Gear unit.................................................................................................................................................................................... 27

Drive motors .............................................................................................................................................................................. 33

Stromag gear cam switch series 51 .......................................................................................................................................... 42

10 Disturbance and fault diagnostics.............................................................................................................................................. 47

These operating instructions are addressed to qualified personnel with training in electrical engineering.

BAL7100-0071e-E
www.conductix.com

Page 1 of 48

The motor cable reel (MLT) serves to wind and unwind a flexible energy supply system (reeling cable) for a mobile consumer. The
motor cable reel is composed of the following main components:

The cable is wound up onto the reel body. The dimensions of the reel body are sufficient to take up the cable length for the travel
distance including 2 windings for tension relief.

The drive unit is composed of magnetic coupling and standard motor. It provides a constant torque into the winding direction. The
slack required for unwinding is realized in the magnetic coupling.
(SRK)
The slip ring body serves for transmission of energy and data.
Voltage range 0-1 kV; amperage mA-630 A

All the main components of the motor cable reel are mounted to the gear unit. It provides the ratio to achieve the required travel
speed and/or torque. By means of the drive console the motor cable reel is mounted to the system.

The name plate is fixed to the slip ring body housing. It lists all technical data, the reel designation and the order number.
For questions regarding the supplied cable reel, e.g. spare parts, reconstruction etc. please state type and order number.

Figure 1

BAL7100-0071e-E
www.conductix.com

Page 2 of 48

The figure on the right shows the lay out of the magnetic coupling. The coupling unit is characterized by a tough and compact design. The torque for transformation can be adjusted at
the magnetic coupling from the outside.

Gear Unit

The magnetic coupling is free from wear, due to a contactless

torque transmission

Motor

Figure 2

The magnetic coupling is supplied with the calculated torque
for the respective application. It always transforms a constant
torque in the direction of winding. During operation the primary
side of the permanent magnetic coupling runs with the nominal speed of the drive motor in the direction of rotation. The
secondary side of the permanent magnetic coupling stops if
the reel is out of operation or is moved in the respective direction during winding off or winding up.

Under off-circuit conditions, winding off the cable/hose is

prevented by the holding torque of the magnetic coupling
against the backstop.

Backstop

Thus the magnetic coupling assumes the slack required on

reel drives in various operating conditions.

The drive units (motor, clutch) are designed for

.

Figure 3

HMK 0.63
HMK 1.25
HMK 2
HMK 3.2
HMK 5
HMK 8
HMK 12.5
HMK 20
HMK 25

0.3 Nm
0.6 Nm
1.2 Nm
1.6 Nm
3.1 Nm
5.0 Nm
7.0 Nm
12.0 Nm
16.0 Nm

0.7 Nm
1.2 Nm
2.0 Nm
3.0 Nm
4.7 Nm
8.1 Nm
12.0 Nm
20.0 Nm
25.0 Nm

BAL7100-0071e-E
www.conductix.com

Page 3 of 48

The winding behavior of the motor cable reel must be observed for commissioning. If required, the torque of the magnet coupling
must be increased in case of a slack cable or idleness of the reel. The torque must be reduced if the cable is over tensioned.
To adjust the torque proceed as follows:
(Motor and coupling can be installed)
1.

Switch off supply voltage

2.

Secure reel body from winding off (block it)

3.

Eliminate the protective screen (4) from the bell housing

4.

Rotate the magnetic coupling so that the name plate (10) becomes visible

5.

Detach the hexagon head screw(s) (n) (5) (at HMK 8 and 12.5 - 2 pieces are displaced by 180) and unscrew it (them) until
the flange (7) can rotate freely. The cheese-head screws (8) remain tightened

6.

Adjust the torque by twisting the flange (7) by means of a round material in the blind hole borings (9), hold coupling body tight

7.

Depending on the direction of rotation the coupling parts move apart or together:

8.

the coupling parts means of the torque!

9.

the coupling parts means of the torque!

10. The torque modification can be determined by a comparative measurement of the gap S before and after the regulation of
the coupling
One rotation at the flange (7) corresponds to the following torques:
HMK 0.63
HMK 1.25
HMK 2
HMK 3.2
HMK 5
HMK 8
HMK 12.5
HMK 20
HMK 25

ca. 0.25 Nm
ca. 0.50 Nm
ca. 0.50 Nm
ca. 1.00 Nm
ca. 1.50 Nm
ca. 2.00 Nm
ca. 3.00 Nm
ca. 2.00 Nm
ca. 4.00 Nm

BAL7100-0071e-E
www.conductix.com

Page 4 of 48

11. After having adjusted the respective torque turn the flange (7) so that two blind hole borings (9) will be arranged symmetrically to the name plate (10). Then screw hexagon head screw(s) (5) back into the boring (11)
12. Mount protective screen (4)
13. Remove blockade of reel body

At HMK 8+12.5 second

fixing bolt 180 misaligned
Motor

Important!
Axialpitch min. 1mm Check after
torque adjustment

Measuring point
for temperature control

Gear

Check radial run at shaft end

(max 0,05m) !

Figure 4

BAL7100-0071e-E
www.conductix.com

Page 5 of 48

Ex works the magnetic coupling is set to the specified rotating direction.
If it should be required to change the rotating direction on site turn the backstop between coupling and motor by 180. Proceed as
follows:
1.
2.
3.
4.
5.
6.
7.

Switch off power supply

Secure reel body against winding off (block it)
Detach screws (5) and dismount motor
Remove locking ring (7) at the backstop
Remove backstop (parts (2), (3), (4) and (6)) from the socket (1)
Turn by 180 and put it back onto the socket (1)
Mount locking ring (7). Mount motor

Motor

Rcklaufsperre
Backstop
Gear box
Figure 5

Figure 6

Sense of direction: left

Sense of direction: right

View for indicating

sense of direction

Motor and permanent magnetic coupling are maintenance-free. Torque transmission within the coupling is contactless, so readjustments due to wear are not required. The installed special ball bearings und the backstop are lubricated for lifetime.

BAL7100-0071e-E
www.conductix.com

Page 6 of 48

The random-winding reel body serves to take up low voltage or control cables.
The capacity of the reel body allows taking up the specified winding length plus 2 additional windings for tension relief (see also
figure 8).

For application on cable reels Conductix-Wampfler exclusively uses reeling cables according to DIN VDE 0250. If the reel cable is
not included in the delivery of the reel system, check the following:
The technical data of the cable provided for the application (weight, diameter, quantity and cross section of the cores, winding
length) must be identical with the data according to which the reel system has been calculated. This is the only way to assure that
the reel system (reel body, drive unit, number of poles of the slip ring body) and the cable to be installed will meet the operational
requirements.

Place dispatch reel or dispatch ring according to the figure below at a distance of some meters parallel to the reel axle. Only this
position guarantees a rewinding free of twists.

Figure 7

To connect the cable to the slip ring body it must be dismantled to a certain length. For the determination of that length proceed as
follows:
1.
2.
3.
4.
5.

Open the cap of the slip ring body housing

Measure the length between flange fixation and upmost point of slip ring body
Dismantle the cable along this measured length
Shorten single cores with regard to the distances between the individual rings
Provide the terminations of the single cores with respective cable lugs

BAL7100-0071e-E
www.conductix.com

Page 7 of 48

The cable, coming from the dispatch reel or ring, must be guided through the cable insertion at the reel body, the cable collar at the
inside of the reel and the hollow shaft of the gear unit to the farthest connecting point at the slip ring body. Then screw tight the
cable gland on the hollow shaft.
After having maintained the minimum bending radius (6x cable diameter) between the cable collar and the cable gland the cable
collar must be tightened. Turn the reel body manually or connect the drive motor temporarily (see operating instructions for drive
motor) and wind the cable slowly onto the reel body. By guiding the cable manually it can be assured that the cable will be wound
up free of twists (note the imprinted writing on the cable if required) and evenly (see below figure).

2 windings for tension

relief

wedge-shaped gap
.

Figure 8

See operating instructions of the respective slip ring body.

BAL7100-0071e-E
www.conductix.com

Page 8 of 48

For the installation of random-winding motor cable reels (EB) observe the relative position of the reel to the cable fixed point.
The deflecting angle of the cable must not exceed 3-5 in any position (s. figure). Proper winding behavior may only be expected if
this maximum permissible angle is kept.

Figure 9

Correct arrangement of the random-winding cable reel to the

cable fixed point.

The maximum permissible angle must also be observed when

using guide rollers. If required the distance of the guide rollers
to the cable reel must be increased.

BAL7100-0071e-E
www.conductix.com

Page 9 of 48

The spiral-winding reel body serves for winding up a reeling medium-voltage cable, a low-voltage or control cable.
The capacity of the reel body is designed to take up the specified winding length plus 2 windings for tension relief. According to the
diameter of the reel body (D) the reel system is supplied completely mounted (D <= 2500 mm) or demounted (D > 2500 mm).

The reel body is supplied completely mounted and is composed of:
2 reel shields (2/3)
1 reel sheathing (4)
1 fixing flange (5)
12 thread bolts (6) with hexagon head nut (8/10), washer (11) and safety nut (9).
12 thread bolts (7) with hexagon heat nut (8), washer (11), safety nut (9).
Spacer and/or sleeve (12). The quantity varies according to the reel type and cable diameter.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Cable
Reel shield
Reel shield
Reel sheathing
Fixing flange
(Adjusting-) thread bolt
Thread bolt
Hexagon head nut
Safety nut DIN 7967
(Adjusting-) hexagon head
nut
Washer
(Distance-) washer or
sleeves
Hexagon head nut
Hexagon head nut
Hexagon head nut
Figure 10

BAL7100-0071e-E
www.conductix.com

Page 10 of 48

If the cable has already been installed ex works, this item can be neglected.
The reels are pre-adjusted and delivered according to the application data from the calculation. If the reel is supplied without cable
the actual cable diameter of the provided cable must be compared with the reel width. For the adjustment of the reel proceed as
follows:
The reel width b must be adjusted to the actual cable diameter at the interior diameter d by removing or joining respective
washers, so that a small air gap will remain between the outer sheathing of the cable and the reel shields.
2. The two reel shields (2/3) must be aligned in parallel or tapering to each other by adjusting the hexagon head nuts (13/14).
3. The dimension b at the outer diameter of an empty reel should be adjusted on such a small dimension that it is only slightly
larger than the measured cable diameter.
4. If the minimum adjustable dimension b at the reel sheathing ( d) is larger than the cable diameter, it is required to adjust a
smaller value at the reel outer diameter D.
5. The alignment must be made several times all around at each pair of spokes. Make sure to adjust the same value on all pairs
of spokes.
6. Measurements are made at the reel sheathing d (inner diameter of the reel/hole circle diameter e) and at the outer diameter D of the reel.


9. After having successfully aligned the hexagon head nut (15) on the hole circle diameter e tighten with and secure
with the lock nut (9).
10. Tighten the hexagon head nuts (13/14) on the hole circle diameter c with . Then double-check the alignment of the
reel body.
1.

BAL7100-0071e-E
www.conductix.com

Page 11 of 48

1 / 6 / 11 / 14a / 22
2 / 7 / 24
3 / 8 / 20 / 21 / 23
4
5
9
10
12

Hexagon head screw DIN 933

Washer DIN 125
Hexagon head nut DIN 985
Fixing plate
Reel plate
Lock nut DIN 7967
1. reel shield
(Adjusting) thread bolt

13
14
15
16
17
18
19 / 20 / 21
25

Hexagon head nut DIN 934 or 439

Thread bolt
Reel sheathing
(Distance) washer DIN 125 without sleeve
2. reel shield
Ramp
(Adjusting) hexagon head nut
Cable duct
(Shortened spoke in the 2. reel shield

BAL7100-0071e-E
www.conductix.com

Page 12 of 48

The reel body is supplied in two halves or several segments. These parts are adjusted ex works to the values of the calculation.
The following components are included in the delivery:
1 reel shield (10) it possesses 4 hole circle diameters - a, c, e and f.
2 reel shield (17) it possesses 2 hole circle diameters - e and f.
Reel sheathing (15) with reel inner diameter d and in case of larger cable diameters a ramp (18) with a hexagon head screw
(22), two or more washers (24) and a hexagon head nut (23).
One or two reel plates (5).
8 or more fixing screws (1) with spring ring (2) and hexagon head nut (3). (the exact number depends on the outer diameter D
of the reel).
24 fixing screws (6/11) with hexagon head nut (8), washer (7) and lock nut (9).
12 (adjusting) thread bolts (12) with hexagon head nut (8/13/19/20), washer (7) and lock nut (9).
23 thread bolts (14) and 1 hexagon head screw (14a) with hexagon head nut (8/21), washer (7) and lock nut (9).
Spacer and/or sleeve (16). The number varies depending on the type of reel and cable diameter.

The gear unit must be placed at such a height to guarantee a minimum ground clearance of half a reel body outer diameter (D/2).

The reel body is supplied in 2 pre-mounted and pre-adjusted halves.

Assembly of the halves with the hexagon head screws (1), washers (2) and hexagon head nuts (3)

Push the reel plates (5) over the hollow shaft into the direction of the fixing flange (4)
Screw reel plate (5) and fixing flange (4) onto the hole circle diameter a with 12 hexagon head screws (6), the appropriate
washers (7) and the hexagon head nuts (8)
Secure the connections with the lock nuts (9)

Connect the reel body with the hexagon head screws (11) on hole circle c and at the projecting thread bolts (12) on hole
circle e with the reel plates (5)
Tighten hexagon head nuts on the gearing side (8) on the hole circle diameter c and e with 350 Nm (M20) or 210 Nm
(M16) and secure with lock nuts (9)

BAL7100-0071e-E
www.conductix.com

Page 13 of 48

The adjustment of the reel width ex works considers the medium cable diameter. The reel width b to be adjusted must however
be in accordance with the actually measured cable diameter. Distance washers (16) or distance sleeves have been installed ex
works between the reel sheathing (15) and the reel shields (10, 17). The position of the distance washers (16) and sleeves is illustrated in figure 2, page 15. By removing or adding individual washers or distance sleeves, the reel width, referred to the actual
cable diameter, must be chosen as small as possible (max. +1 mm).

1. Tighten hexagon head nuts (8 and 21) on the hole circle diameter f with (M20) or (M16) and secure with
lock nuts (9).
2. Align reel shields (10/17) by adjusting the hexagon head nuts (19/20) in parallel or tapering to the outside.
3. Adjust the dimension b at the reel sheathing by means of distance washers/sleeves as low as possible referring to the actual
cable diameter.
4. If the minimum adjustable dimension b at the reel sheathing is larger than the measured cable diameter, it is required to
adjust a smaller value at the reel outer diameter.
5. Adjustments must be made several times all around at each pair of spokes. Make sure that the same values are adjusted at
all pairs of spokes.
6. Measurements are made at the reel sheathing d (inner diameter of the reel /hole circle diameter f) and the outer diameter D
of the reel.


9. Tighten hexagon head nuts (8/21) on the hole circle diameter f with (M20) or (M16) and secure with lock
nuts (9).
10. Tighten hexagon head nuts (8/19/20) on hole circle diameter e with (M20) or (M16).
11. Make sure that the adjusted position will not be changed.

BAL7100-0071e-E
www.conductix.com

Page 14 of 48

From approx. 30 mm cable diameter the delivered material will include a ramp for the cable entry. The ramp (18) is screwed to the
reel sheathing (4), so that the first layer passes over to the second layer without a break. Moreover this will prevent the cable from
being crushed in the area of the cable duct.
For the assembly proceed as follows:
1.
2.
3.

Bore a hole 8 at a distance as shown in the picture (figure 12).

Put washers under the ramp (24) until its height complies with the cable diameter.
Screw ramp (18) tight with the reel sheathing by means of the hexagon head screw (22) and the hexagon head nut (23).

Ramp on winding off abnormal

Ramp on winding off normal

Figure 12

BAL7100-0071e-E
www.conductix.com

Page 15 of 48

Conductix-Wampfler exclusively uses reeling cables according DIN VDE 0250 for application on cable reels. If the reel cable is not
included in the delivery of the reel system, check the following:
The technical data of the cable provided for the application (weight, diameter, number and cross section of the cores, winding
length) must be identical with the data, according to which the reel has been calculated. This is the only way to assure that the reel
system (reel body, drive unit, number of poles of the slip ring body) and the cable to be installed will meet the operational requirements.

Place dispatch reel or dispatch ring according to the figure below at a distance of some meters parallel to the reel axle. Only this
position guarantees a rewinding free of twists.

Figure 13

To connect the cable to the slip ring body it must be dismantled to a certain length. For the determination of that length proceed as
follows:
1. Open the cap of the slip ring body housing
2. Measure the length between flange fixation and upmost point of slip ring body
3. Dismantle cable along this measured length
4. Shorten single cores with regard to the distances between the individual rings
5. Provide the terminations for the single cores with the respective cable lugs

1.
2.

Push the cable termination onto the reel sheathing between the reel shields.
On the cable duct guide the cable termination out of the reel body to the outside (If a ramp is available, the cable must be
guided out of the reel wheel in front of that ramp).

BAL7100-0071e-E
www.conductix.com

Page 16 of 48

3.
4.

6.
7.
8.

Guide the cable termination through the cable gland and the hollow shaft of the gear unit to the farthest connecting point of the
slip ring body.
Tighten cable gland (the not dismantled part of the cable must be within the rubber ring of the cable gland).
Observe the minimum bending radius of the cable between cable gland and cable duct

Reeling up the cable by slowly and constantly turning the reel body or provisional connection of the drive motor (see operating
instructions drive unit). Jerky reeling by motor must be absolutely avoided!
Bring cable end to cable fixed point.
Is a deflection device available, the cable will be led from the reel through the deflection device to the cable fixed point (see
operating instructions "deflection device").

See operating instructions about the corresponding "slip ring body".

After having completed above works the cable should be wound up and off several times (if possible in regular reel operation).
Subsequently it must be checked on the full and empty reel if the reel width has been changed. First check the width at the outer
diameter on the empty reel and adjust it to the lowest possible dimension, if required (= measured cable diameter).
Readjustment as described above.
Then wind up the cable and check the reel width at the outer diameter. Minor widening is permissible. The winding behavior of the
individual case will reveal, which degree of widening cannot be tolerated. For this judgment consider the horizontal displacement of
the individual cable layers.
If the windening seems to be too large, the reel can be adjusted at the inner diameter, so that the spare winding will already be
slightly clamped. Make sure however, that the reel width at the outer diameter must not be smaller than the actual cable diameter.

Starting from reel size ES1236 the delivered material includes a fixing angle to stabilize the cable between cable entry at the reel
wheel and cable gland.
1. The angle for cable guidance at the hole circle diameter e must be mounted with an offset of approx. 60 to the cable entry
2. Fix cable with cable collar(s)

60
Figure 14

BAL7100-0071e-E
www.conductix.com

Page 17 of 48

Fix the reel body to the hollow shaft of the gear unit by means of the reel flange. The reel flange is composed of clamping elements, outer and inner rings, the wheel flange or flange bearing and one or two fixing flanges depending on the reel body and the
appropriate clamping screws.

The clamping element is a force-locked and detachable connection between drive unit and fixing flange. The torque is transfered
force-locked from the wheel flange or flange bearing across the outer and inner ring of the clamping elements to the gear shaft.
.

The fixing flange produces the force-locked connection between clamping element and reel body (spiral-winding or randomwinding).

1.
2.
3.
4.

Inner ring
Front spring washer
Back spring washer
Clamping screw
M10 =
M12 =
5.
Flange
6.
Shaft
7. Fixing flange

70 Nm
100 Nm

Figure 15

BAL7100-0071e-E
www.conductix.com

Page 18 of 48

1.
2.
3.
4.
5.

8.
Clean position for the flange (5) for the clamping set (1-4) and grease or oil it.
Clamping screws (4) must not be tightened yet, so the inner ring (1) can be pushed upon.
Push clamping set onto the flange (5).
Push flange (5) incl. clamping set onto the shaft and bring into requested position. Flange and shaft can be oiled (do not use
MoS2 here).
Align the clamping set, i.e. achieve plane parallelism of both spring washers by tightening the clamping screws.

6.

Clamping tight by tightening the screws evenly in several steps one after the other (not cross-over"). Several rotations are required here, before all screws are clamped with the respective tightening torque (see table a.o.).

Type of gear

W 63.x
W 80.x
W 100.x
W 125.x
K 161.3, K165.3

Tightening torque Ma
(Nm)
40
52
85
85
250

1.
2.
3.
4.

Detach the clamping screws equally and one after the other after several rotations in order to prevent the washers from canting on the inner ring.
Do not remove clamping screws completely from the threaded holes to prevent the washers from falling off.
Take off the flange from the shaft, after having removed any corrosion from the shaft and the hub.
Take off clamping set from the hub.

BAL7100-0071e-E
www.conductix.com

Page 19 of 48

The slip ring body (SRK) serves for the transmission of energy or data from the reeling cable to the fixed installed cable. All works
at the slip ring body must be executed by qualified staff.

The slip ring body type 18 is designed for the following values:
Max. operating voltage:
690 V AC
Max. amperage:
25 A at 100% ED

The cable must only be connected when the power supply is switched off and by qualified staff.
The reeling cable comes from the reel body and is connected to the slip rings (rotating part of the slip ring body). The fixed installed
cable is connected to the current collectors (standing part of the slip ring body).

(1) Connection of the reel cable on the ring side on sheathing

clamps
Abbildung 16

Connection of fixed installed cable on the brush side with flat

connections

BAL7100-0071e-E
www.conductix.com

Page 20 of 48

The slip ring body type 45 is designed for the following values:
Max. operating voltage:
415 V AC
Max. amperage:
25 A at 100% ED

The cable must only be connected when the power supply is switched off and by qualified staff.
The reeling cable coming from the reel body is connected to the individual rings at the clamping board of the slip ring body. The
fixed installed cable is connected to the current collectors.

Current collector

Clamping board

Slip ring

Figure 17

BAL7100-0071e-E
www.conductix.com

Page 21 of 48

The slip ring bodies types 70, 88 and 110 are designed for the following values:
Max. Operating voltage:
660 VAC
Max. amperage:
25 A at 100% ED

The cable must only be connected when the power supply is switched off and by qualified staff.
The reeling cable coming from the reel body is connected to the slip rings of the slip ring body. The fixed installed cable is connected to the current collectors.

1. Phase connection of the reel cable on the ring side, only for core number 5 + PE Phase connection of the reel cable on the
ring side on terminal clamps
2. PE-connection on the ring side (reel cable)
3. Phase connection of the fixed arranged cable on the brush side
4. PE-connection of the fixed arranged cable on the brush side
5. Supporting washer (from 7 poles)
6. Supporting washer (standard from 6 poles + PE)

- brush not central to the ring

Figure 18

BAL7100-0071e-E
www.conductix.com

Page 22 of 48

The slip ring body types 50, 71 and 90 have been designed for the following values:
Max. operating voltage:
660 V AC
Max. amperage:
Type 50 40 A at 100% ED
Type 71 63 A at 100% ED
Type 90 80 A at 100% ED

The cable must only be connected when the power supply is switched off and by qualified staff.
The reeling cable coming from the reel body is connected to the slip rings of the slip ring body. The fixed installed cable is connected to the current collectors.

2
1
3

Figure 19

1. Phase connection of the reel cable on the ring side

2. PE-connection of the reel cable on the ring side
3. Phase connection of the fixed arranged cable on the brush side
4. PE-connection of the fixed arranged cable on the brush side
5. Supporting washer (from 5 poles)

BAL7100-0071e-E
www.conductix.com

Page 23 of 48

The slip ring body types 130 and 131 have been designed for the following values:
Max. operating voltage:
660 V AC
Max. amperage:
Type 130
125 A at 100% ED
Type 131
200 A at 100% ED

The cable must only be connected when the power supply is switched off and by qualified staff.
The reeling cable coming from the reel body is connected to the slip rings of the slip ring body. The fixed installed cable is connected to the current collectors.

3
2

2
PE

1. Phase-connection of the reel cable on the ring side

2. PE-connection of the reel cable on the ring side
3. Phase-connection of the fixed installed cable on the
brush side
4. PE-connection of the fixed installed cable on the
brush side

3,4

Figure 20

BAL7100-0071e-E
www.conductix.com

Page 24 of 48

The slip ring bodies have been designed for the following values:
Max. operating voltage:
660 VAC
Max. amperage:
Type 210, 270 and 320
125 A at 100% ED
Type 211, 271 and 321
200 A at 100% ED
Type 212, 272 and 322
315 A at 100% ED

The cable must only be connected when the power supply is switched off and by qualified staff.
The reeling cable coming from the reel body is connected to the slip rings of the slip ring body. The fixed installed cable is connected to the current collectors.

1.
2.
3.

1/ 2

4.
3/ 4

Phase-connection of the reel cable on the ring side

PE-connection on the ring side
Phase-connection of the fixed installed cable on the
brush side
PE-connection of the fixed installed cable on the brush
side

Abbildung 21

BAL7100-0071e-E
www.conductix.com

Page 25 of 48

The slip ring bodies must be maintained at regular intervals.
The maintenance must be carried out when the power supply is switched off and by qualified staff.
Normally maintenance is required every 1500 operating hours. This period may be much shorter in case of high temperature
(T>40C), high humidity, strong changes in temperature as well as strong influence by dust and dirt. Many cases require a sight
control at regular intervals. If the pollution on the slip ring bodies is very strong the maintenance intervals must be chosen respectively.
At least the following works must be done during maintenance:
1. Basic cleaning of the complete slip ring body
2. Removal for humidity and dust from the insulator surfaces with a soft cloth or a pencil.
3. Examination of the insulators as to damage or replacement
4. Examination or cleaning of the ring sliding surfaces on which the current collectors are running
5. Removal of enamel beads, arcing spots or oxidation
6. Inspection of the current collectors for wear or replacement
7. Control of the fixing and connecting screws for tight fit
Cleaning of the ring sliding surfaces can be made with a very fine abrasive paper.

BAL7100-0071e-E
www.conductix.com

Page 26 of 48

The remaining components of the reel system (reel body, drive unit and slip ring body) are mounted to the gear unit. The reel system with the gear unit is mounted to the system.
Conductix-Wampfler uses two types of drive units, which have been developed especially for installation on motor cable reels:
Spur gear, types W63, W80, W100 und W125.
Straight bevel gear pair, types K12x.3, K16x.3, K20x.3 and K25x.3

On low-voltage motor cable reels (<1 kV) the drive unit must be mounted plane onto the fixing structure, avoiding any tension due
to unevenness. It must be fixed to an adequate stiff basement with an evenness of 0,1 mm. Use screws of strength category
minimum 8.8. These must be tightened evenly.
On medium-voltage motor cable reels (>1 kV) the drive unit has been mounted onto a console ex works. Fixation of the reel system
is made by means of the console, which must also be fixed plane to the fixing structure.

The drive unit is completely filled with oil on delivery. Prior to commissioning the included breather plug must be mounted to the
provided position.

W-gear unit

K-gear unit
Breather plug

Figure 22

BAL7100-0071e-E
www.conductix.com

Page 27 of 48

The gear is driven by a horizontal driveshaft. The hollow shaft for the installation of the reel body as well as the slip ring body and
the drive shaft are arranged in parallel. The further projecting piece of the hollow shaft is for the installation of the reel body. The
gear housing is made of aluminum. The wheel sets are hardened. Each gear is equipped with an identification plate, which states
all the technical details:

Control of the temperature at the bearings and the oil sump (max. +80C)
Control of terms for oil change (10.000 operating hours)
Control of the drive unit for extraordinary noise emission
Control of the oil density, little drain of leak oil possible at the shaft exits
Cleanness of the breather plug or vent hole
Control of the water content in the oil, visual control of the filling hole

Oil changes are to be performed after 10.000 hours of operation. By checking the analytical values, the oil change intervals may be
extended. Drain the oil at operating temperature. After draining the initial oil filling, flush the gear. Be sure that the flushing oil is
compatible with the gear oil used. As flushing oil it is recommended to use the same type of oil. Do not fill in any fresh oil before oil
deposits, abrasion parts and residues of gear oil and flushing oil have been removed (see Table). Clean the securing screw and
insert a new copper ring. When performing an oil change, absolute cleanliness is essential.

The gear unit is lubricated by splash lubrication. With this type of lubrication the anti-friction bearings will be provided with a permanent oil filling.

W63.2

W63.3

W80.2

W80.3

W100.2

W100.3

W125.2

W125.3

0,6

0,8

1,2

1,6

2,5

3,0

4,5

6,0

BAL7100-0071e-E
www.conductix.com

Page 28 of 48

Schmierstoffbezeichnung / Manufacturer / Dsignation

Kennzeichnung nach

Umgebungstemperatur C
Ambient temperature C
Temprature ambiante C

DIN 51512
Viscosity acc. To DIN
51512

Caractriq. suivant

DIN 51512

-20C bis 80C

(Standard)
-30C bis 80C
(Sonder)
-40C bis 100C
(Sonder)

Gear oil

Energol

Compound

80W85

GR-XP 100

103-100

Omala l 100

75W90

CLP HC69

All gear boxes are delivered with following lubricants:

resp.
resp.

Total EP 80W85
Fina D 2042 SAE 75W-90
BERUSYNTH GP 68

(standard)
(special)
(special)

BAL7100-0071e-E
www.conductix.com

Page 29 of 48

The gear unit is driven by a horizontal or vertical drive shaft. The hollow shaft for the installation of the reel body as well as the slip
ring body and the drift shaft are arranged at an angle of 90. The further projecting piece of the hollow shaft is for the installation of
the reel body. The gear housing is made of high-quality cast. The wheel sets are hardened. Each gear unit is equipped with an
identification plate, which states all the technical details:

Temperature control at the bearings and oil sump (max. +80C)

Control of terms for oil change (s. table on 7.5.1.1)
Control of the gear unit for extraordinary noise emission
Control of the oil density, little drain of leak oil possible at the shaft exits
Cleanness of the breather plug or vent hole
Control of the water content in the oil, visual control of the filling hole

The first oil change is required after 50 to 100 operating hours, all the other changes must be made after 10.000 hours, however
once a year at the latest for gear type K25x.3 or after 3 years at the latest for types K12x.3, K16x.3, K20x.3.

First oil change after

Regular oil change after
Latest oil change

50-100 h
10.000 h
every 3 years

50-100 h
10.000 h
every 3 years

50-100 h
10.000 h
every 3 years

50-100 h
once a year
once a year

Drain the oil filling in a warm operating state. After having drained the first oil filling the gear unit must be flushed. The flushing oil
should be identical with the used gear oil. After having removed the oil sump, abrasion and remainders of gear and flushing oil, fill
in the appropriate amount of fresh oil (see table). The locking screw must be cleaned and provided with a new Cu-ring. Absolute
cleanness must be observed during the oil change.

The gear unit is lubricated by splash lubrication. The bearings as well as the gear wheels and bevel gears are provided with a
permanent oil filling. The outer bearings of the drive shafts (bevel gear shafts) are lubricated for lifetime. Prior to delivery the gear
units are equipped with the appropriate oil filling ex works.
The gear units of types K16x.3, K20x.3 and K25x.3 are equipped with an inspection glass at the side to control the oil level. Control
of the oil level after 10 minutes of downtime. If the oil filling is sufficient the oil surface is visible through the inspection glass.

BAL7100-0071e-E
www.conductix.com

Page 30 of 48

Upper edge
Inspection glas
max

The exact fill level (e.g. after oil change and in general on
drive unit type K12x.3) can be measured by means of a
measuring meter above the filler bore in horizontal gear
position. Measurement is from the gear unit upper edge
to the oil level.

min

Filling in liter
max. oil level (mm) from upper edge
min. oil level (mm) from upper edge

Lubrication is made with high-alloy, age-resisting and non-foamy raffinates with the highest pressure absorbing capacity. (FZG-test
DIN 51354 force grade over 12). The oils must not be mixed during oil change. If the following oils are not available, only equivalent
ones must be used.

-20C to 80C
(standard)
-30C to 80C
(special)

CLP
ISO VG 100

Degol
BG 100

Energol
Falkon
GR-XP 100 CLP 100
Enersyn
HTX 220

Spartan
EP 100

Rendin
CLP 100

Mobil
gear
627
Mobil SHC
629

Omala l 100

Renolin
Unksyn
CLP 150

Omala HD 150

The gear units are filled with Mobilgear 627 ex works.

BAL7100-0071e-E
www.conductix.com

Page 31 of 48

The gear unit must be stored under a roof and placed on a base (e.g. wooden pallet). Storing must be made in such a way that
humidity (condensed water) or contaminant will concentrate on the outside of the shaft sealing rings. The surfaces of the shaft
sealing rings must be lubricated for correct operation. Bare parts must be conserved.
We cannot assume any warranty for damage due to incorrect storage.

For a long-term storage of more than 6 months the gear unit must be completely filled with oil. It must be observed to use the same
oil as for the first oil filling ex works. For subsequent commissioning the complete oil must be drained. Commissioning as described
under item 3 and 4.

BAL7100-0071e-E
www.conductix.com

Page 32 of 48

The motors must be stored in enclosed and dry places only. Storage in the open air with roofing is only permissible for a short time.
If stored outdoors temporarily they must be protected against harmful environmental influences and mechanical damage.
Transport or storage on the fan covers is not permissible. For transport use the ring bolts of the motors with the help of appropriate
fasteners. The ring bolts are only intended for lifting the motors without additional attachment parts, such as base plates, gear units
etc.

To slide on transmission elements (coupling, bevel or belt pulley) use the respective devices or warm up the part to be slid on. To
slide on these elements the shaft ends are equipped with centerings with threaded holes according to DIN 332 part 2. It is not
permitted to fix transmission elements to the shaft by force, since this could damage the shaft, the bearing or other parts of the
motor. All elements to be installed to the shaft end must be dynamically balanced. The rotors have been balanced with the full
feather key.
The motors must be positioned free of vibrations if possible. Special regulations must be observed for motors with low vibrations.
A very exact alignment is required for direct coupling with the motorized machine. The axles of both machines must be in alignment. The height of the axle must be aligned by respective underlaying of the motorized machine.
Ventilation exits must be kept open and prescribed minimum distances must be maintained, so that the cooling air will not be impaired. Make sure that the blown out, heated cooling will not be drawn in again. For outdoor installation of the motors (protection
grade IP 44) it must be observed, that the motors will be protected against direct climatic influences (direct rain, snow, ice, freezing of the ventilator). The type of construction permissible for the motors is stated on the identification plate. Installation in different
types of construction is only permitted with the approval of the manufacturer and, if required, reconstruction according to his specifications.

All works at the motor must be done under off-circuit conditions. The installation must be made by qualified people considering the
respective prescriptions.
First compare the conditions of the power system (voltage and frequency) with the data on the identification plate of the motor. The
dimensions of the connecting cables must be adjusted to the nominal currents of the motor.
Item 8 of this document about clamping plate switching shows the most common circuit diagrams for the basic version of three
phase motors, which show how to make the connection. For other versions we provide special circuit diagrams, which are stuck to
the terminal box cover or are placed into to the terminal box.
The motors must be put into operation with an overload protection adjusted according to the nominal data of the motor. Otherwise
there will be no warranty claim in case of damage by the winding process. Prior to the first switch-on we recommend controlling the
insulation resistances. The resistance winding against mass and between the phases should be 5 Mega ohms (in cold condition
with crank inductor, measure voltage 500 Volt). After longer storage it is urgently required to measure the insulation resistance.

BAL7100-0071e-E
www.conductix.com

Page 33 of 48

Prior to coupling the work machine check the rotating direction of the motor, to avoid any damage at the main engine. The rotating
direction can be changed by exchanging the connections of 2 phases.

all connections of the terminal box must be tightened,

all minimum value of the air gaps must be kept (large 8 mm up to 500 V, larger 14 mm up to 1000 V),
the interior of the terminal box must be clean and free from foreign matters,
unused cable inlets must be closed and the locking screws must be tightened,
the sealing in the terminal box cover must be clean and stuck into and all sealing surfaces must be provided accordingly to
guarantee the protection type.
Prior to switching on the motor it must be checked that all safety regulations are observed. The same is required for operation and
when the motor is switched off.
For commissioning we recommend to observe the currents, when the motor is loaded with its work machine, so that eventual overload is immediately recognized. During switch-on the starter must always be in the starting position.

On the first commissioning and in particular after a longer storage it is required to check the insulating resistance of the winding
against mass. Depending on the nominal voltage UN the following minimum values must be kept:

1 > PN 10
10 < PN 100

6,3
4

If the value falls below the minimum value the winding must be dried properly and the insulating resistance determined again.

BAL7100-0071e-E
www.conductix.com

Page 34 of 48

If it is required during maintenance works to dismount the motor, remove the existing sealing compound from the centering edges
and seal again with an appropriate motor sealing compound when reassembling the motor. Existing copper sealing disks must be
reinstalled in any case.

The anti-friction bearings of the motors are usually lubricated with anti-friction bearing grease according to DIN 51825 as listed in
the following table:

K2P

Lithium base

KPER 63-315, K11R 132-225

KN... (abbreviated designation for squirrel-cage standard motor)

With normal load and under normal environmental conditions the quality of the grease allows an operation of the motor of approx.
10 000 hours for a 2-pole type and of 20 000 hours for a multi-pole type without replacing the grease of the anti-friction bearings,
unless otherwise specified. The condition of the grease filling, however, should already be checked occasionally before this period
has been expired. The indicated number of running hours is only applicable for operation with rated speed.
The bearings are relubrictated after having been thoroughly cleaned with an appropriate solvent. Use the same type of grease.
Please note that the free space of the bearing may be filled up with grease by about 2/3. Filling up the bearings and bearing covers
completely with grease will increase the bearing temperature and result in stronger wear.

In order not to impair the effects of the cooling air all parts of the motor must be cleaned at regular intervals. Mostly it is sufficient to
blow them out with water- and oil-free compressed-air. In particular the vent holes and clearances must be kept clean. The deposited carbon dust from natural abrasion in the interior of the motor or the slip ring must be removed at regular intervals. For the
regular inspections of the work machines it is recommended to include the electro motors as well.

A continuity test of the thermistor circuit with test lamp, crank inductor and similar items is strictly forbidden, because this would
result in an immediate destruction of the sensors.
If it is required to re-measure the cold resistance (at approx. 20C) of the circuit, the measurement voltage must not exceed 2.5 V
DC. We recommend measurement with Wheatstone-bridge with a supply voltage of 4.5 V DC. The cold resistance of the circuit
must not exceed 810 Ohm, measuring the warm resistance is not required.

BAL7100-0071e-E
www.conductix.com

Page 35 of 48

low voltage

Y high voltage

Figure 24

At star-delta switch without bridges

Connection according to the diagram of the switch

Figure 25

Clamping plate switching as above

Connection of the release unit
from the
motor

Connection is made according to the connection diagram of the

release unit

Figure 26

BAL7100-0071e-E
www.conductix.com

Page 36 of 48

Unlike standard motors brake motors are equipped with a brake type BZFM on the rear stub shaft. The brake torque corresponds
to the 2.5-fold nominal torque of the motor. This brake can also be mounted to a standard motor later on. The basic design and the
designation of the components are listed in the figure below:

Figure 27

01
02
03
04
05
06
07
08
09
10
11
12

Coil body with coil

Friction lining medium
Slip-on shaft BZFM 0,25 6,3
Adjusting screw
N-side bearing shield
Adjusting ring
Anchor plate
Friction lining
Fan cover
Groove nut
Spring-locked connecting pin
Fan blade

13
14
15
16
17
18
19
20
21
22
23
24

Mounting part
Cheese-head screw
Bearing
Connecting cable
Rubber collar
Cheese-head screw
Cheese-head screw
Slip-on shaft BZFM 10 25
Sealing ring
Lifting thread
Hand-operated brake (special equipment)
Pilot hole

BAL7100-0071e-E
www.conductix.com

Page 37 of 48

The brakes prevent the cables from winding off in case of power loss or when the motor is switched off. They provide their holding
torque under off-circuit conditions. The installation sizes 0.25 to 6,3 generate this holding torque force-locking by a conical clamping connection, while on sizes 10 to 25 this torque is provided by an adhesive joint.

Connect the brakes according to the technical data to AC-voltage via a rectifier unit. The rectifier is fixed in the terminal box of the
motor. Voltage can be supplied directly at the motor clamping plate or by a separate control.
Bremsspule

The brake coil is connected to the rectifier at the + and clamps.

The two ~ clamps are joined with the motor clamping plate (V1 and V 2).

- AC-circuit switching (fig.29) with retarded break times

- DC and AC-circuit switching (fig.30) with short respond times

W2

U2

V2

U1

V1

W1

L1

L2

L3

Brake coil
Bremsspule

W2

U2

V2

U1

V1

W1

Figure 28

Brake coil
Bremsspule

W2

U2

V2

U1

V1

W1

L1

L2

L3

L1

N (L2)

Steuerspannung

Control voltage

Brake with AC-circuit switching

L1

Figure 29

L2

L3

L1

N (L2)

Steuerspannung

Figure 30

Control voltage

Brake with DC and AC-circuit switching an additional

switching contact is required (K); the brake connecting cable
must be reconnected from + to 1.

BAL7100-0071e-E
www.conductix.com

Page 38 of 48

Abbildung 29

Abbildung 30

The friction lining medium must be adjusted to the presetting dimension A to assure the maximum abrasion of the friction lining for
the BG 0.25 6.3, by a slight pull of the grooved nut (No. 10 in figure 27, initially with the aid of measuring plates or feeler gauges.

0,25 1,5
2,5 6,3
10 25

1,5 0,3
1,8 0,3
2,5 1,5

2
2,5
-

After having removed the measuring plates retighten the grooved nut (10) with the minimum tightening torques according to table
2, to guarantee the braking torque transmission. The presetting dimension will then be reduced to the distance dimension A in
table 1 (position of the distance dimension see figure 31).

0,25

0,63

1,6

2,5

6,3

20

30

50

80

120

150

Figure 31
BAL7100-0071e-E
www.conductix.com

Page 39 of 48

The adhesive torque mentioned in the technical data (MN) is

achieved by fully turning in the adjusting ring (06). A reduction can
be made according to figure 32 and table 3.

Installation size BZFM V7

Reduction
MN
Nm

0,25
0,63
1,6
2,5
dimension in mm (figure2 )
0
0
0
0

6,3

10

16

25

0,90 x MN

Nm

0,65

0,65

0,95

1,15

1,15

1,50

1,60

1,90

1,70

0,80 x MN

Nm

1,30

1,30

1,90

2,30

2,30

3,00

3,10

3,80

3,30

0,70 x MN

Nm

1,95

1,95

2,85

3,45

3,45

4,50

4,70

5,70

5,00

0,60 x MN

Nm

2,60

2,60

3,80

4,60

4,60

6,00

6,20

7,60

6,60

This resetting is to maintain a functional air gap S (see dimensional sheet 2), by means of the adjusting screws (04) and the fastening screws (19).
Resetting the brake is possible up to the limits of possible wear (minimum thickness of friction lining, see dimensional sheet). As
soon as the minimum thickness is reached, the friction lining (08) must be replaced by unscrewing the coil body (01).

The brakes have been built in a way that they can be refitted for handoperation without mechanical treatment, if required. The basic
configuration of the system hand-operated brake is shown in figure 33.

Ventilate

Figure 33

BAL7100-0071e-E
www.conductix.com

Page 40 of 48

0.25
0.63
1.6
2.5
4
6.3
10
16
25
MN
no
NzN
UN
RK
PK
t1
t5
PVN
J
Usp
IK

-1
-1
Nm min min V- Ohm A
W
V- Ohm A
3
525 0.20
21
2001 0.10
6.3
441 0.24
25
1681 0.12
13.5
298 0.35
37
1136 0.18
27
256 0.41
43
977 0.21
37 3600 2900 105
200 0.52
55 205
764 0.27
65
162 0.65
68
618 0.33
125
106 0.99 104
404 0.51
250
59 1.77 186
226 0.91
380
51 2.07 217
194 1.06
=
=
=
=
=
=
=
=
=
=
=
=

W
21
25
37
43
55
68
104
186
217

ms

ms
55
70
85
125
150
190
310
350
410

ms
20
25
30
35
40
50
60
70
80

120
150
170
210
230
260
280
310
380

kg/
kW
cm2 kg
0.01
0.4
1.8
0.015
0.9
2.8
0.02
2.0
4.5
0.028
2.0
6.2
0.033
4.6
8.8
0.045
7.0 11.4
0.09
25
15
0.11
45 25.7
0.14
87 37.8

adhesive torque brake

max. idle speed
nominal switching speed
supply voltage (f = 5060 Hz)
coil resistance at 20C
excitation power at 20C
turn-on time
turn-off time (guide values)
nominal switching capacity with self-ventilated motor (S4 40%)
mass moment of inertia of the rotating parts
coil voltage at 20C
excitation current at 20C

DC-circuit switching
AC-circuit switching

BAL7100-0071e-E
www.conductix.com

Page 41 of 48

Depending on the respective requirements in the operating conditions and the resulting circuit diagram it may be required to install
a gear cam switch. This switch is usually equipped with one to twelve cam rings. According to the layout of the cable or hose reel
these cam rings are used for limitation of final positions, bridging for crossing of central feeding to avoid slack signal or to regulate
the cable pull depending on the wound up diameter. The gear cam switch is powered by a coupling or a chain.

AC

Snap-in switch-

ing

Snap-in switch-

ing

1) T = 0 ms

(VDE 0660
part 206)

DC

Ith
A

Ui
V

24V
A1)

80 V
A1)

ja

62)

250

10

1.2 mm

ja

--

--

5 mA

--

10

1.2 mm

2) VDE 0660 T200

92
97

Figure 34

BAL7100-0071e-E
www.conductix.com

Page 42 of 48

Each contact is assigned a cam plate, which is continuously adjustable. The cam plates (1) can be adjusted independently by
means of the adjusting worm (2). The adjustment can be made without detaching any parts beforehand. The worm is self-locking.
To preset the worm use screwdrivers of 10 mm or 4 mm and a hexagonal wretch of 4 mm.
If the worm makes a clockwise rotation (360), the clamp plate rotates clockwise, too by 2.464 (view to the rear part, the B-side of
the switch).
The standard cam plates have been designed in a way to provide a max. useful path and a slowing-down path. Cam plates with
other useful paths can be installed as special plates.
If the slowing-down path is exceeded the switch will not be damaged. The contact is however opened or closed again.
Slowing-down path

Useful path

Figure 35

After the contacts have been adjusted the gear cam switch must be closed again immediately with the cap, to prevent penetration
of dust or water, which might affect a correct disconnection.

BAL7100-0071e-E
www.conductix.com

Page 43 of 48

Accidents due to touching live parts will be prevented as well.

When placing on the cap make sure that all the screws are equally tightened to prevent the cap from canting and avoid improper
contact pressure of the sealing.
During the assembly of the cables it must be observed that the clamping nut will be carefully tightened after having introduced the
cable (2 to 3 Nm depending on the type of cable). Since on some cables the plastic sheathing will be deformed permanently at the
clamping position of the Pg-gland due to constriction, it is recommended to retighten the clamping nut by half a rotation after 3 to 4
days.
The cable entry to the gear cam switch shall be designed in a way that the cable will not be able to conduct water to the Pg-gland.

The design of the gear unit with planetary grades provides the possibility to install a block displacement in addition to the individual
contact adjustment starting from a useful revolution of 17.5. In this case the last gear speed will also be equipped with an adjusting
worm, however in black color.
With the help of this adjusting worm (2) all cam plates (1) can be adjusted together. The relative adjustment of the individual contacts against each other remains unchanged.
Turning the worm to the right by one rotation (360) the cam plate will also be turned to the right by 0,575 (view to the rear part,
the B-side of the switch).

1.

Cam plate

2.

Adjusting worm (black)

3.

Rough scale with 5-graduation

Figure 36

BAL7100-0071e-E
www.conductix.com

Page 44 of 48

Any works at the gear cam switch must only be executed by qualified staff observing the VBG4 regulations!
In particular it is required to observe the following operational safety advice:
The gear cam switch is constructed according to the state of the art and safe to operate. This equipment may however imply some
risks if operated by unauthorized people, improperly or not in accordance with the specifications.
Each person in charge of the assembly or disassembly, commissioning, handling and repair of the gear cam switch at the operators facility must have read and understood the complete operating instructions and especially the safety advice. We are not responsible for any damage or disturbance due to the non-observation of these operating instructions.
Each method of operation that might influence the security of the gear cam switch must be avoided.
The operator is obliged to immediately report any change at the gear cam switch that might influence the safety.
The operator is obliged to operate the gear cam switch in faultless condition only. Any reconstructions or modifications without
authority, which might endanger the security as well as the installation of foreign accessories are not permitted.
After the respective electronic assembly or repair the respective safety measures must be tested (e.g. earth resistance).

These operating instructions are subject to any technical modifications that will be required for the improvement of the gear cam
switches.

BAL7100-0071e-E
www.conductix.com

Page 45 of 48

The user must guarantee the observance of this guideline about the electromagnetic compatibility 89/336/EWG and also observe
the brochure advice on EMC for operation and installation of electromagnetic couplings, brakes and limit switches No. 170 00
0000 956 (manufacturers of systems or machines). Brochure on request.
Emitted interference must be eliminated at the source of interference, if possible. Below you will find some protective circuits, depending on the load switched by the contact.
Contact in the
limit switch

Switched load

Contactor

Relays

Relays
coils

Valves

Protective circuit

Figure 37

Basically maintenance or inspection works at the gear cam switch are not required.
Do not remove dust deposits with compressed air, since this would press the dust more into the contacts what would affect the
switching capacity. The cap sealings of the protective housings must be renewed when opening the cap after a longer time of
operation. Never use gasoline or other solvents for cleaning the gear cam switch!

BAL7100-0071e-E
www.conductix.com

Page 46 of 48

Prior to commissioning the electric circuit must be controlled and all screwed connections must be checked for tight fit. In a first run
find out if the cable is wound up properly and without any twists over the complete distance. The cable should form a certain sag
during winding up and winding off (see below figure).

Note:

Conductix-Wampfler motor reels are tested at works and adjusted to the calculated required torque. If disturbances
should occur in spite of this please proceed according to the following table.

BAL7100-0071e-E
www.conductix.com

Page 47 of 48

The reel does not wind up though the

motor is live.

The reel does not wind up though the

motor is rotating.

The reel winds up, on a shutdown of the

motor however the cable is wound off.
The reel works, but the coupling emits a
high-pitched whistle.

Improper winding of the cable

Reel does not wind up though the motor

is live
No electric contact in the slip ring body

Bad insulation in the slip ring body

wrong rotational direction of the

backstop, motor cannot rotate.
wrong drive of the motor.

install backstop reversed..

exchange phases

feather key on motor shaft is missing

or broken
torque of the coupling adjusted too
low
magnetic coupling is stuck
reel rotates on the shaft. clamping
set not tightened
damage of toothed wheel in the gear
installation height or operation mode
not in accordance with specifications
backstop damaged

replace feather key

sealings are not run in yet

no measure required, high-pitched

whistle disappears after some hours
of operation
align gear/reel position

the reel shaft is not really horizontal

or rectangular to the track.
the reel cable has not been placed
free of twists or is not free of twists
by itself. Strong twisting can sometimes be recognized at the outer
sheathing (writing or color strip).
the reel fixed point is placed incorrectly to the reel center
torque of the coupling adjusted too
weak (see figure 1).
defective motor
loose connections at the rings or at
the current collectors
wear of the collector shoes
strong pollution
high humidity due to lack of sealing
condensation

readjust torque
exchange magnetic coupling
tighten clamping set. operating
instruction
exchange gear
check installation parameters
exchange backstop

wind off the cable completely by

travelling into the final position. Detach the fixed and feeding point;
eliminate twists.
try to reach an improvement by
shifting the cable fixed point parallel
to the reel shaft.
adjust torque.
operating instructions
replace motor
tighten connections
replace collector shoes
clean
replace defective sealing and tighten
cap
install heating

BAL7100-0071e-E
www.conductix.com

Page 48 of 48