Ground Fault Cable Retractor GR1000L Service Manual
Contents
1. Slide hub and new mainspring housing assembly onto main shaft and key Line up the timing hole near the outer edge of spring housing assembly and timing hole in the spool flange Secure with six lock nuts Insert main shaft into hub in the base and reassemble retaining ring to the protruding end of main shaft Check that there is little axial play and tighten setscrew Secure cover and gasket to spool assembly using the six lock nuts Adjust the spring tension See Apply Spring Tension Replacement Parts ed 00273 BMP SM3180 08E Page 4 of 5 Aero Motive Dec 03 Item Number Recommended Spare Parts Part Number C01590218 H92110023 H22110412 M34060019 C22490119 H41210021 6187000000 4011900000 4077300020 H18110023 5385600000 M67620008 H18110024 H80130008 H42320037 H96610003 6187300000 H82630046 00576P0020 STM2 M13630009 H92110026 Daniel Woodhead Company w A Woodhead Industries Inc Subsidiary Northbrook IL USA 888 996 6343 Fax 847 272 8133 www danielwoodhead com wetechsup danielwoodhead com SM3180 08E Qty Description Cheese HD screw M5 x 25 included with 6 Lock washer M8 Included with 6 Grommet Set screw M12 x 25 included with 5 Base includes 4 Kit Guide assembly includes 1 2 Main shaft 2 Hex lock nut M5 included with 18 23 Main spring housing assembly Main spring hub Main spring spacer Key Retaining ring included with 15 Ratchet spa2. cable and to padlock spool to prevent its inadvertent WARNING rewinding in the event of a ground fault will create an explosion hazard Hazards or unsafe practices COULD result in severe personal injury or death A Personnel should be kept at a safe distance from Ground Fault reel and cable In the event of WARNING a ground fault the sudden surge of power will cause cable to move violently Hazards or unsafe practices COULD result in severe personal injury or death A This reel is intended for use in grounding circuit only The electrical path is not insulated WARNING from the reel frame Hazards or unsafe practices COULD result in severe personal injury or death Check all electrical connections on retractor and ground cable terminations before use WARNING Failure to do so may result in shock hazard Hazards or unsafe practices COULD result in severe personal injury or death When cable is pulled out and connected to provide ground fault protection all cable should be fully extended to provide maximum current capacity A padlock must be installed on reel trough the hole provided in flange of spool This padlock prevents spool assembly rotation and assures that the cable remains unwound should a ground fault occur MAINTENANCE AND SERVICE A If a ground fault condition has occurred remove reel from service immediately and return it to Aero Motive Company for inspection and if necessary repair Failure to
3. do so could WARNING result in an electric shock hazard Hazards or unsafe practices COULD result in severe personal injury or death ELECTRICAL Inspect all cable connections monthly Resistance through reel slip ring assembly should never exceed 0 001 ohms If so return to Aero Motive Company for inspection and repair NOTE The slip ring assembly has been designed in such a manner that it cannot be disassembled MAIN SPRING REPLACEMENT A Spring pocket assemblies are sealed to prevent disassembly Do not attempt to remove WARNING spring from its pocket Hazards or unsafe practices COULD result in severe personal injury or death Carefully inspect all wire connections after any service work is conducted Hazards or unsafe practices COULD result in severe personal injury or death A WARNING SM3180 08E Page 3 of 5 Aero Motive Dec 03 If reel will not develop tension or retract cable the spring assembly may need to be replaced To replace mainspring disconnect the input grounding connection Remove cover and gasket Loosen setscrew and remove retaining ring Slide complete spool with main shaft out of hub in the base Remove the six lock nuts that fasten the mainspring housing assembly to spool assembly Remove mainspring housing assembly being careful not to misplace the key Remove hub from mainspring housing assembly Install hub into new mainspring housing assembly Insert key into slot in main shaft
4. of sufficient strength and rigidity to support it under all conditions to which it will be subjected Mounting holes will accommodate 1 2 inch or 12mm bolts Hazards or unsafe practices MAY result in minor personal injury or product or property damage gt CAUTION a_i SSS ee as SM3180 08E Page 1 of 5 Aero Motive Company Dec 03 CABLE INSTALLATION A WARNING All steps related to termination of the cable must be followed carefully Hazards or unsafe practices COULD result in severe personal injury or death Select suitable cable size 4 0 or 2 0 AWG to fit application Cable should have fine stranding for flexibility and a jacket suitable for rough handling Remove cover and gasket Loosen nut on cable connector and pass cable end through the cable connector then through cable clamp Either strip and tin the cable end or apply a suitable pin connector Insert cable end or pin connector into the 65 inch diameter hole on the rotating part of the slip ring Secure cable in place by tightening the set screw and jam nut on the slip ring NOTE Allow some slack in the cable between its termination at the slip ring and its entrance into the spool assembly at the cable connector Tighten the nut on cable connector Hold cable clamp against inside edge of cable connector and tighten screw to secure cable Replace cover and gasket securing them with six lock nuts The cable can now be wound onto the spool assembly A
5. Ground Fault Cable Retractor GR1000L Service Manual AERO MOTIVE COMPANY WW A Woodhead Industries Inc Subsidiary IMPORTANT SAFETY INSTRUCTIONS Please read this manual carefully and follow its instructions Improper use or failure to follow these instructions could result in serious injury death or property damage Operators should be instructed in the safe and proper use and maintenance of this product Keep this manual for future reference The following safety precautions call attention to potentially dangerous conditions A DANGER Immediate hazards which WILL result in severe personal injury or death A WARNING Hazards or unsafe practices which COULD result in severe personal injury or death Hazards or unsafe practices which MAY result in minor personal injury or product or CAUTION property damage NOTE Instruct operators in the safe proper use and maintenance Keep this manual for future reference Model GR1000 reel retracts up to 50 feet 4 0 or 60 feet of 2 0 AWG grounding cable used to protect equipment and personnel in the event of a ground fault The collector ring electrical path through the reel is designed with a current carrying capacity greater then that of the largest cable 4 0 AWG to be installed on the reel A Failure to lock spool assembly in position with cable fully extended as instructed will create WARNING an explosion hazard In the event of a fault condition hazards or unsafe
6. cer included with 15 Kit Ratchet pawl includes 13 14 16 39 Spring included with 15 Spacer included with 18 Kit Ratchet includes 8 17 Clamp included with 22 Conduit nut 1 inch included with 22 Gasket included with 22 Kit Cable connector includes 19 20 21 Kit Spool assembly includes 8 Slip ring assembly Gasket included with 26 Slip ring cover Retaining ring Kit Cable stop Warning label Screw M10x20mm included with 38 Lock washer M10 included with 38 Washer M10 included with 38 Screw M6x20mm included with 38 Lock washer M6 included with 38 Washer M6 included with 38 Bolt M12x40 included with 38 Jam nut M12 included with 38 Kit Slip Ring Bracket includes 30 31 32 33 34 35 36 37 Clevis pin 3 16 DIA x 1 2 included with 15 o3f o om om ow om os fo S 4 pp 9 So Ss Ss A S 4 pp BD Ss pf es Ss Ss 2 S 4 pp S Woodhead Canada LTD w A Woodhead Industries Inc Subsidiary Mississauga Ontario Canada 905 624 1079 FAX 905 624 9151 www woodhead ca Aero Motive Company w A Woodhead Industries Inc Subsidiary Kalamazoo MI USA 269 337 7700 FAX 800 333 6119 www aeromotive com techhelp aeromotive com Page 5 of 5 Aero Motive Dec 03
7. practices COULD result in severe personal injury or death A The internal electrical path is not insulated from the reel frame therefore this reel is WARNING unsuitable for uses other than retracting ground cables Use for other applications will create an electric shock hazard Hazards or unsafe practices COULD result in severe personal injury or death Failure to install operate and maintain retractor in accordance instructions may result in WARNING electrical shock Hazards or unsafe practices COULD result in severe personal injury or death If a ground fault has occurred return reel to Aero Motive Company for inspection and A WARNING possible repair before placing back in service Failure to do so could result in an electric shock hazard Hazards or unsafe practices COULD result in severe personal injury or death INSTALLATION REEL MOUNTING Reel may be mounted with the base up base down or in any position that maintains the main shaft in a horizontal position Reel should be mounted with spool assembly in line with the direction of cable travel Misalignment of reel and cable travel direction will cause cable to be deflected at a sharp angle CAUTION around cable guide rollers This may shorten life of cable and or slow retraction rate Hazards or unsafe practices MAY result in minor personal injury or product or property damage Reel should be bolted securely to a flat metal surface
8. rically sound connection at both ends of this cable will create an electrical shock hazard Unsafe practices or hazards COULD result in severe personal injury or death Ground connection cable should be as large or larger than cable installed on spool assembly To attach cable to reel connect 5 8 inch diameter copper rod protruding beyond base Connection should be made with a commercial fitting specifically intended for attaching this cable to 5 8 inch diameter copper rod SM3180 08E Page 2 of 5 Aero Motive Dec 03 CABLE GUIDE A Pulling cable at sharp angles to cable guide will shorten cable life and retard retraction speed CAUTION Hazards or unsafe practices MAY result in minor personal injury or product or property damage To position guide assembly remove two screw and washers Place guide assembly so that cable will wrap directly onto assembly with as little deflection over roller as possible Cable guide assembly can now be positioned in any one of for locations Insert and tighten the two screws and washers through base into guide assembly OPERATION RATCHET LOCK Model GR1000 is equipped with a ratchet which will hold spool assembly at any of several positions per spool assembly revolution and prevent it from retracting To release the ratchet pull the cable out until the ratchet assembly disengages Reel can then retract cable GROUND FAULT CONNECTION A Failure to unwind full length of
9. warning label is provided with retractor and must be attached to free end of cable between adjustable cable stop and the point where the cable jacket is stripped off see parts drawing To attach label remove adhesive cover from back Place center of label on center of cable Wrap cable both ways from center so both sides if any remains adhere to each other back to back See illustration Cable stop Cable jacket Cable jacket Cable Cable N Warning label Warning label If cable is replaced at a later date contact Aero Motive Co at 1 800 999 8559 for replacement label APPLYING SPRING TENSION A CAUTION Check to make sure that the cable can still be pulled out without winding the main spring to the end If cable can not be pulled out completely too many prime turns have been applied and some will have to be removed Operating reel with too many prime turns will restrict cable travel and shorten life of the main spring Hazards or unsafe practices MAY result in minor personal injury or product or property damage After cable is fully wound on spool assembly develop one and two prime tension turns by rotating spool assembly one or two times against spring tension Pass cable through cable guide assembly and install cable stop with desired amount of cable protruding Apply warning label as discussed in CABLE INSTALLATION GROUND CONNECTION A WARNING Failure to make a mechanically and elect
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