Aero Housewares GR900 Series User's Manual
Contents
1. ADJUSTING CABLE GUIDE Cable guide position is set by rotating the spring pocket assembly Loosen three clamps holding spring pocket assembly in place by unscrewing three hex head bolts Unless required do not completely remove bolts or clamps Reposition guide as required making sure clamps straddle ribs on outside diameter of spring pocket assembly and retighten hex head bolts A CAUTION Pulling the cable at sharp angles to the cable guide will shorten the cable life and retard retraction speed OPERATION RATCHET LOCK All reels are supplied with a ratchet lock to hold drum at any of several positions per drum revolution and prevent if from retracting If ratchet lock is not required constant tension move spring clip and spring to adjacent cable guide screw To release ratchet pull cable out until ratchet pawl disengages GROUND FAULT CONNECTION When the cable is pulled out and connected to provide ground fault protection all of the cable should be fully extended to provide maximum current capacity and a padlock must be installed on the reel through the hole provided in the flange of the spool This padlock prevents drum rotation and assures that the cable remains unwound should a ground fault occur a Fn M3120 18D Page 3 of 6 Aero Motive Company Jul 01 A WARNING Failure to unwind the full length of cable and then padlock the spool to prevent its inadvertent rewinding in the event of a ground fault will create a2. both screws 19 extension spring 15 shoulder screw 21 and ratchet pawl 22 from spring pocket assembly 14 6 Remove spring pocket assembly 14 from base 3 and replace with new spring pocket assembly 55 Assemble in reverse order Spring pocket assemblies are sealed to prevent disassembly Don not attempt to remove A WARNING spring from its pocket Uncontrolled release of spring tension may occur causing property damage personal injury or death Carefully inspect all wire connections after any service work is conducted Failure to do so A WARNING hee could result in property damage personal injury or death MAINTENANCE ELECTRICAL 1 Inspect all cable connections at least monthly 2 Resistance through the 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 manner that it cannot be disassembled nnn nn a M3120 18D Page 4 of 6 Aero Motive Company Jul 01 REPLACEMENT PARTS Ess gt Finn M3120 18D Page 5 of 6 Aero Motive Company Jul 01 Reference Pa
3. 35 1 WARNING LABEL Included in drum kit A below 36 1 SLIP RING BRACKET Included in drum kit A below 37 2 SCREW PAN HD M8 X 16MM Included in drum kit A below KITA H05040005 AR DRUM KIT GR900 Includes items s 26 28 29 33 35 36 amp 37 KIT B H05040013 AR CLAMP KIT STAINLESS STEEL Includes 3 each of 4 amp 5 KIT C H26340009 AR ROLLER GUIDE KIT Includes item 13 16 17 and 18 Aero Motive Company WwW A Woodhead Industries Inc Subsidiary PO Box 2678 Kalamazoo MI 49003 2678 616 337 7700 800 999 8559 FAX 800 333 6119 www aeromotive com SM3120 18D AKAPP Electro Industrie WwW A Woodhead Industries Inc Subsidiary Nijverheidsweg 14 Box 54 NL 3771 ME Barneveld NL 3771 AB Barneveld Holland 31 34 241 4022 FAX 31 34 249 2384 www akapp com Woodhead Asia PTE LTD WwW A Woodhead Industries Inc Subsidiary 401 Commonwealth Drive 04 04 Haw Par Technocentre Singapore 0314 65 261 6533 FAX 65 479 3588 sales wasia com sg Woodhead Connectivity LTD Woodhead Canada LTD WwW A Woodhead Industries Inc Subsidiary Factory No 9 Rassau Industrial Estate Ebbw Vale Gwent NP3 5SD United Kingdom 0495 35 0436 FAX 0495 35 0877 sales wdhd co uk WwW A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario L4W 3Y5 Canada 905 624 6518 FAX 905 624 9151 www woodhead ca Page 6 of 6 Aero Motive Company Jul 01
4. Ground Fault Cable Retractor GR900 Series Service Manual AERO MOTIVE COMPANY 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 A CAUTION Hazards or unsafe practices which MAY result in minor personal injury or product or property damage Model GR900 retracts up to 40 feet of 1 0 or 2 0 AWG grounding cable intended to protect equipment and personnel in the event of a ground fault The collector rings electrical path through the reel has a current carrying capacity greater then that of the largest cable 2 0 AWG to be installed on the reel Failure to lock the cable drum in position with the cable fully extended as instructed will create an explosion hazard in the even of fault condition and may result in property damage personal injury or death A WARNING The internal electrical path is not insulated from the reel frame therefore thi
5. ed carefully Failure to properly terminate the cable may result in property damage personal injury or death 9 The cable can now be wound onto the cable drum 10 A warning label 35 is provided with the retractor and must be attached to the free end of the cable between the adjustable cable stop 34 and the point where the cable jacket is stripped off see parts drawing To attach the label remove the adhesive cover from the back and place the center of the label on the center if the cable Wrap the cable both ways from the center so both sides if any re mains adhere to each other back to back See illustration Cable jacket Cable jacket Cable Cable YY Warning label Cable stop Warning label If cable is replaced at a later date contact Aero Motive Co 1 800 999 8559 for replacement label nn a M3120 18D Page 2 of 6 Aero Motive Company Jul 01 SPRING TENSIONING CAUTION Failure to test for adequate spring revolutions can cause spring damage Hazards or unsafe practices MAY result in minor personal injury or product or property damage NOTE A minimum 2 pre tension turns is required Additional turns can added as long as one unused spring turn remains when cable is completely extended If entire cable cannot be pulled out decrease spring tension until full one turn remains All reels require pretensioning turns to spool assembly before connecting free end of working cable Set
6. h the cable run e When mounted overhead in base up position add a secondary chain bracket or other safety device to prevent reel from falling in case the mounting bolts are removed or loosened from vibration INSTALLING CABLE 1 Select the proper cable size 1 0 or 2 0 AWG to fit the application The cable should have fine stranding for flexibility and a jacket suitable for rough handling 2 After removing the outer drum half 29 pass the end of the cable through the neoprene cable seal 30 3 Adjust the neoprene cable seal 30 to fit the cable diameter by cutting away the smaller rings with a sharp knife The remaining hole size should be smaller then the cable diameter and must stretch when inserting the cable 4 Finish the end of the cable by either stripping and thinning or applying a suitable pin connector 5 Insert the cable end or pin connector through the diameter hole provided in the terminal on the rotating portion of the slip ring assembly 27 6 Lock the cable securely in place with the set screw and jam nut provided 7 Clamp the cable to the inside of the inner drum half 33 using the two hole clamp 23 screws 25 and washers 24 Provide slack between the cable termination on the slip ring assembly 27 and the cable clamp 23 to allow free alignment 8 Reinstall the outer drum half 29 and drum gasket 26 with the four screws A WARNING All steps related to termination of the cable must be follow
7. n explosion hazard which could result in property damage personal injury or death A WARNING Personnel should be kept at a safe distance from the Ground Fault Reel and Cable In the event of a ground fault the sudden surge of power will cause the cable to move violently and could cause property damage personal injury or death This reel is intended for use in a grounding circuit only The electrical path is not insulated A WARNING from the reel frame Property damage personal injury or death could result if retractor is not used in accordance with this manual _ Check all electrical connections on retractor and ground cable terminations before use A WARNING ne Failure to do so may result in shock hazard causing property damage personal injury or death SERVICE A WARNING If ground fault condition has occurred remove the reel from service immediately and return it to Aero Motive Company for inspection and if necessary repair Failure to do so could result in and electric shock hazard causing damage personal injury or death MAINSPRING REPLACEMENT If the reel will not develop tension or retract cable the spring assembly may need to be replaced To replace the mainspring Disconnect the input grounding connection Remove junction box cover 11 and connector 12 Remove shaft retainer screw 1 and shaft retainer 2 Remove drum and main shaft from base 3 Remove cable guide 16 spring clip 20
8. rt Number Number Qty Description 1 C03500231 1 SCREW PAN HD M5 X 12MM 2 M41100003 1 SHAFT RETAINER 3 H22110385 1 BASE 4 3 CLAMP Included in clamp kit B below 5 3 SCREW HEX HD M6 Included in clamp kit B below 6 M34370006 1 MAIN SHAFT ELECTRICAL WELDING REEL 7 C47040141 1 O RING 8 C34620105 1 THREAD PLUG 9 C71140112 1 NUT NPT LOCKING 10 M14240007 1 JUNCTION BOX GASKET 11 H82640002 1 JUNCTION BOX COVER 12 C75620419 1 STRAIN RELIEF CONNECTOR NPT 500 13 C03500253 10 SCREW PAN HD M6 X 16MM Included in roller guide kit C below 14 H41220076 1 SPRING POCKET ASSEMBLY 15 C60610121 1 EXTENSION SPRING 16 M04730007 1 CABLE GUIDE Included in roller guide kit C below 17 M24060125 4 ROLLER SHAFT Included in roller guide kit C below 18 M86700006 4 ROLLER Included in roller guide kit C below 19 C03500255 2 SCREW PAN HD M6 X 20MM 20 M53350002 1 SPRING CLIP 21 C15070225 1 SCREW SHDR 8 X 10 16MM 22 M86750002 1 RATCHET PAWL 23 M70780007 1 CABLE CLAMP 24 C01070517 2 FLAT WASHER M5 25 C03500237 2 SCREW PAN HD M5 26 1 DRUM GASKET Included in drum kit A below 27 H96610001 1 SLIP RING ASS Y ELECTRIC WELDING REEL 28 4 SCREW Included in drum kit A below 29 1 OUTER DRUM HALF Included in drum kit A below 30 M86550002 1 CABLE SEAL 31 M37810027 1 SEAL COVER 32 C03500201 4 SCREW PAN HD M4 X 12MM 33 1 INNER DRUM HALF Included in drum kit A below 34 STM2 1 CABLE STOP ST2 KIT
9. s reel is unsuitable for other uses other than retracting ground cables Use for other applications will create an electrical shock hazard and could result in property damage personal injury or death A WARNING Failure to install operate and maintain the retractor in accordance with these instructions A WARNING may result in electrical shock causing property damage personal injury or death If ground fault has occurred return the reel to Aero Motive Company for inspection and possible repair before placing back in service Failure to do so could result in electrical shock hazard and may result in property damage personal injury or death A WARNING Installation Misalignment of the reel and cable travel direction will cause the cable to be deflected at a sharp angle around the cable guide rollers The reel should be bolted securely to a flat metal surface of sufficient strength and rigidity to support it under all conditions to which it will be subjected Mounting holes will accommodate 7 16 or 3 8 bolts Nothing smaller then 3 8 or 10mm bolts should be used Se a O Tee Le ay ee ey ee ae we eT M3120 18D Page 1 of 6 Aero Motive Company Jul 01 MOUNTING The fixed base of the reel allows mounting in several different positions including base up base down or wall mounted Here are general mounting requirements e Main shaft must be horizontal e Centerline of the spool assembly must be on line wit
10. spring tension by turning fully wrapped reel through a specific number of revolutions or turns Number of pretension turns depends on application and desired tension A minimum of 2 set up turns is needed for most applications Additional tension may be added by repeating above process Failure to pretension reel may result in insufficient tension to retract and may shorten spring life After cable is installed apply the extra warning label 35 shipped with the reel to the insulated cable that protrudes beyond the cable stop Check to make sure that the cable can still be pulled out without winding the main spring to the end If the cable can not be pulled out completely too many prime turns have been applied and some will have to be removed Operating the reel with too many prime turns will restrict the cable travel and shorten the life of the main spring CONNECTING GROUND The ground connection cable should be as large or larger than the cable installed on the drum It is attached to the reel by connecting to the diameter copper rod protruding beyond the junction box cover 11 on the base 3 Connection should be made with a commercial fitting specifically intended for attaching this size cable to 4 diameter copper rod A WARNING Failure to make mechanically and electrically sound connection at both ends of the cable will create and electrical shock hazard and could result in property damage personal injury or death
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