The technical data and images which appear in this manual are for informational purposes only.

NO WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS
MANUAL. Conductix makes no warranty (and assumes no liability) as to function of equipment or operation of systems
built according to customer design or of the ability of any of its products to interface, operate or function with any portions of
customer systems not provided by Conductix.

Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and
material discovered and reported to Seller within one year after shipment of such goods to Buyer.

Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to effect repairs on site, Seller’s
obligation hereunder to remedy defects shall be limited to repairing or replacing (at Seller’s option) FOB point of original
shipment by Seller, any part returned to Seller at the risk and cost of Buyer. Defective parts replaced by Seller shall
become the property of Seller.

Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service
recommended by Seller and altered only as authorized by Seller. Seller is not responsible for defects which arise from
improper installation, neglect, or improper use or from normal wear and tear.

Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for
all parts procured from others according to published data, specifications or performance information not designed by or
for Seller.

Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform
to applicable specifications or which differ from that agreed to be supplied which non-conformity is discovered and
forthwith reported to Seller within thirty (30) days after shipment to the Buyer. Seller’s obligation to replace or refund the
purchase price for non-conforming goods shall arise once Buyer returns such goods FOB point of original shipment by
Seller at the risk and cost of Buyer. Goods replaced by Seller shall become the property of Seller.

There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title
and freedom from encumbrances and, except as herein expressly stated and particularly, and without limiting the
foregoing, there is no guarantee or warranty, express or implied, of merchantability or of fitness for any particular
purpose or against claim of infringement or the like.

Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s
design or of the ability of any goods to interface, operate or function with any portions of Buyer’s system not provided
by Seller.

Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage
arising out of, connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of
any products or services shall in no case exceed the price paid for the product or services or any part thereof which
give rise to the claim. In no event shall Seller be liable for consequential, special, incidental or other damages, nor
shall Seller be liable in respect of personal injury or damage to property not the subject matter hereof unless
attributable to gross misconduct of Seller, which shall mean an act or omission by Seller demonstrating reckless
disregard of the foreseeable consequences thereof.

Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and
recommended capacities and design functions or under abnormal conditions. Seller assumes no liability for loss of time,
damage or injuries to property or persons resulting from the use of Seller’s products. Buyer shall hold Seller harmless
from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or
utilization of services, respectively, of Seller and shall defend any suit or action which might arise there from in Buyer’s
name - provided that Seller shall have the right to elect to defend any such suit or action for the account of Buyer. The
foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
1.0 Specifications
1.1 Hydraulic Drive Motor
1.2 Slip Ring
1.3 Spool
1.4 Gear Reducer

2.0 Handling
3.0 Installation
4.0 Inspection
5.0 Cable Installation
6.0 Maintenance
6.1 Chain Tension
6.2 Drive Sprocket Selection
6.3 Replacing Guide Sprockets
6.4 Guide Unit Replacement
6.5 Magnetic Coupler
6.6 Slip Ring
6.7 Maintenance Schedule
6.8 Torque Chart
This cable reel has been specifically designed for the storage and operation of medium-high voltage mining cables.
This manual is designed to provide basic information required to install, operate, and maintain this trailing cable reel. In
the event that technical assistance is needed, please contact the original manufacturer.

1.1 Drive Motor Assembly 1.3 Spool

Voltage: 380/3/50, 575/3/60 1.3.1 Cable Size Range
Power: 2 hp 2.0 inch OD minimum
Amperage: 3.1 F.L.A. @ 460V 2.5 inch OD maximum
1.3.2 Retraction Speed
1.2 Slip Ring 175 FPM maximum
1.2.1 Power Circuits
1.4. Gear Reducers
Voltage: 7,200 Volts maximum
1.4.1. Lubrication
Amperage: 250 Amps maximum Mobil Delvac Synthetic Gear Oil 75W-90
1.2.2 Ground Circuit
or equivalent.
Voltage: 600 Volts maximum
Amperage: 250 Amps maximum
1.2.3 Ground Check Circuit
Voltage: 600 Volts maximum
Amperage: 75 Amps maximum
1.2.4 Heater Circuits
Voltage: 600 Volts maximum
Amperage: 35 Amps maximum

2.1. Reel should only be lifted using provided lift points.

3.1 Mount reel on drill. 3.4 Terminate motor power to terminals in motor control
3.2 Connect feeder cord to drill using HV coupler. box.
3.3 Connect heater leads. 3.5 Connect reel control lead to motor control.
4.1 Inspect chain for proper tension and alignment. 4.4 Inspect and grease main spool bearings.
(see Chain Tension Section 6.1)
4.5 Check alignment of slip ring brushes before
4.2 Ensure all guards and shields are properly operation and after any adjustments are made
installed and all hardware is tight. to the slip ring. Misalignment can result in
accelerated wear of the brushes.
4.3 Inspect rollers on guide head for alignment and
free rotation, grease if needed.

5.1 Ensure that the proper guide drive sprocket is 5.7 At least 1-1/2 wraps of inactive cable should be
installed for the cable OD that is being installed. (see maintained on the spool to reduce stress on the cable
Drive Sprocket Selection Section 6.2) clamps and terminations.
5.2 Operate the reel until the guide head is at the end of 5.8 Operate reel to wind the remaining cable
travel on the side of the reel opposite the feeder cord. onto the spool, making sure to check for
proper spacing and cable lay on the spool
5.3 Feed the trailing cable through the guide head and
drum.
between two of the spool drum spokes, keeping it
next to the outside flange. 5.9 Refer to cable manufacturer’s instructions
for proper cable handing and installation
5.4 Route cable through u-bolt clamp on inner flange of
procedures.
spool and through watertight in junction box.
5.5 Terminate cable to slip ring brushes in junction box. Reel is now ready for operation
5.6 Install p-shaped cable clamp using a bolt through
0
the flange, the clamp should be placed 30 around
the spool from where the cable passes through the
drum spokes.

6.1 Chain Tension

All chains must be properly tensioned to ensure smooth
operation and prevent excessive wear of chain and
sprockets.
All sprockets must be properly aligned to prevent
excessive wear on chain.

6.1.1 The Spool-Limit Switch chain should have .313-.625 in.

(0.8-1.6 cm) of slack when tensioned.
6.1.2 The Spool-Reducer chain should have 1.75-2.25 in.
(4.5-5.7 cm) of slack when tensioned.

6.1.3 The Reducer-Guide chain should have .563-1.13 in.

(1.4-2.9 cm) of slack when tensioned.

6.1.4 The Guide chain should have .50-1.0 in. (1.3-2.5 cm) of slack when tensioned.
6.2 Drive Sprocket Selection
Cable OD Gearbox Guide Drive
The sprockets that drive the guide head unit are
interchangeable to allow for reeling of a wide range of (inches) Sprocket Sprocket
cables. Before installing any cable make sure the correct 2.00-2.18 80B9 80B21
sprockets are installed and the chain is properly tensioned, 2.19-2.30 80B9 80B20
use of the incorrect sprocket will lead to incorrect cable
spacing and potential damage to the cable or reel. 2.31-2.50 80B10 80B20

6.3 Replacing Guide Drive Sprockets

6.3.8. Clean threads and apply thread locking
6.3.1. Ensure the reel is powered down and compound to the setscrews and insert them
appropriate measures are taken to prevent in the collar of the sprocket.
activation of reel during servicing. 6.3.9. Place the sprocket on the shaft making
6.3.2. Open chain guard covering the drive sprockets sure to fully engage the key and aligning
and tensioner. the sprocket with the sprocket that drives it.
6.3.3. Loosen the four bolts that hold the tensioner in 6.3.10. Tighten set screws.
place and loosen chain.
6.3.11. Replace the chain and install connector
6.3.4. Remove connecting link from chain and place
chain out of the way. link.
6.3.5. Remove set screws from the collar of the 6.3.12. Use chain tensioner to tighten chain (see
sprocket. Chain Tension Section 6.1)
6.3.6. Pull sprocket off of shaft. 6.3.13. Tighten chain tensioner.
6.3.7. Select proper sprocket for the cable size to be 6.3.14. Replace chain guard and tighten
used.
hardware.
6.4. Guide Unit Replacement 6.4.5. Lower cable until it is free of the guide head.
6.4.6. Remove the guide head unit retaining bar
6.4.1. Operate reel until the guide head is at the
end of travel at either end. located at the end of the guide channel.
6.4.2. Remove the four 1/2-13 bolts from the 6.4.7. Remove the two bolts attaching the guide
bottom plate of the guide head and set head drive angle to the guide head unit.
6.4.8. Slide the guide head to the end of the guide
bottom plate aside.
channel and remove.
6.4.3. Remove the lynch pin from the lower guide 6.4.9. Repeat steps above in reverse order to install
roller shaft. guide head.
6.4.4. While supporting the cable, remove the
lower guide roller and shaft.
6.5. Magnetic Coupler Torque Adjustment
6.5.1. Remove guard screws.
6.5.2. Remove safety mesh guard.
6.5.3. Remove the three locking screws.
6.5.4. Hold gearbox side of coupler stationary and screw or unscrew the motor side of the coupler to adjust
the output torque. Screw the coupler together to increase torque and apart to decrease torque.
6.5.5. Reinstall locking screws and mesh guard, apply thread locking compound to screws for reassembly.
6.6. Slip Ring Safety
DANGER: Hazard of electrical shock or burn. Always disconnect the power from the slip ring before attempting to perform
any service function. Follow lock-out/tag-out procedures where appropriate.
 6.6.1. Inspect brush holders for proper alignment. Locate brush holders so that the entire brush contact
surface rides squarely on the ring with the brush moving freely in the brush holder. Position brush
holders so the brush makes contact with the middle of the conductor and is not offset.

6.6.2. Inspect brush contact surface by removing the brush if required. Remove surface dirt, oxidation,
pitting, or other contaminants by using a brass or poly brush or 320 grit sand paper. Care is to be taken
not to load-up the brush surface with dust or contaminants.
6.6.3. To remove and replace brush on square post mounted brush holder (ground check circuit):
a) Remove the brush shunt lead and brush lead wiring from top of brush holder by removing top
terminal screw.
b) Lift springs slightly with a hook type tool.
c) Tilt brush out from under the spring and away from holder for removal.
d) To reassemble, replace the brush in the reverse fashion.
6.6.4. To remove and replace metal type DF style brush holder assembly on standard insulators (power and
ground circuits):
a) Remove the brush shunt leads and brush lead busbar from top of brush holder.
b) Remove top brush assembly from the bracket.
c) To reassemble, replace assembly in reverse order.
d) Torque brush holder nuts to 96 in lbs.
 6.6.5. Inspect the ring surface for dirt, oxidation, or other contaminants. A properly operating ring will have a
film that appears burnished in color with a darker surrounding color where the brushes track. If the ring
requires cleaning, order Slip Rings Polishing Kit Part No. XA-41286.

6.6.6. Inspect all electrical connections for corrosion and tightness. Loose and/or corroded terminations will
cause a concentration of excessive heat.

6.6.7. Moisture is a major cause of slip ring deterioration. Water will corrode parts and break down insulation.
Dust and dirt present within the enclosure will affect the proper operation of the assembly. Most dusts can
cause excessive brush and slip ring wear, and conductive dust, if allowed to accumulate, will form a path
for short circuiting.

6.6.8. Periodically perform an inspection by removing the enclosure and checking for condensation, water and
dust collection. If contaminants are found, wipe the enclosure and the assembly with a lint free cloth. If
the problem persists, take steps to remedy the leakage or condensation problem.

6.6.9. In addition to using the slip ring polishing kit when cleaning the slip ring assembly, use only clean dry low
pressure air or a vacuum cleaner to remove the contaminants form the rings. Do not use any solvents,
aerosol sprays, or liquid cleaners on the slip ring assembly.

After physical inspection of the slip ring electrical tests should be done to verify the integrity of each circuit. These tests
include:

6.6.10. Continuity tests from circuit to circuit and each circuit to ground.
There should be no continuity to other circuits
There should be continuity from junction box to junction box for each circuit

6.6.11. Megger Test - A megger test voltage of 1000V is typically acceptable for this test. Test voltages up to
15KV may be used on the three high voltage circuits only.

~ Circuits should be tested to ground only - 1MΩ is the minimum acceptable resistance.
6.7. Maintenance Schedule

Interval Item Action

Visually inspect for damage. Damage may include cuts in the
Cable jacket, excessive abrasion or wear, twisting or general distortion
of the cable shape.
Check that the guide rollers turn freely and all mounting hardware
Monthly Guide Rollers
is tight. Grease rollers.
Check that the guide head rollers turn freely and all mounting
Guide Assembly hardware is tight. Also check that the guide head moves freely in
the track.
Check chain for corrosion and tension. Lubricate and readjust as
Chain Circuits
needed.
Main Spool Bearings Grease.

Semiannually Limit Switch Jack Shaft Bearings Grease.

Guards and Covers Check hardware to ensure it is still tight.
Slip Ring Inspect brushes and rings for wear and contamination.
Magnetic Coupler Check spider bushing. Replace if worn.
6.8. Torque Chart
6.8.1. Bolts should be tightened to torques listed below unless otherwise specified.

Size Torque (ft-lb) (N-m)

1/4-20 8.4 11.4
5/16-18 17 22
3/8-16 31 42
1/2-13 74 100
5/8-11 140 190
3/4-10 240 325
7/8-9 390 529

Recommended Spare Parts

Part No. Description Qty
XA-536818 2 in. Roller, Narrow 4
XA-530337 2 in. Roller, Wide 4
030102-100.2 4 in. Roller Assembly 4
XA-30068C Brush 35A 4.0 Bore CG 4
XA-30069C Brush 75A 4.0 Bore CG 1
XA-DRA3-20A-4000 Brush Holder 200A Double w/ Brushes 4
XA-537818 Cable Guide Assembly 1
XA-535283 Chain Link Assembly 1
XA-535605 Horizontal Roller Assembly 2
XA-C35 Roller Chain #35 6.5 ft
XA-C80 Roller Chain #80 20 ft
XA-535606 Vertical Roller Assembly 4
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Conductix-Wampfler
10102 F Street Omaha, NE 68127 USA

Customer Support Phone: 800 521 4888 Fax: 800 780 8329

Phone: 402 339 9300 Fax: 402 339 9627

info.us@conductix.com www.conductix.us