Conductix-Wampfler BEF150 User manual

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 1 of 54

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 2 of 54
Contents
1General Notes.........................................................................................................................................5
1.1 About this document...................................................................................................................................5
1.2 Limitation of liability ....................................................................................................................................5
1.3 Copyright....................................................................................................................................................5
1.4 Spare parts.................................................................................................................................................6
1.5 Warranty and guarantee.............................................................................................................................6
1.6 Customer service........................................................................................................................................6
2Safety Rules............................................................................................................................................7
2.1 Requirements on the personnel .................................................................................................................8
2.1.1 Qualifications..............................................................................................................................................8
2.1.2 Unauthorized personnel.............................................................................................................................8
2.1.3 Instruction...................................................................................................................................................9
2.2 Personal protective equipment...................................................................................................................9
2.3 Intended use.............................................................................................................................................10
2.4 Improper use............................................................................................................................................10
2.5 Protective measures to be taken by the operator / user...........................................................................10
3Terminology..........................................................................................................................................11
4Technical Specifications......................................................................................................................12
4.1 Type plate.................................................................................................................................................12
4.2 Technical specifications............................................................................................................................12
4.3 Operating conditions.................................................................................................................................13
4.4 Type designation code: ............................................................................................................................13
4.5 Dimensional drawings ..............................................................................................................................13
5Functional Description.........................................................................................................................14
5.1 Function....................................................................................................................................................14
5.2 Construction.............................................................................................................................................14
5.3 Danger zone.............................................................................................................................................15
6Transport and storage .........................................................................................................................16
6.1 Shipment..................................................................................................................................................16

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 3 of 54
6.1.1 Safety instructions for transport................................................................................................................16
6.1.2 Transport inspection.................................................................................................................................16
6.2 Packing.....................................................................................................................................................17
6.3 Storage of packed parts ...........................................................................................................................17
7Commissioning ....................................................................................................................................18
7.1 Mechanical attachment.............................................................................................................................18
7.2 Electrical installation.................................................................................................................................23
7.2.1 Connecting the feed cable........................................................................................................................28
7.3 Pretensioning ...........................................................................................................................................30
7.3.1 Adjustment ...............................................................................................................................................30
8Operation ..............................................................................................................................................31
8.1 Safety.......................................................................................................................................................31
8.2 Function....................................................................................................................................................31
8.3 Winding behaviour....................................................................................................................................31
9Service...................................................................................................................................................34
9.1 Safety.......................................................................................................................................................34
9.2 Service intervals and maintenance work..................................................................................................34
9.2.1 Reel..........................................................................................................................................................34
9.3 Replacing springs.....................................................................................................................................37
9.3.1 Prerequisites ............................................................................................................................................38
9.3.2 Series connection.....................................................................................................................................38
9.3.3 Parallel connection...................................................................................................................................42
9.4 Changing the direction of rotation.............................................................................................................44
9.4.1 Series connection.....................................................................................................................................44
9.4.2 Parallel connection...................................................................................................................................47
10 Troubleshooting...................................................................................................................................49
11 Dismantling and disposal....................................................................................................................50
11.1 Safety.......................................................................................................................................................50
11.2 Dismantling...............................................................................................................................................50
11.3 Disposal....................................................................................................................................................51

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 4 of 54
12 Additional Documents .........................................................................................................................52
13 Indices...................................................................................................................................................53
13.1 Figures .....................................................................................................................................................53
13.2 Keywords..................................................................................................................................................54

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 5 of 54
1General Notes
1.1 About this document
This document makes it possible for you to work safely and efficiently with a spring cable reel.
This document is a part of the spring cable reel, and must be kept accessible to personnel at all times in its immediate vicinity.
Personnel must read this document carefully and understand it before starting any work. A basic condition for workplace safety is
the observance of all safety and handling instructions appearing below.
Local accident protection regulations and general safety regulations apply for the area of use of the spring cable reel.
The figures in this document are to be used for basic understanding, and may deviate from the actual design under some
circumstances.
In addition to this manual, the instructions located in the appendices for the individual assembled components also apply.
1.2 Limitation of liability
All information and instructions in this Installation and Operating Manual have been compiled with due regard to the standards and
regulations in force, best engineering practice, and the findings and experience we have accumulated over many years.
The manufacturer is in no way liable for damages resulting from:
Non-observance of the operating instructions
Improper use
Use by untrained personnel
Unauthorized modifications
Technical changes
Use of unauthorized replacement parts and accessories
The actual scope of delivery may differ from the explanations and illustrations described here for special variants, if additional
order options are utilized, or due to the latest technical changes.
The obligations agreed upon in the delivery agreement and our General Terms of Business apply, as do the delivery conditions of
the manufacturer and all regulations applicable at the time the contract was concluded.
All products are subject to technical modifications in the context of improvement of function and further development.
1.3 Copyright
This document is subject to copyright, and is exclusively intended for internal use by the customer.
Provision of the installation and operating instructions to third parties, duplications in any form – even in part – as well as the reuse
and/or disclosure of their content are not permitted without the written approval of the manufacturer, except for internal use by the
customer.
Violations will be subject to damages. This will not exclude additional claims.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 6 of 54
1.4 Spare parts
WARNING!
Safety risk due to wrong spare parts!
Wrong or faulty spare parts can result in damages, malfunctions or complete failure as well as
impair safety.
→Use only original spare parts of the manufacturer!
→Order replacement parts from your contracted dealer or directly from the manufacturer.
Contact data:
Conductix-Wampfler GmbH
Rheinstrasse 27 + 33
79576 Weil am Rhein - Märkt
Germany
Tel.: +49 ( 0) 7621 662-0
Fax: +49 ( 0) 7621 662-144
[email protected]
www.conductix.com
Replacement parts list:
Separate document delivered with the order. If necessary, request from Conductix-Wampfler.
Please specify the order number in your request.
1.5 Warranty and guarantee
The terms of warranty and guarantee can be found in the General Terms of Business of the manufacturer (see www.conductix.de).
1.6 Customer service
Our customer service is available for technical questions (see contact data).
Our employees are always interested in new information and experience from the field that can be valuable for the improvement of
our products.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 7 of 54
2Safety Rules
Safety and hazard information is identified in this manual by the use symbols. Signal words are used to indicate the degree of
hazard in these safety instructions. Always observe safety and hazard information and work carefully to avoid accidents, bodily
harm or property damage!
DANGER!
... indicates an immediately hazardous situation, which if not avoided, may result in death or
serious injury.
DANGER!
... indicates an immediately hazardous situation due to electricity, which if not avoided, may
result in death or serious injury.
WARNING!
... indicates a possibly hazardous situation, which if not avoided, may result in death or serious
injury.
WARNING!
... indicates a possibly hazardous situation due to electricity, which if not avoided, may result
in death or serious injury.
CAUTION!
... indicates a possibly hazardous situation, which if not avoided, may result in moderate or
minor injury.
Tips and recommendations:
... refers to useful tips and recommendations as well as information for efficient and trouble-free
operation.
CAUTION!
... indicates measures that help avoid property damage.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 8 of 54
2.1 Requirements on the personnel
2.1.1 Qualifications
WARNING!
Injury due to insufficient qualifications!
Improper use can result in serious injury to person and property.
→All activities may only be performed by qualified personnel.
The following qualifications have been mentioned in this manual for different areas of operation:
Trained personnel/operators
have been instructed by the operator about the tasks assigned to him/her and the possible hazards resulting from improper use.
Qualified specialists
due to their specialized training, knowledge, and experience, as well as knowledge of applicable regulations, are capable of
carrying out work assigned to them, while independently recognizing and avoiding possible risk. Personnel are considered qualified
if they have successfully concluded training, for example, as electricians, master electricians, electrical engineers, or electrical
technicians. Personnel are also considered qualified who have been employed correspondingly for several years, have been
educated in theory and practice during that time, and have whose knowledge and skills in the trade required have been tested. The
operator of the machine or system must document that the corresponding certification or other documentation of qualification are
present or have been demonstrated.
Only those persons are authorized as personnel who can be expected to perform their work reliably. People whose capacity
for reaction is influenced e.g. by drugs, alcohol, or medications are not authorized.
When selecting personnel, follow all age- and occupation-specific guidelines applicable at the location of use.
2.1.2 Unauthorized personnel
WARNING!
Danger due to unauthorized personnel!
Unauthorized personnel who do not meet the requirements described here do not
understand the danger in the working area.
→Keep unauthorized personnel away from the working area
→In case of doubt, address the person and direct them away from the working area
→Stop work as long as unauthorized personnel is in the working area

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 9 of 54
2.1.3 Instruction
Before commissioning the equipment, personnel must be instructed by the operator. For better transparency, the performance of
this instruction must be logged.
Example of instruction log:
Date Name: Type of instruction Instruction given by Signature
5 November
2010
John Doe First safety training for
personnel
Horst Müller
2.2 Personal protective equipment
Always wear: For all work:
Protective headgear
For protection from falling and flying parts and materials.
Protective gloves
For the protection of hands from friction, scrapes, stabbing, or deep wounds, as well as from contact with
hot surfaces.
Work safety clothing
Primarily as protection against entrapment by moving machine parts. Working clothes must fit tightly with
low resistance to tearing, close-fitting sleeves and no protruding parts.
Protective footwear
Used to protect from falling heavy parts and slipping on slippery floors.
For special tasks,
wear:
When carrying out particular tasks, special safety gear is required. The individual sections specify
this gear in detail.
Safety goggles
To protect the eye from harmful influences such as strong light, chemicals, dust, splinters, or weather.
Respirator (FFP-3 – according to country-specific requirements)
For protection against materials, particles or organisms.
Here, protection from dust resulting from the wear of the carbon brushes.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 10 of 54
2.3 Intended use
The spring cable reel is used for the transmission of power and data to mobile consumers with automatic winding using a coil
spring. Unwinding is not carried out manually, but rather by the mobile consumer.
Both the reel and the cable are permanently installed.
Flexible reel-capable energy or control cables are used.
The spring cable reel must always be mounted with its axis horizontal.
2.4 Improper use
Improper use is any use other than those listed in 2.3.
Use for any purpose other than or in addition to the intended use is permitted only after discussion with the manufacturer.
2.5 Protective measures to be taken by the operator / user
The spring cable reel is used in commercial/industrial areas. The operator of the spring cable reel is therefore subject to legal
regulations concerning workplace safety. In addition to the safety instructions in this manual, all valid safety, accident protection
and environmental protection regulations applicable for the place of operation of the spring cable reel apply.
This particularly includes:
The operator must be informed of applicable workplace safety regulations and carry out a risk assessment to detect additional
dangers resulting from the specific working conditions in the place of operation of the spring cable reel. This must be
implemented in the form of operating instructions for the operation of the spring cable reel.
For the entire period of use of the spring cable reel, the operator must check whether the operating instructions prepared
correspond to the current state of regulations, and update the operating instructions as needed.
The operator must clearly regulate and determine responsibilities for installation, operation, troubleshooting, and maintenance.
The operator must ensure that all employees involved with the spring cable reel have read and understood this manual. The
operator must furthermore train personnel at regular intervals and inform them of hazards.
The operator must provide personnel with all required safety gear.
The operator is furthermore responsible for ensuring that the spring cable reel is always in a technically trouble-free condition. The
following thus applies:
The operator must ensure that the service intervals described in this manual are observed.
The operator must regularly have all safety systems inspected for functionality and completeness (once yearly if possible, but
at least as often as required by applicable national regulations).
If the device or system has been modified, the safety systems must be inspected again and adapted to the changed
conditions in such a way that the device or system is safe again.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 11 of 54
3Terminology
Fig. 1 Main assemblies of the spring cable reel
Item
Description
1
End flange, both sides
2
Slip ring body, housing with type plate
3
Reel-capable cable (optional)
4
Coil spring with protective guard
5
Fastening flange
Power spring
Coil spring without coiling gap, with large energy storage capacity.
Spring nominal values
nv : pre-loading rotations
na: work rotations
nR: reserve rotations
nBl: rotations until block = nv + na + nR
Winding direction: left by default (as seen from slip ring body housing: counter-clockwise)
Protective guard
Sheet metal housing in which the drive springs are installed to protect service personnel from injury.
Protection class
Protection against contact and against penetration of foreign bodies and water (see EN 60529; DIN VDE 0470-1).
3
1
2
1
4
5

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 12 of 54
4Technical Specifications
4.1 Type plate
The type plate is located on the top part of the slip ring body housing (see Fig. 2).
The technical specifications can be read off the type plate (depending on the model and variant).
Fig. 2 Type plate
4.2 Technical specifications
Example:
Data Value
Model
BEF 325524 – 1824/04ML – 2MB (T)H/L
Spring rotations
depending on the cable take-off
Max. total
44
Pretension nv
20
Reserve nr
4
Year of construction
2010
Slip ring body
1824 21+PE+2xS/04ML
Electrical current
21x25A+PE+4x20mA
Voltage
690 V/10 V
Protection class
IP65
Winding length
24 m
Order number
123456xxx

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 13 of 54
4.3 Operating conditions
Requirements for the working environment:
Designation Value Notes
Winding behaviour
0.3 m/s
2
Max. acceleration
Temperature range
-20 to 40 °C
Operation in air - Maritime climate possible for short periods, mild chemical
atmosphere, not in radioactive environment
Other values may be possible upon request.
4.4 Type designation code:
The type designation code includes the specification and the design features of the spring cable reel.
BEF 32 55 24 - 1824/04ML - 2 MB(T) H/L
Uncoiling direction
L = left
R = right
Circuit
H = series
- = parallel
Spring type
Number of springs
Slip ring body
Winding width
Outside diameter
Winding diameter
Model series
4.5 Dimensional drawings
See separate documentation for dimensional drawings and dimensional tables.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 14 of 54
5Functional Description
5.1 Function
The spring cable reel is designed for the automatic coiling cables for mobile consumers. The cable is wound using pretensioned
coil springs that are installed inside the body of the reel.
The reel is equipped with a fastening flange that is connected to the fixed axis by two threaded pins.
Unwinding is automatic and is implemented on site.
5.2 Construction
The reel is ball bearing mounted.
The reel body consists of a solid screwed plate structure (galvanised plate). Inside the reel body there is the spring chamber with
the spring set.
The drive springs and ball bearings are lubricated with a special grease for the temperature range from -55 °C to +100 °C.
Against the flange side is the chamber in which the slip ring body is housed. This area is covered by a two-part plastic or steel hub
(protection classes: IP54 steel, IP65 plastic).
The metric entry for the reel-capable cable (cable collar) is located in the lower part of the hub.
The slip ring of the slip ring body is screwed onto the fixed axis.
The current collector part is connected to the rotating reel body.
Fig. 3 Reel mount
fixed
Reel mount and cable
entry provided on site
rotating
Cable feed through the
wall

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 15 of 54
5.3 Danger zone
When using spring cable reels, there are two main danger zones to take into consideration:
Rotating reel
During operation, the reel cable is unrolled and/or rolled back in under spring tension. The reel body turns during these actions.
WARNING!
Danger zone: rotating parts!
Danger of injury from rotating machine parts!
→During operation, keep a safe distance from the rotating reel body!
Reel cable
During operation, the reel cable is unrolled and/or rolled back in under spring tension. The cable represents an obstacle. Increased
alertness is required in this area.
DANGER!
Danger zone: reel cable!
Danger of stumbling resulting in injury due to moving exposed cables!
→During operation, keep a safe distance from the reel cable!
DANGER!
Danger zone: reel cable!
While the reel cable is being wound by spring tension, there is a danger of
entanglement/crushing.
→Increased alertness is required in the winding area!
DANGER!
Danger zone: reel cable!
Danger of crushing and entanglement resulting in injury due to cables being reeled in!
→During winding, keep a safe distance from the rotating reel body!

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 16 of 54
6Transport and storage
6.1 Shipment
6.1.1 Safety instructions for transport
WARNING!
Danger of death due to hanging loads!
Falling parts or those swinging out of control can lead to severe injury or even death.
→Never step under hanging loads
→Only use the attachment points provided; do not fasten lifting accessories to projecting
machine parts or components built onto eyes.
→Be sure the connection elements are firmly seated
→Use only authorized lifting accessories and connection elements with sufficient load capacity
→Do not use torn or worn ropes or straps, but rather replace them with new ones
→Do not attach ropes or straps to sharp corners and edges, and do not knot or twist them
→Move loads only under supervision
→Set down the load when leaving the workplace
WARNING!
Possible damage from improper transport!
Improper transport can result in substantial property damage.
→Act with care when unloading packaged parts upon delivery as well as during internal
transport, and observe the symbols and the hazard information on the packaging
→Use only the attachment points provided
→Wait to remove packaging material until just before installation
6.1.2 Transport inspection
Check the delivery for completeness and transport damage immediately upon receipt.
Procedure in case of externally detectable transport damage:
→Do not accept delivery, or accept it only with reservations
→Note the scope of damage on the transport documents or on the transporter's delivery note
→File a complaint
CAUTION!
Damage compensation claims may only be made within the applicable claim periods.
→Claim every defect as soon as the defect is detected.

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 17 of 54
6.2 Packing
The individual packaged parts must be packed according to the transport conditions to be expected. Only environmentally friendly
materials have been used for packaging.
The packaging must protect the individual components from transport damages, corrosion, and other damage until installation.
Do not destroy the packaging and remove it only just before installation.
Handling packaging materials:
Dispose of packaging material according to valid legal regulations and local guidelines.
CAUTION!
Environmental damage due to improper disposal!
Packaging material is a valuable resource and can be reused, processed or recycled in many
cases.
→Dispose of packaging materials in an environmentally appropriate manner
→Comply with locally applicable disposal guidelines; if necessary, engage a specialist with
disposal
6.3 Storage of packed parts
Store packed parts under the following conditions:
Do not store outdoors
Store in a dry, dust-free place
Do not expose to aggressive media
Protect from direct sunlight
Avoid mechanical vibrations
Storage temperature: 15-35 °C
Relative humidity: max. 60 %
When storing for more than 3 months, check the general condition of all parts and the packaging at regular intervals. If
necessary, add or replace the preservative
CAUTION!
Under some circumstances, there may be instructions for storage on the packed parts which
go beyond the requirements listed here.
→Follow them appropriately

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 18 of 54
7Commissioning
CAUTION!
Installation
→During electrical installation of the reel, note whether it was delivered with or without the
wound cable.
CAUTION!
Commissioning may only be carried out by an electrician.
7.1 Mechanical attachment
The unit must be mechanically attached to a stable connection point with adequate load capacity. Beams, massive masonry or
fastening blocks (accessories) may be used as connection points.
Use the three drilling templates depending on the flange size:
Flange size
Drilling templates
61-F001-0039
BEF150
61-F001-0055
BEF185 – 325
61-F001-0056
BEF400 + 500
The three drilling templates for cutting out are on the following pages.
CAUTION!
Check the drilling templates!
If you use the drilling templates shown below, then please note the following:
→Do not scale the document while creating and printing the PDF! In the print menu, select the
function "No scaling"
→Before cutting the templates out, check their dimensions!

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 19 of 54
Fig. 4 Drilling template BEF150/61-F001-0039

Installation Manual
Spring Cable Reel
BEF150 – BEF500
MAL6100-0001a-EN
www.conductix.com translated document Page 20 of 54
Fig. 5 Drilling template BEF185 – 325/61-F001-0055