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.