CONDUCTIX VersaReel User manual

www.conductix.us VersaReel™
Maintenance Manual
VersaReel Maintenance ManualXA-578590

2 VersaReel Maintenance Manual
XA-578590
CONDUCTIX INCORPORATED
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.

VersaReel Maintenance Manual 3
XA-578590
CONDUCTIX-WAMPFLER FIELD SERVICE
Need Field Service for our products? We Can Handle It!
Ask us for a quote on expert system installations, inspections, preventative maintenance, and
repairs/retrofits.
As the world’s largest single source manufacturer of mobile electrification products, Conductix-
Wamplfer has the unique ability to offer a degree of service not found anywhere else. Conductix-
Wampfler's team of highly qualified service technicians and engineers have years of experience
servicing our complete line of products.
We can provide:
• Annual service contracts
• Installation
• Commissioning
• Installation supervision to ensure your installers avoid common mistakes.
• Troubleshooting to get you up and running.
• Pre-planned inspections to complement your preventive maintenance program.
Call 1.800.521.4888 for further details.

4 VersaReel Maintenance Manual
XA-578590
TABLE OF CONTENTS
SECTION 1 - SAFETY 5
Safety Information Responsibility 5
Safety Messages 5
Electrical Warnings 6
Operational Warnings 6
Maintenance Warnings 6
UL Rating 6
Labels and Marking 6
SECTION 2 - OVERVIEW 7
SECTION 3 - REPLACING PARTS 8
Quick Mount Base 8
Guide Arm 8
Feeder Cord 9
Ball Stop 10
Spring Motor 11
Cable and Tri-Tap 12
Ground Fault Interrupter (GFCI) 14
Cable End Accessory 15

VersaReel Maintenance Manual 5
XA-578590
SECTION 1 - SAFETY
Safety Information Responsibility
All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before installation,
operation, or maintenance.
The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and follow
the information provided could cause harm to yourself or others and/or cause product damage. No one should install, operate, or attempt
maintenance of this product prior to familiarizing themselves with the information in this manual.
Safety Messages
Safety messages in this manual are preceded by the HAZARD SYMBOL and one of three words: CAUTION, DANGER, OR WARNING. These
safety messages are intended to alert you to potential hazards that could cause harm to you or others and/or cause product damage.
CAUTION
• The HAZARD SYMBOL used with the word CAUTION indicates unsafe actions or situations that have the potential to cause injury,
and/or minor equipment or property damage.
DANGER
• The HAZARD SYMBOL used with the word DANGER describes immediate hazards that have the potential to cause severe personal
injury or death.
WARNING
• The HAZARD SYMBOL used with the word WARNING describes unsafe actions or situations that have the potential to cause severe
injury, death, and/or major equipment or property damage.
NOTE
• The word NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not
hazard related.

6 VersaReel Maintenance Manual
XA-578590
SECTION 1 - SAFETY
Electrical Warnings
WARNING
• Properly ground this equipment before use in accordance with both the National Electric Code and local electrical codes and
ordinances.
• Disconnect the electrical power from the cable reel before any service functions are performed.
• Do not use this cable reel for loads greater than the current rating listed on the label or voltage greater than 120V.
• Electrical wiring on the reel must be done by a qualified electrician.
Operational Warnings
WARNING
• Exercise care when handling the cable reel during normal operation. This cable reel has a rotating spool powered by springs under
tension.
• For use in indoor, dry location only.
• Do not allow cable to retract without restricting the retraction speed.
Maintenance Warnings
WARNING
• Do not install cable different from that for which the reel is intended. Changes in diameter, weight per foot, length of cable, or
flexibility will affect the operation of the reel.
• Mounting hardware and fasteners should be installed to maintain tightness under vibration and checked periodically to assure
tightness.
• Overhead installation mountings should be such that the reel is not suspended by bolts in tension. A safety chain or cable is
strongly recommended to minimize damage and/or possible injury in the event of mounting failure.
• Do not disassemble the spring motor for any reason. Serious personal injury could result. This cable reel is equipped with springs
under tension. Contact the factory for assistance:
In the US call: 1-800-521-4888
In Canada call: 1-800-667-2487
UL Rating
All reels in catalog are cULus listed.
Listed cable reels are intended for general use and are provided with permanent mounting means. If not completely wired from the
factory, any needed electrical wiring or connections must be done by a qualified electrician.
Labels and Marking
Every cable reel is marked with a label which includes the Conductix-Wampfler name and logo, the product catalog number, the individual
product serial number, NEMA rating, amps, volts, watts, and cable footage.

VersaReel Maintenance Manual 7
XA-578590
SECTION 2 - OVERVIEW
1. Spring Motor
2. Spool
3. Base
4. Frame
5. Guide Arm
6. Feeder Cord
7. Feeder Cord Cover
8. Ball Stop
9. GFCI
10. End Accessory
3
5
7
1
2
8
9
10
4
6

8 VersaReel Maintenance Manual
XA-578590
SECTION 3 - REPLACING PARTS
Figure 8-1 1. Quick Mount Base
2. Frame
3. Hardware
Figure 8-2
Figure 8-3
Quick Mount Base
Tools needed: 7/16 wrench (2).
1. Remove hardware from both sides of the frame. See Figure
8-1.
2. Remove reel away from base.
CAUTION
• Reel weight requires care to be taken when removing
reel from base.
3. Mount new quick mount base to structure using hardware.
4. Secure reel frame to quick mount base using mounting
hardware. Torque to 50 inch lbs See Figure 8-1.
Guide Arm
Tools needed: phillips head screw driver.
1. Keep reel from spinning by locking in place on ratchet.
Remove ball stop. Remove guide arm. See Figure 8-2.
2. Remove any cable end accessory and GFCI if installed on
cable. See cable end accessory and GFCI replacement
instructions.
3. Install new guide arm by inserting cable through cable
opening. See Figure 8-3.
4. Re-attach arm to reel using the same screws and tighten
down. Torque to 50 inch lbs.See Figure 8-2.
5. Re-attach ball stop, cable accessory and GFCI if needed. See
cable end accessory and GFCI replacement instructions.
13
2

VersaReel Maintenance Manual 9
XA-578590
SECTION 3 - REPLACING PARTS
Figure 9-1
Figure 9-2
Feeder Cord
Tools needed: phillips head screw driver.
1. Remove feeder cord cover. See Figure 9-1.
2. Remove strain relief bracket. See Figure 9-2.
3. Disconnect cable from quick connectors by lifting lever. See
Figure 9-3.
4. Connect new feeder cord. See Figure 9-4.
5. Wago connectors should be disconnected first. Then remove
strain relief. The old feeder cord can then be discarded. New
feeder cord should be cut and stripped at the proper length.
Then install the feeder cord into the strain relief. Then reattach
the wago connectors in the proper location.
6. Make sure wires are connected properly to the correct
corresponding quick connector. See Figure 9-5.
• Black wire connected to wire from #2 hole.
• White wire connected to wire from #3 hole.
• Green wire connected to #GRD hole.
7. Re-attach strain relief bracket making sure cable is correctly
located. See Figure 9-2.
8. Re-attach the cover. See Figure 9-1.
Figure 9-4
Figure 9-3
Figure 9-5

10 VersaReel Maintenance Manual
XA-578590
SECTION 3 - REPLACING PARTS
Ball Stop
Tools needed: phillips screw driver.
1. Keep reel from spinning by locking in place on ratchet.
2. Attach new ball stop on cable in location for application. See
Figure 10-1 and Figure 10-2.
A. Remove screws completely to replace ball stop.
B. Loosen and move ball stop along cable to adjust hanging
length.
NOTE
• Donut style ball clamp used on reels using 12/3
cable, clamp style used on reels with 16/3 cable.
Figure 10-1
Figure 10-2

VersaReel Maintenance Manual 11
XA-578590
SECTION 3 - REPLACING PARTS
Figure 11-1
Figure 11-2
Spring Motor
Tools needed: phillips screw driver.
1. Remove all tension on spring by removing guide arm and
having a controlled spool retraction. Let reel retract completely
while holding on to guide arm and cable accessory to prevent
damage to reel.
2. Remove cable off spool by lifting over and off of flange.
Remove enough cable to expose spring motor screws. See
Figure 11-1.
3. Remove spring motor by removing the 3 screws attaching it to
the flange. See Figure 11-2.
WARNING
• Never take apart spring motor assembly.
4. Re-attach new spring motor to shaft. See Figure 11-3.
5. Attach new spring motor to flange with screws.
Tighten 3 screws down properly. Torque to 20 inch lbs.
See Figure 11-2.
6. Hand wind cable back on spool. Make sure cable is spooled
on tightly and evenly preventing uneven and loose stack up.
See Figure 11-4.
7. Place 6 pre turns in reel by winding reel forward 6 full
revolutions. Keep a hold of reel during pre-turning to prevent
retraction. See Figure 11-5
8. Once pre-turns are placed tensioning the reel, lock the reel
out on ratchet to prevent retraction.
9. Re-attach guide arm. Torque screws to 50 inch lbs.
Figure 11-3
Figure 11-4
Figure 11-5

12 VersaReel Maintenance Manual
XA-578590
SECTION 3 - REPLACING PARTS
Figure 12-1
Cable and Tri-Tap
Tools needed: phillips screw driver, electrical wire crimpers, proper
wire connectors.
1. Remove Spring Motor (see Page 11.)
2. Remove strain relief bracket. See Figure 12-1.
3. Remove cable wires from quick connector. See Figure 12-1.
4. Install new cable or cable with tri-tap through slot in drum.
See Figure 12-2.
• For Tri-Tap without GFCI, install cable through guide arm
before wiring.
Figure 12-2

VersaReel Maintenance Manual 13
XA-578590
SECTION 3 - REPLACING PARTS
5. Strip cable properly and install proper cable connector to each
wire with crimper. See Figure 13-1.
6. Attach connector to correct corresponding quick connector
inside drum. See Figure 13-2 and Figure 13-3.
• Black wire connected to wire from #2 hole.
• White wire connected to wire from #3 hole.
• Green wire connected to #GRD hole. See Figure 13-4.
7. Re-attach strain relief bracket. See Figure 13-2.
8. Re-attach spring motor. See Page 11 Spring Motor
Replacement.
9. Attach ball stop in proper location.
10. Attach GFCI if applicable. See GFCI installation instructions
11. Attach desired end accessory. See cable end accessory
instructions
Figure 13-1
Figure 13-2 Figure 13-3
Figure 13-4

14 VersaReel Maintenance Manual
XA-578590
SECTION 3 - REPLACING PARTS
Ground Fault Interrupter (GFCI)
Tools needed: phillips head screw driver.
1. Remove existing GFCI by removing each end cover. See
Figure 14-1.
2. On both sides, remove strain relief bracket, cable gasket and
disconnect wires from connectors. See Figure 14-2.
3. Install new GFCI 5” from cable accessory. See Figure 14-3.
4. Connect new GFCI. Install cable gaskets to both sections of
cable. See Figure 14-2.
NOTE
• Make sure GFCI is installed in correct orientation of the
line and load labeled on GFCI: "Line" towards the spool
side and "load" towards the end accessory side
5. Connect wires to connector on both ends and install strain
relief. See Figure 14-2.
• White wire to silver screw.
• Green wire to green screw.
• Black wire to brass screw.
6. Re-attach GFCI covers. Make sure gasket has proper
placement in case. See Figure 14-2.
Figure 14-1
Figure 14-2
Figure 14-3

VersaReel Maintenance Manual 15
XA-578590
Cable End Accessory
1. Remove existing accessory.
2. Install desired end accessory.
3. Follow proper wiring instructions for type and style of
accessory:
A. If required, strip cable jacket and wires to correct length.
B. Attach black, white and green wire to correct accessory
connection.
C. Correctly install any strain relief plates or nuts included with
accessory.
SECTION 3 - REPLACING PARTS

Contact USA for our Global Sales Offices
www.conductix.us
© Conductix-Wampfler | 2017 | Subject to Technical Modifications Without Prior Notice
USA / LATIN AMERICA
10102 F Street
Omaha, NE 68127
Customer Support
Phone [phone]
Phone [phone]
Fax [phone]
[email protected]
[email protected]
CANADA
18450 J.A. Bombardier
Mirabel, QC J7J 0H5
Customer Support
Phone [phone]
Phone [phone]
Fax [phone]
[email protected]
MÉXICO
Calle Treviño 983-C
Zona Centro
Apodaca, NL México 66600
Customer Support
Phone [phone]
([phone]
([phone]
Fax [phone]
[email protected]
BRAZIL
Rua Luiz Pionti, 110
Vila Progresso
Itu, São Paulo, Brasil
CEP: 13313-534
Customer Support
Phone [phone]
Fax [phone]
[email protected]
VersaReel Maintenance Manual XA-578590