CONDUCTIX Wampfler PBL400 Series User manual

PBL400 MOTORIZED CABLE REEL MANUAL
XA-970200.6 | 03.01.21
www.conductix.us Motor Driven Cable Reel
PBL400 Series
Manual

PBL400 MOTORIZED CABLE REEL MANUAL XA-970200.6 | 03.01.21
2
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 Inc. 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 Inc.
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.
CONDUCTIX INCORPORATED

PBL400 MOTORIZED CABLE REEL MANUAL
XA-970200.6 | 03.01.21
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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-Wampfler 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.

PBL400 MOTORIZED CABLE REEL MANUAL XA-970200.6 | 03.01.21
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TABLE OF CONTENTS
SECTION 1 - SAFETY 6
Safety Information Responsibility 6
Safety Messages 6
Limitation of Liability 6
Personnel Requirements - Qualifications 7
Personnel Requirements - Unauthorized Personnel 7
Personnel Requirements - Training 8
Personal Protective Equipment 8
SECTION 2 - GENERAL INFORMATION 9
Introduction 9
Specifications 9
Component Overview 9-10
Electrical Component Overview 11
SECTION 3 - HANDLING 12
SECTION 4 - INSTALLATION 14
Mounting 14
Wiring 15
SECTION 5 - OPERATION 16
Initial Operation 16
General Operation 16
SECTION 6 - MAINTENANCE & REPAIR 17
Cable Replacement 17
Chain Circuit Inspection 18
Chain Tension Adjustment 18
Motor Replacement 19-20
Stacker Wheel Assembly Inspection 19
Stacker Wheel Guide Roller Replacement 19
Stacker Wheel Assembly Replacement 20
Stacker Wheel Spring Replacement 20
Guide Roller Inspection 20
Guide Roller Replacement 20

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TABLE OF CONTENTS
SECTION 6 - MAINTENANCE & REPAIR (CONTINUED) 17
Complete Guide Replacement 21
Single Roller Replacement 21
Spool Roller Inspection 21
Spool Roller Replacement 21
Slip Ring Inspection 21-22
Slip Ring Replacement 22-24
Slip Ring Brush Replacement 24
Electrical Components 25
Signal Terminations Table 26
Motor and Safety Interlock Diagram 27
Retraction Limit Changes 28
Extension Limit Changes 28
Limit Switch Replacement 29
Fuse Replacement 29
Variable Frequency Drive Replacement 30
Variable Frequency Drive Programming 30-31
Programmable Relay Replacement 31
Programmable Relay Programming 32
DC Power Supply Replacement 32
Line Reactor Replacement 33
SECTION 7 - MAINTENANCE SCHEDULE 34
SECTION 8 - TORQUE CHART 34
SECTION 9 - TROUBLESHOOTING 34-35
Contact Information 36

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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
The following safety messages are used in this manual to alert you to specific and important safety related information.
CAUTION
CAUTION indicates unsafe actions or situations that have the potential to cause injury, and/or minor equipment or property damage.
DANGER
DANGER indicates hazards that have the potential to cause severe personal injury or death.
WARNING
WARNING indicates unsafe actions or situations that have the potential to cause severe injury, death, and/or major equipment or property
damage.
NOTE
NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not hazard related.
Limitation of Liability
All data and information in this mounting instructions have been compiled in compliance with the applicable standards and regulations,
best practice and our many years of experience and knowledge.
The manufacturer accepts no liability for damages resulting from:
• Failure to comply with this document
• 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 descriptions provided here if the model in question is a special one,
if additional equipped has been ordered or due to recent technical changes.
The obligations agreed upon in the delivery agreement and our General Terms and Conditions of business apply, as do the delivery
conditions of the manufacturer and the legal 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.

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SECTION 1 - SAFETY
Personnel Requirements-Qualifications
WARNING
Inadequately trained persons are at risk of injury!
Improper use can result in serious personal injury or material damage. All activities must only be performed by qualified personnel.
Only persons who can be expected to perform their work reliably are acceptable personnel. People whose reactions are impaired by drugs,
alcohol or medications, for example, are not authorized.
When selecting personnel, follow all age- and occupation-specific guidelines applicable at the location of use.
The following qualifications are specified in the operating instructions for certain fields of activity.
Trained personnel and operators
• The owner of the machine or system must document that the appropriate training has taken place.
Specialist personnel
• Will consist of persons capable of performing assigned tasks and independently identifying and avoiding potential hazards based on
their specialist training, knowledge and experience as well as their knowledge of the applicable regulations.
Persons are deemed to be technically qualified if they have successfully completed training as a master electrician, apprentice
electrician, electrical engineer or electrical technician. Persons are also considered technically qualified if they have been employed in
an appropriate capacity for several years, receiving theoretical and practical training in that line, and their knowledge and skills have
been tested by a specialist in the appropriate field of training.
• The machine or system owner must document that the appropriate certificates or other proofs of qualification have been or are being
provided.
Personnel Requirements-Unauthorized Personnel
WARNING
Danger due to unauthorized personnel!
Unauthorized persons who do not meet the requirements described here are not acquainted with the dangers 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 working, as long as unauthorized persons are in the working area.

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SECTION 1 - SAFETY
Personnel Requirements-Training
Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better traceability.
Example of a training log:
Date Name Training Type Training Instructor Signature
11/5/2019 John Doe First safety training
for personnel
Dave Miller
Personal Protective Equipment
For every task, always use:
Safety helmet: For protection against falling or flying parts and materials.
Protective gloves: For the protection of hands against friction, scrapes, puncture or deeper wounds, as well as against contact with hot
surfaces.
Protective work clothing: Primarily for protection against entrapment by moving machine parts. Work clothing must be close fitting with
a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.
Protective footwear: For protection against heavy failing parts and slipping on slippery floors.
For special tasks, specific protective equipment is required when executing particular tasks:
Safety eye wear: For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather effects.
Hearing protection: For protection against loud noises and to prevent acoustic trauma.
Breathing mask (FFP-3) - according to country-specific requirements): For protection against materials, particles, and organisms. In this
case, for protection against the dust produced by the abrasion of carbon brushes and the PVC insulation of the conductor rail.

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SECTION 2 - GENERAL INFORMATION
Introduction
The Conductix PLB400 is a motorized cable reel designed
specifically for the storage and protection of 400 Hz aircraft cable.
It is designed to be used in a variety of mounting positions and
locations where 400 Hz ground power is required to be provided to
an aircraft.
This manual is designed to provide the information required to
install, operate, maintain, and perform basic repair of the PLB400
series reels. All the above functions should be performed by
qualified individuals. In the event that technical assistance is
needed, please contact:
Conductix-Wampfler
10102 F St.
Omaha, NE 68127 USA
Phone: [phone] | 402-339-9300
Fax: [phone] | 402-339-9627
www.conductix.us
Specifications
Drive Motor Power: Three Phase
Power: 1 HP (745 W)
Voltage: 200/208/220/230/240/380/400/440/460
Volts (Depending on Model)
Frequency: 50/60 Hz
Control Circuits:
Voltage: 24 Volts DC
Slip Ring:
Power Circuits:
Voltage: 600 Volts maximum
Amperage: 260 Amps maximum
Control Circuits:
Voltage: 250 Volts maximum
Amperage: 2 Amps maximum
Cable Travel:
90 feet (27 meters) maximum with 2.38 inch
(60 mm) diameter cable
125 feet (38 meters) maximum with 1.69 inch
(43mm) diameter cable
Cable Speed:
100 feet per minute (30 meters per minute) maximum
Component Overview
Mechanical Component Overview
Side Panel
Access Panel Front Plate Side Panel
Roller Guide
Assembly
Roller Guide
Cover Panel
Mounting Holes
Rotary
Disconnect
Switch
Junction Box
Cover Panel
Side PanelBack Plate

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SECTION 2 - GENERAL INFORMATION
Part Name Function Performed
Side and Access Panels Provides physical protection to personnel from moving parts, provides access points of entry to perform
maintenance and repairs, and structurally connects the front frame plate to the back frame plate.
Front Plate Structural frame.
Roller Guide Assembly Guides the cable in and out of the reel enclosure without letting it rub on any stationary surfaces.
Back Plate Structural frame and mounting points.
Mounting Holes Threaded holes provided for use as mounting points to mount the reel to a support structure. Requires use
of M12-1.75 (size, thread of bolts)
Rotary Disconnect Switch Main power switch for the drive and controls of the cable reel. This does not disconnect power to the cable.
Power Junction Box
Electrical enclosure that contains the connector blocks and leads for incoming 400Hz power, interlock
controls with the passenger loading bridge and 400Hz generator, and reel drive motor incoming power if
entering all from one conduit.
Motor Control Junction
Box
Electrical enclosure that contains the reel drive and controls as well as fuses. It can also be the point of
incoming reel drive motor power if this power is entering separate from the 400Hz power.
Spool Circular body which the cable is wrapped around when retracting.
Spool Rollers Ensures that the cable remains in proper position on the spool at all times.
Slip Ring The sliding rotary electrical contact which transfers the 400Hz power and reel motor controls from the
stationary mount to the rotating spool cable.
Slip Ring Enclosure Electrical enclosure that contains the slip ring.
Motor Assembly Drive motor which provides power to the spool to extend or retract the cable.
Stacker Wheel Assembly Mechanical device that guides cable to the proper position on the spool for proper cable wrap and spool fill.
Motor Control
Junction Box
Spool Rollers Stacker Wheel Assembly
Power
Junction Box
Roller Guide
Assembly
Spool
Motor Assembly
Slip Ring
Enclosure
Limit Switch

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SECTION 2 - GENERAL INFORMATION
Electrical Component Overview
Part Name Function Performed
Power Terminal Electrical connector block for connection of 400Hz power to the cable.
Control Terminal Electrical connector block for connection of interlock signal wires and remote reel control wire.
Rotary Disconnect Switch Main power switch for drive and controls of the cable reel. This does not disconnect power to the cable.
Limit Switch Provides signals to determine the limits of cable travel.
Variable Frequency Drive Controls the input power to the reel drive motor. It is used to control the motor speed and direction and
monitor the motor performance.
Programmable Relay Programmable control which monitors all inputs and provides output to the variable frequency drive and the
motor brake.
Line Reactor Filters out voltage inconsistencies on the incoming power to protect the variable frequency drive.
E-Stop Relay Disconnects power to the drive and controls when pressed. This only stops operation and does NOT
disconnect the 400Hz power.
Fuse Block Overload protection on the incoming power to the variable frequency drive.
DC Power Supply Power source for the programmable relay electronics as well and signal circuitry.
Conduit to
Limit Switch
Conduit to
Motor Conduit to Power
Junction Box
Line
Reactor
Fuse Block
Rotary
Disconnect
Switch
DC Power
Supply
Programmable
Relay
Motor Control
Junction Box
Rotary
Disconnect
Switch
Conduit Fitting
Power
Junction Box
Power Terminal
Conduit Fitting
Control Terminal
Variable
Frequency Drive Limit Switch
Motor Control Junction Box
E-Stop
Relay
Conduit to E-Stop

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SECTION 3 - HANDLING
Lifting eye bolts or other rigging mounted to reel mounting holes.
Flat support from bottom for horizontal mount.
M12-1.75
Eye Bolts
(Not included)
Mounting Holes
Flat Support
WARNING
When handling the reel, only lift using approved methods at specific locations.

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SECTION 3 - HANDLING
Flat support from bottom for vertical mount.
Mounting Holes
Flat Support
Cable Exit
Slings around the reel.
Slings
Cable Exit
Mounting Holes Mounting Holes
Slings
Cable Exit
NOTE
• Slings must be at least 15ft long.

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SECTION 4 - INSTALLATION
Mounting
NOTE: Check installation drawings to determine reel orientation
when installed.
• If the reel is to be mounted in a vertical position on the
passenger loading bridge, the mounting holes must be
oriented such that one set is along the upper edge of the back
plate, the other set is along the lower edge of the back plate,
and the cable exits from the bottom side of the reel. See
illustration.
• If the reel is to be mounted in a vertical position on the
tarmac, the mounting holes will be oriented with one set
along each vertical side of the back plate, and the cable exits
from a vertical side of the reel or can be mounted in the
same vertical orientation as on a passenger loading bridge by
mounting the reel on 40 inch (1m) risers to allow the cable
room to exit the bottom side of the reel.
• If the reel is to be mounted in a horizontal position, regardless
of location, the mounting holes must be oriented upward with
the reel hanging below the supporting structure. The cable
will then exit on one of the vertical sides.
Mount the reel to a frame structure capable of supporting a
minimum of a 1000lb (454kg) load using eight M12-1.75 class 8.8
bolts in the eight threaded mounting holes provided.
Cable Exit
Cable Exit
Mounting Holes
Mounting Holes
Up
Down
Vertical Position
Horizontal Position

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SECTION 4 - INSTALLATION
Wiring
NOTE: Your reel may be set up for all incoming wiring to
enter through one conduit or two separate conduits, one for
motor power and one for cable power and control signals.
Follow the instructions that follow for either single or dual
conduit depending on your specific application.
Single Conduit
1. Locate and remove the eight M6 mounting screws in the outer
edge of the side panel that covers the two reel junction boxes
and the panel. This panel is the one that has a red rotary
disconnect handle visible on it.
2. Install a seal type conduit fitting and conduit into the power
junction box. This is the junction box without a visible discon-
nect switch handle.
3. Pull 400 Hz power leads, interlock safety wires, remote reel
control wires, and reel motor power wires through the conduit
and into the power junction box.
4. Terminate the 400 Hz power leads in the large terminal block as
labeled.
5. Terminate the smaller wires in the small terminal strip as
labeled. This is a cage clamp type terminal strip. To insert the
wires, insert a narrow straight bit screw driver in the slot above
the wire entrance and press firmly with the screw driver. This
will release the clamp spring. You must hold pressure on the
screw driver while inserting the wire.
6. Close the power junction box lid and secure latching screws.
7. Reinstall the junction box cover panel and the mounting screws.
Power Junction Box
Power Terminal Conduit Fitting
Control Terminal
Motor Control
Junction Box
Rotary Disconnect Switch
Power Junction Box
Power Terminal Conduit Fitting
Control Terminal
Limit Switch
Dual Conduit
1. Locate and remove the eight M6 mounting screws in the outer
edge of the side panel that covers the two reel junction boxes
and the panel. This panel is the one that has a red rotary
disconnect handle visible on it.
2. Install a seal type conduit fitting and conduit into the power
junction box. This is the junction box without a visible discon-
nect switch handle.
3. Install a seal type conduit fitting and conduit into the motor
control junction box. This is the junction box with the visible
disconnect switch handle.
4. Pull 400 Hz power leads, interlock safety wires, and remote reel
control wires through conduit and into the power junction box.
5. Terminate the 400 Hz power leads in the large terminal block as
labeled.
6. Terminate the smaller wires in the small terminal strip as
labeled. This is a cage clamp type terminal strip. To insert the
wires, insert a narrow straight bit screw driver in the slot above
the wire entrance and press firmly with the screw driver. This
will release the clamp spring. You must hold pressure on the
screw driver while inserting the wire.
7. Terminate the motor power leads at terminals L1, L2, and L3 of
the rotary disconnect switch.
8. Terminate the ground lead into the ground wire connector. This
connector can be identified with the green/yellow wires that all
terminate in it. To connect the wire, strip the insulation off the
end of the wire about .25-.38 inches (6-10mm) and push the
wire into an open hole of the connector. When inserted fully
you will be able to see the wire strands through the clear cover
on the opposite side of the connector. The wire can not be
removed once inserted.
9. Close both junction box lids, ensuring that the disconnect
handle rod engages into the disconnect handle on the motor
control junction box, and secure the latching screws.
10. Reinstall the junction box cover panel and the mounting
screws.

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SECTION 5 - OPERATION
Initial Operation
The reel is factory programmed to the operating specifications
given for the installation intended, no further programming is
required for initial start up.
The reel is equipped with an electronically controlled brake motor.
Do not attempt to extend the cable or pull the cable from the reel
by any means other than the reel control buttons. Doing so will
cause damage to the reel and result in undesirable operation. The
reel is usually shipped with the cable in a fully retracted position.
1. Turn on the motor power and control power to the reel.
2. Rotate the rotary disconnect handle on the motor control junc-
tion box from the OFF to the ON position.
3. Allow 30 seconds for the electronic controls to boot up.
4. Press the DOWN button on the power cable head. The reel will
start to extend the cable. Release the button to stop the reel if
needed.
5. Hold the DOWN button until the reel stops automatically. Be
sure to manually pull the cable across the ground so it does not
tangle in a pile on the ground.
6. Ensure that a minimum of one full wrap of cable is left on the
spool drum after full extension. If less than one full wrap is left
on the drum, consult the factory.
7. Press the UP button on the power cable head. The reel will
retract the cable. Again, release the button to stop the reel if
needed.
8. Hold the UP button until the reel stops automatically.
WARNING
If the reel does not stop before 2 feet (.6m) of cable is left
outside the reel, release the UP button so the reel does not
retract the power cable head into the roller guide. Consult
factory to determine why the reel did not stop.
9. The reel is now fully operational.
General Operation
1. Turn rotary disconnect switch to ON.
2. Press and hold the DOWN button on the power cable head or
at a remote control location to extend the cable. Release the
DOWN button to stop the reel. The reel will stop automatically
when it reaches the maximum extension length of the cable.
3. Press and hold the UP button on the power cable head or at
a remote control location to retract the cable. Release the UP
button to stop the reel. The reel will stop automatically when it
reaches the cable storage length.
NOTE: The reel is equipped with a drive overload detection
system. When the reel detects an overload situation, typically
caused by an obstruction of the cable movement, the reel
will automatically stop all motion and will be disabled for 30
seconds. If the reel does not run or is running and stops and
will not restart, check for obstructions or pinch points on the
cable.

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SECTION 6- MAINTENANCE & REPAIR
Mechanical Components
Cable Replacement
WARNING
The replacement cable must be exactly the same length as
the original cable in order to ensure proper operation of the
reel and prevent damage to the reel or cable.
1. Extend the cable to the end limit.
2. Disconnect all power sources to the reel following required
lock-out tag-out procedures.
3. Remove the access panel from the reel. This is the panel
mounted to the large face of the reel opposite of the mounting
side. It is held in place by eight M6 bolts.
4. Remove the eight M6 nuts securing the slip ring cover and the
slip ring cover.
5. Record all wire identifications and termination locations.
Disconnect the large power lead connections at the slip ring
brush buss bar points.
6. Disconnect the control wires from the terminal block. To do
this insert a narrow straight bit screwdriver into the slot above
the wire entrance. Press firmly with the screw driver. This will
release the connector.
7. Loosen the watertight gland nut where the cable enters the slip
ring enclosure.
8. Clamping the cable to the reel is one P-shaped clamp on the
inside of the spool drum and one U-bolt that clamps the cable
to a spool spoke. Look through the access panel and locate the
P-shaped clamp.
9. Remove the M6 nut of the P-shaped clamp and M10 U-bolt
retaining the cable.
10. Slip the cable out of the slip ring enclosure entrance, through
the spool drum opening, out the stacker wheel guide, and out
of the cable guide.
11. Insert new cable by threading the cable through the cable
guide assembly and stacker wheel assembly.
12. Feed the cable around the spool drum to the spool drum
opening. Make sure the cable is between the spool drum
surface and each of the rollers and not over the outside of any
roller.
13. Pass the cable through the spool drum opening.
14. Slip the watertight gland nut, then thrust washer, and finally
the gland onto the end of the cable.
15. Insert the end of the cable into the slip ring enclosure.
16. Terminate the control wires in the reverse order of removal.
Install the control wires into the terminal strip in the same
manner that the old ones were removed.
17. Insert the watertight gland into the watertight body and follow
with the thrust washer and gland nut.
18. Tighten the watertight gland nut.
19. Make a gradual transition loop of cable from the slip ring
entrance to the spool drum opening.
20. Clamp the cable in place to a spool spoke using the M10
U-bolt.
Note: Use caution to ensure there is clearance between
the cable or U-bolt and the top of the motor when the spool
rotates. Also, do not over tighten the U-bolt. Over tightening
will cut the cable or damage the conductors. This U-bolt,
in combination with the short section of cable between the
U-bolt and slip ring entrance, serve as the drive arm for
the slip ring. Ensure that the U-bolt is positioned 10 inches
(254mm) or closer to the slip ring entrance to avoid excessive
stress on the cable.
21. Reinstall the P-shaped clamp on the M6 stud in the spool
drum.
22. Reinstall the slip ring cover.
23. Reinstall the side panel.
24. Reinstall the access panel.
25. Turn on the power to the cable reel.
26. Press the IN button and check the running limits of the
reel. They should not have changed. If the retraction limit
is different than previously, the new cable length may be
different than the old cable.
Cable
Entrance
Slip Ring Brush Buss Bar
U-Bolt
Spool Drum Opening
Control Wire
Terminal
P-Shaped Clamp

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SECTION 6 - MAINTENANCE & REPAIR
Chain Circuit Inspection
1. Disconnect all power sources to the reel following required
lock-out tag-out procedures.
2. Remove the access panel from the reel. This is the panel
mounted to the large face of the reel opposite of the mounting
side. It is held in place by eight M6 bolts.
3. The drive chain is located behind the slip ring cover and spool
spokes but is in plain view. Observe the straight sections of
the chain spanning between the motor sprocket and the spool
sprocket. One side will have tension on it while the other side
will have slack.
4. Check the lateral movement of the slack side of the chain.
You should be able to move the chain between 0.25 and 0.75
inches (6-20mm). If the lateral movement exceeds 0.75 inch
(20mm), the chain needs to be tightened. Proceed to next
section. If the lateral movement is within the specified range,
no adjustment is necessary; replace access panel.
M10 Jack Screw
M10 Mounting Bolts
Spool Sprocket Lateral Movement
Motor
Limit Switch
Chain Tension Adjustment
1. Disconnect all power sources to the reel following required
lock-out tag-out procedures.
2. Remove the access panel as described in the previous
procedure if not already done.
3. Loosen the four M10 bolts that mount the motor mount bracket
to the reel frame. Be careful not to allow the chain to loosen
such that it jumps sprocket teeth. This will allow the spool to
rotate and may cause injury.
4. Loosen the two M10 bolts that hold the limit switch bracket to
the motor mounting bracket.
5. Turn the M10 motor jack screw clockwise to tighten the chain.
Check the lateral movement of the loose side of the chain. You
should be able to move the chain 0.25inches (6mm). If the
lateral movement exceeds 0.25 inches (6mm), continue turning
the jack screw in a clockwise direction.
6. Retighten the four M10 bolts to hold the motor in the new
location.
7. Adjust the limit switch bracket until the sprocket fully engages
the drive chain. Be careful to avoid using the limit switch or
bracket to apply tension to the drive chain. Tighten the two
M10 bolts to hold the limit switch in position.
8. Replace the access panel.
Motor Replacement
1. Disconnect all power sources to the reel following required lock-
out tag-out procedures.
2. Remove the access panel from the reel. This is the panel
mounted to the large face of the reel opposite of the mounting
side. It is held in place by eight M6 bolts.
3. Remove the eight M6 nuts securing the slip ring cover and
remove the slip ring cover.
4. Secure the spool and cable so that the spool can not rotate.
Once the chain has been removed the spool is free to rotate.
This could allow the cable to free spool off of the reel. Such un-
controlled motion can be dangerous and could cause personal
injury or damage to the reel.
5. Loosen the four M10 bolts that mount the motor mount bracket
to the reel frame.
6. Loosen the two M10 bolts that hold the limit switch bracket to
the motor mounting bracket. Remove the nylon block mounted
between the chain and the limit switch bracket.
7. Turn the M10 motor jack screw in a counter clockwise direction
and slide the motor in the slotted holes of the reel frame toward
the spool shaft to loosen the chain.
8. Remove the chain from the motor sprocket.
9. Open the motor junction box and disconnect the three power
leads, two brake lead wires, and one ground wire. Mark or
record which power lead is hooked to which motor leads as this
may vary for different applications.
10. Support the motor and remove the four M10 bolts previously
loosened to remove the chain.
11. Remove the motor and mounting bracket between the spool
spokes and along side the slip ring. Be careful not to hit the
slip ring or dislocate the slip ring brushes.
12. Remove the four M12 bolts that attach the motor to the motor
mount bracket.

PBL400 MOTORIZED CABLE REEL MANUAL
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19
SECTION 6 - MAINTENANCE & REPAIR
Motor Replacement (continued)
13. Install the motor mount bracket onto the new motor.
14. Measure the distance of the chain sprocket from the motor
gearbox.
15. Remove the chain sprocket from the old motor output shaft
and install on the new motor in the same position relative to
the gearbox. Apply a thread locking compound to the sprocket
set screws and ensure the set screws are installed to the
proper torque.
16. Mount the new motor in reverse order of removing the old
motor then follow the Chain Tension Adjustment section to set
the chain tension, and Extension and Retraction Limit Changes
section to reset the cable end limits.
Stacker Wheel Assembly Inspection
1. Disconnect all power sources to the reel following required
lock-out tag-out procedures.
2. Remove the eight M6 screws along the outer edge of the reel,
for the side panel adjacent to the cable entrance, and the side
panel.
3. Check the condition of the guide rollers where the cable passes
through as well as the drive roller on the outside of the roller
box. Look for excessive wear or damage to these rollers. Verify
that the rollers all turn freely.
4. Check the steel cable that connects the gas spring to the frame
and the guide head for damaged sections.
5. Check the cable pulley to ensure it still rolls freely.
6. Check for loose or missing hardware.
7. If any of the above components except the guide rollers are
damaged, replace the entire stacker wheel assembly.
8. Check the gas spring to ensure it still provides enough force to
hold the guide head firmly against the previous wrap of cable on
the spool and that the gas spring has not been bent. Look for
signs of oil leaking from the gas spring.
9. If the gas spring shows signs of damage or weakening but the
other components of the stacker assembly look good, you may
replace only the gas spring.
Stacker Wheel Guide Roller Replacement
1. Disconnect all power sources to the reel following required lock-
out tag-out procedures.
2. Remove the eight M6 screws along the outer edge of the reel,
for the side panel adjacent to the cable entrance, and the side
panel.
3. Reach through the cable guide opening with one wrench and
through the side that the panel was removed from and remove
the M6 screw and nut that hold the roller retainer block in place
for each corner of the roller guide.
4. Remove the worn or damaged rollers and axle(s).
5. Place the new axle(s) and rollers in the retainer block.
6. Reinstall the retainer block on the guide head frame.
7. Reinstall the side panel.
Stacker Wheel Assembly
Stacker Mounting Bolts
Stacker Mounting
Bolts
Mounting Bolts
Retainer Block
Open Side
Guide Rollers
Mounting Bolts
Gas Spring
Yoke
Steel Cable
Cable Pulley
Ram of Gas Spring
Drive Roller

PBL400 MOTORIZED CABLE REEL MANUAL XA-970200.6 | 03.01.21
20
Roller Guide Replacement
1. Disconnect all power sources to the reel following required
lock-out tag-out procedures.
2. Remove the three M6 screws along the outer edge of the reel,
for the small side panel covering the cable entrance, and the
side panel.
3. Continue to the following sections for appropriate repair being
performed.
SECTION 6 - MAINTENANCE & REPAIR
Stacker Wheel Assembly Replacement
1. Extend the cable to the end limit.
2. Disconnect all power sources to the reel following required lock-
out tag-out procedures.
3. Remove the eight M6 screws along the outer edge of the reel,
for the side panel adjacent to the cable entrance, and the side
panel.
4. One side of the guide head frame is open to allow the cable to
pass through. Remove the two M6 retainer block screws and
nuts that hold the guide roller over the open guide head frame
side.
5. Remove the two retainer blocks, the guide roller, and guide roller
axle from the open frame side. Note: The adjacent two rollers
and roller axles may become loose with the retainer blocks re-
moved. If these parts are loose, remove them as well to prevent
dropping the parts into the reel.
6. Remove the six M8 bolts that mount the stacker wheel assem-
bly frame between the reel main panels.
7. Slip the cable out of the guide head through the opening and
pull the stacker assembly out of the reel.
8. Install the new stacker wheel assembly in the reverse order.
9. Ensure the stacker drive roller is on the outside of the last wrap
of cable next to the wrap that is currently being placed on the
spool.
10. Check that the clearance between the stacker drive wheel and
the spool drum in not more than ½ inch (12mm).
11. Replace all the reel panels, reconnect the power, and retract
the cable.
Guide Rollers
Frame
Mounting BoltsFrame Axle Bolts
Mounting Bolts
Stacker Wheel Spring Replacement
1. Extend the cable to the end limit.
2. Disconnect all power sources to the reel following required lock-
out tag-out procedures.
3. Remove the eight M6 screws along the outer edge of the reel,
for the side panel adjacent to the cable entrance, and the side
panel.
4. The end of the gas spring that mates with the frame assembly
has a threaded stud but is simply inserted into a clearance hole.
Use a small pry bar or a large straight bit screwdriver to pry the
base part of the spring out of the hole.
5. Tip the base end of the gas spring away from the frame and lift
the spring and pulley assembly out of the cable.
6. The ram end of the gas spring also has a threaded stud which
is threaded into the yoke and pulley assembly. Unscrew the
yoke and pulley assembly from the gas spring.
7. Screw the yoke and pulley assembly onto the ram end of the
new gas spring. Tighten the joint by hand but do not use a
wrench to tighten. If needed, use a locking pliers to hold the
ram of the gas spring but it must be used only on the shoulder
right next to the yoke. Damage or scoring on the ram surface
will cause the gas spring to leak and fail prematurely.
8. Place the pulley into the steel cable near the guide head as-
sembly like it was when removed.
9. Using a small pry bar or large straight bit screwdriver, compress
the spring against the steel cable. Use caution not to bend the
spring ram.
WARNING
The gas spring has a limited extension rate however it is still
a source of stored energy and must be handled with care.
10. While compressing the spring manipulate the base end onto
the frame block, then slide it over until the threaded stud drops
into the clearance hole.
11. Replace the reel side panel, reconnect the power, and retract
the cable.
Guide Roller Inspection
1. Disconnect all power sources to the reel following required
lock-out tag-out procedures.
2. Check the condition of the guide rollers where the cable passes
through. Look for excessive wear on the roller surfaces as well
as the bearings.
3. Check to see that all the rollers rotate freely.
4. Check for loose or missing hardware.