Magnetek G Series User manual
Motorized Cable Reel
Technical Manual
Type Series G
Part Number: 121-58068 R00
September 2021
© Copyright 2021 Magnetek
Motorized Cable Reel Technical Manual
September 2021
Page 3 of 86
SERVICE INFORMATION
For questions regarding service or technical information contact:
1.866.MAG.SERV
(1.866.624.7378)
International Service
Outside the U.S. and Canada call 1.262.783.3500, press 3.
Columbus McKinnon Corporation
Magnetek
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051 USA
Telephone: 800.288.8178
E-mail: field.service@magnetek.com
Fax Numbers:
Main:800.298.3503
Sales:262.783.3510
Service: 262.783.3508
Canada Service Information:
161 Orenda Road
Unit 1
Brampton, Ontario
L6W 1W3 Canada
Telephone: 800.792.7253
Fax: 905.828.5707
416.424.7617 (24/7 Service pager)
Website
www.columbusmckinnon.com/magnetek
© 2021 Columbus McKinnon Corporation
All rights reserved. This notice applies to all copyrighted materials included with this product, including, but
not limited to, this manual and software embodied within the product. This manual is intended for the sole
use of the person(s) to whom it was provided, and any unauthorized distribution of the manual or dispersal
of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means
whatsoever without the expressed written permission of the Columbus McKinnon Corporation.
Motorized Cable Reel Technical Manual
September 2021
Page 4 of 86
PREFACE AND SAFETY
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products,
adjustable frequency drives, and industrial braking systems for material handling applications. This manual
has been prepared by Magnetek to provide information and recommendations for the installation, use,
operation and service of Magnetek’s material handling products and systems (Magnetek Products).
Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should know,
understand and follow the instructions and safety recommendations in this manual for Magnetek Products.
The recommendations in this manual do not take precedence over any of the following requirements
related to cranes, hoists, lifting devices or other material handling equipment which use or include
Magnetek Products:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
Magnetek Products are used,
• Plant safety rules and procedures of the employers and the owners of the facilities where the
Magnetek Products are being used,
• Regulations issued by the Occupational Health and Safety Administration (OSHA),
• Applicable local, state or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the industries in which Magnetek Products are used.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users
and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the
responsibility of the employer to make its employees aware of all of the above listed requirements and to
make certain that all operators are properly trained. No one should use Magnetek Products prior to
becoming familiar with and being trained in these requirements and the instructions and safety
recommendations for this manual.
Product Warranty Information
Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a
drive by untrained personnel. A drive should only be programmed by a trained technician who has read
and understands the contents of this manual. Improper programming of a drive can lead to unexpected,
undesirable, or unsafe operation or performance of the drive. This may result in damage to equipment or
personal injury. Company shall not be liable for economic loss, property damage, or other consequential
damages or physical injury sustained by the purchaser or by any third party as a result of such
programming. Company neither assumes nor authorizes any other person to assume for Company any
other liability in connection with the sale or use of this product.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK’S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE
VISIT WWW.COLUMBUSMCKINNON.COM/MAGNETEK.
WARNING
Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or
performance of the drive.
Motorized Cable Reel Technical Manual
September 2021
Page 5 of 86
DANGER, WARNING, CAUTION and NOTE Statements
Read and understand this manual before installing, operating or servicing this product. Install the product
according to this manual and local codes.
The following conventions indicate safety messages in this manual. Failure to heed these messages could
cause fatal injury or damage products and related equipment and systems.
DANGERS, WARNINGS and CAUTIONS
Throughout this document DANGER, WARNING and CAUTION statements have been deliberately placed
to highlight items critical to the protection of personnel and equipment.
NOTE: A NOTE statement is used to notify people of installation, operation, programming or maintenance
information that is important, but not hazard-related.
DANGERS, WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.
Registered Trademarks
Trademarks are the property of their respective owners.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the most extreme situations.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury. It may also be used to alert against unsafe practices.
Motorized Cable Reel Technical Manual
September 2021
Page 6 of 86
Table of Contents
1 About this document .............................................................................................................................9
1.1 Revision index .............................................................................................................................. 9
1.2 Applicable documents ..................................................................................................................9
1.3 Additional information.................................................................................................................10
1.4 Symbols and markings ...............................................................................................................11
2 Safety..................................................................................................................................................12
2.1 Intended use...............................................................................................................................12
2.2 Duties of the operator.................................................................................................................12
2.2.1 Personal protective equipment ..............................................................................................13
2.2.2 Personnel...............................................................................................................................13
2.2.2.1 Electrician ..................................................................................................................... 13
2.2.2.2 Qualified personnel .......................................................................................................13
2.2.2.3 Instructed personnel .....................................................................................................14
2.2.3 Installation and operation.......................................................................................................14
2.2.4 Maintenance ..........................................................................................................................14
2.2.5 Conversion.............................................................................................................................14
2.2.6 Disposal .................................................................................................................................14
2.3 Markings on the device ..............................................................................................................15
2.4 Residual risks .............................................................................................................................15
2.4.1 Electric current.......................................................................................................................15
2.4.2 Rotation .................................................................................................................................16
2.4.3 Reeling cable ......................................................................................................................... 16
2.4.4 Swinging loads.......................................................................................................................16
2.4.5 Hot surfaces........................................................................................................................... 16
2.4.6 Gear oil ..................................................................................................................................16
3 Description..........................................................................................................................................17
3.1 Type key..................................................................................................................................... 17
3.1.1 Spiral version .........................................................................................................................17
3.1.2 Cylindrical version.................................................................................................................. 17
3.2 Layout.........................................................................................................................................18
3.2.1 Spiral version .........................................................................................................................18
3.2.2 Cylindrical version.................................................................................................................. 19
3.3 Function......................................................................................................................................19
3.4 Device usage types ....................................................................................................................19
3.4.1 Vertical power supply.............................................................................................................20
3.4.2 Horizontal power supply ........................................................................................................20
4 Transport and storage ........................................................................................................................22
4.1 Checking the delivery .................................................................................................................22
4.2 Transporting the device.............................................................................................................. 22
4.3 Storing the device.......................................................................................................................23
5 Installation........................................................................................................................................... 24
5.1 Installing the device in its installation location ............................................................................25
5.2 Installing the drive unit and reel body in the installation location................................................25
5.2.1 Installing the drive unit ...........................................................................................................25
5.2.2 Assembling the reel body ......................................................................................................26
5.2.3 Installing the reel body on the drive unit ................................................................................28
5.2.3.1 Terminal strip cable enclosure ...................................................................................... 30
5.2.4 Removing the transport lock ..................................................................................................32
6 Electrical installation ...........................................................................................................................33
6.1 Layout of the slip ring assembly .................................................................................................34
Motorized Cable Reel Technical Manual
September 2021
Page 7 of 86
6.1.1 Blocked version .....................................................................................................................34
6.1.2 Air gap version .......................................................................................................................35
6.2 Spiral version.............................................................................................................................. 36
6.2.1 Dismantling the blocked slip ring assembly ........................................................................... 36
6.2.2 Installing the blocked slip ring assembly and electrically connecting it.................................. 37
6.2.3 Connecting the reeling cable to the terminal strip..................................................................40
6.2.4 Disassembling the air gap slip ring assembly........................................................................41
6.2.5 Installing the air gap slip ring assembly and electrically connecting it ................................... 42
6.2.6 Connecting the reeling cable to the terminal strip..................................................................45
6.3 Cylindrical version ......................................................................................................................46
6.3.1 Disassembling the blocked slip ring assembly ...................................................................... 46
6.3.2 Installing the blocked slip ring assembly and electrically connecting it.................................. 47
6.3.3 Connecting the reeling cable to the terminal strip..................................................................50
6.3.4 Disassembling the air gap slip ring assembly........................................................................51
6.3.5 Installing the air gap slip ring assembly and electrically connecting it ................................... 52
6.3.6 Connecting the reeling cable to the terminal strip..................................................................55
6.4 Connecting the permanently routed cable to the brush holders................................................. 56
6.5 Gear cam limit switch (optional) ................................................................................................. 57
6.6 Heater (optional)......................................................................................................................... 58
7 Commissioning ................................................................................................................................... 59
7.1 Aligning the device .....................................................................................................................59
7.1.1 Spiral version .........................................................................................................................59
7.1.2 Cylindrical version.................................................................................................................. 59
7.2 Test run ......................................................................................................................................60
7.3 Checks during commissioning....................................................................................................60
8 Operation ............................................................................................................................................ 61
8.1 Operating the device according to intended use ........................................................................61
8.1.1 Malfunctions...........................................................................................................................61
8.2 Manual operation of the device ..................................................................................................61
9 Maintenance ....................................................................................................................................... 62
9.1 Manual mode.............................................................................................................................. 63
9.1.1 Button .................................................................................................................................... 63
9.1.2 Manual ventilation..................................................................................................................63
9.2 Maintenance intervals ................................................................................................................64
9.3 Device cleaning and care ...........................................................................................................65
9.4 Exchanging the reeling cable .....................................................................................................66
10 Fault....................................................................................................................................................67
11 September 2021 motor ....................................................................................................................... 70
12 Permanent magnetic coupling ............................................................................................................71
13 Gearbox ..............................................................................................................................................72
13.1 Design ........................................................................................................................................72
13.1.1 Symbols .................................................................................................................................72
13.2 Gear oil quantity .........................................................................................................................73
13.3 Inspecting the gear oil ................................................................................................................73
13.4 Checking the quality ...................................................................................................................74
13.5 Checking the gearbox for leaks..................................................................................................75
13.5.1 Topping off the gear oil .......................................................................................................... 75
14 Spare parts drawing............................................................................................................................76
14.1 Spiral version..............................................................................................................................76
14.2 Cylinder version..........................................................................................................................77
14.3 Slip ring assembly ...................................................................................................................... 78
15 Disassembly ....................................................................................................................................... 79
15.1 Disassembling the complete device ...........................................................................................79
15.2 Disassembling the device into individual components ...............................................................79
Motorized Cable Reel Technical Manual
September 2021
Page 8 of 86
16 Disposal and recycling........................................................................................................................80
17 Appendix.............................................................................................................................................81
17.1 Cable screw connection .............................................................................................................81
17.2 Tightening torques......................................................................................................................82
17.2.1 Gear plate ..............................................................................................................................82
17.2.2 Reel flange Nord-Lock®wedge-locking washers...................................................................82
17.2.3 Slip ring assembly..................................................................................................................83
17.2.4 Motor terminal board connection ...........................................................................................83
17.3 Replacing the brush holders....................................................................................................... 84
Motorized Cable Reel Technical Manual
September 2021
Page 9 of 86
1 About this document
These operating instructions are part of the device. In this document, the term “device” refers to the
product “motorized cable reel”, type series G.
XThe operating instructions:
– must be carefully read and observed when performing any kind of work on and with the device;
– must be included in the documentation of the higher-level system when installing the device;
– must be handed over to the new owner if there is a change of ownership of the device.
1.1 Revision index
1.2 Applicable documents
XIn addition to observing these operating instructions, observe the following:
– Installation instructions for the permanent magnetic coupling
– Motor supplier documentation
– Limit switch supplier documentation
– Data sheet for heater
Date Version Revision Note
23/02/2017 V1 First edition
01/08/2017 V2
• Adjustment of warning notes according to ANSI
Z535
• Adjustments according to in-house terminology
• Revised Section “Symbols and Markings”
• Revised Section “Electrical installation of the
device”
• Revised Section “Spare parts drawing”
• Removed Section “Commissioning the device”
29/05/2019 V3
• Change of structure
• Change of layout
• Change of content
15/10/2020 V4
• Revised Section “Maintenance”
Added “Manual ventilation on motor”
• Revised Section “Electrical installation”
Added “Gear cam limit switch (optional)”
Added “Heater (optional)”
Motorized Cable Reel Technical Manual
September 2021
Page 11 of 86
1.4 Symbols and markings
The following symbols and markings are used in these operating instructions:
Symbol Signal Word Meaning
DANGER A danger that will result in serious injuries or
death.
WARNING A danger that may result in serious injuries or
death.
CAUTION A danger that may result in minor or moderate
injuries
NOTICE A note that helps avoid property damage.
INFORMATION A note that facilitates general understanding
or serves to improve workflows.
Marking Meaning
• Bulleted list
pCross-reference
1
2
3
Key
[---]
Additional information
• to a component
• Instructions or
• a legend
3Prerequisite for an action
XAction instruction
– Subordinate action instruction
1.
2.
3.
Action instruction sequence
Action result
Motorized Cable Reel Technical Manual
September 2021
Page 12 of 86
2 Safety
Operators and maintenance personnel must follow all operating instructions and safety and warning
procedures before working on and with this device.
►The operating instructions:
– must be carefully read;
– must be kept in the immediate vicinity of the device.
2.1 Intended use
The device supplies a mobile unit with electricity, and is either fixed or installed on a mobile unit.
►Keep the device in proper operating condition.
►Observe the operating instructions and additional information.
Consider other uses (for example, all kinds of load movement) unintended use.
2.2 Duties of the operator
Read, understand and observe the operating instructions, in particular the safety chapter, |page 12
when performing all kinds of work on and with the device.
►When operating the device, always consider the following documents and regulations:
• Operating instructions
• Applicable documents
• Additional information
• Local regulations: laws, standards and directives
►Observe the five safety rules for all work on the device:
– Disconnect the device from the power supply.
– Secure the device against reactivation.
– Establish a voltage-free state.
– Ground and short-circuit the device.
– Cover or fence off any adjacent parts with a voltage barrier.
Motorized Cable Reel Technical Manual
September 2021
Page 13 of 86
2.2.1 Personal protective equipment
►Wear the following items before operating the device:
2.2.2 Personnel
Using this device requires basic electrical and mechanical knowledge.
►Only qualified and/or trained personnel should carry out these tasks.
►Obtain regular training on the device.
The following table lists specific tasks and the corresponding level of training required for personnel to
perform that task:
2.2.2.1 Electrician
Electricians have completed professional training. They also have demonstrated knowledge of and
experience with electrical systems. In addition, they know relevant standards and regulations, can
competently perform assigned tasks, and can detect and avoid hazards.
2.2.2.2 Qualified personnel
Qualified personnel have completed training. They have also demonstrated knowledge and experience. In
addition, they know relevant standards and regulations, can competently perform assigned tasks, and can
detect and avoid hazards.
Safety goggles Safety shoes
Hard hat Safety harness/fall-arresting
device
Safety gloves
Specific Task Level of Training Required
Transport Instructed personnel
Installation Qualified personnel
Electrical installation Electrician
Commissioning Qualified personnel
Operation Instructed personnel
Decommissioning Qualified personnel
Maintenance Electricians / qualified personnel
Troubleshooting Electricians / qualified personnel
Dismantling Qualified personnel
Disposal Instructed personnel
Motorized Cable Reel Technical Manual
September 2021
Page 14 of 86
2.2.2.3 Instructed personnel
Instructed personnel have been trained by qualified personnel. Instructed personnel can perform assigned
tasks and avoid known dangers.
2.2.3 Installation and operation
►Carefully read the operating instructions before installing and operating the device.
►Observe the safety and warning notes.
►Observe the markings on the device.
►Replace or clean missing and illegible markings.
►Observe the five safety rules (|page 12) while installing the device.
►Only operate the device in proper technical conditions.
►If the device fails to operate properly, shut it down and resolve the problem.
2.2.4 Maintenance
Regularly maintaining the device can contribute to optimal performance and help boost its safety and
reliability.
►Resolve all technical problems as soon as you discover them.
►While maintaining this device, only replace parts on the device using the same parts or the same parts
of the original device.
2.2.5 Conversion
Improperly converting the device may lead to injury and/or property damage.
►Contact customer service before performing any conversions of the device.
►While converting this device, only replace parts on the device using the same parts or the same parts
of the original device.
2.2.6 Disposal
Improperly disposing device can lead to environmental damage.
►Dispose of parts and components as required by local regulations.
Motorized Cable Reel Technical Manual
September 2021
Page 15 of 86
2.3 Markings on the device
The following markings appear on the surface of the device for information purposes and to prevent injury
and/or property damage.
2.4 Residual risks
Operating this device without becoming familiar with its operating instructions and safety procedures poses
risk of personal injury and/or property damage. Note that operators who follow the operating instructions
and safety procedures for this device will reduce the risk (but not all of the risk) of personal injury and/or
property damage.
2.4.1 Electric current
An electric current powers this device. To avoid death by shock and other personal injuries, never touch
electrically conductive components on this device.
►Observe the five safety rules (|page 12).
►Check the electrical insulation of the device.
►Check the protective conductor system for electrical continuity.
►Do not use the PE protective conductor system as a PEN system.
►Observe EN, VDE and locally applicable safety regulations.
Marking Meaning
The rating plate identifies the device and contains the
specifications.
Unwinding direction of the device (right).
Unwinding direction of the device (left).
Danger due to electric current.
Motorized Cable Reel Technical Manual
September 2021
Page 16 of 86
2.4.2 Rotation
The reel body of the device rotates during operation. Limbs can be crushed and/or severed if a person
reaches or places limbs and other body parts inside the rotating reel body. Note that crushing and severing
injuries also pose a serious risk of death.
►Secure the working range of the device against unauthorized access.
►Wear personal protective equipment.
►Train operators and maintenance personnel about the risks of reel body rotation associated with this
device, the need for keeping limbs away from the device, and the importance of using good judgment.
2.4.3 Reeling cable
The reeling cable of the device may tear, fall off or move uncontrollably during operation. Limbs may be
drawn in and get caught when winding the reeling cable. Note that crushing and severing injuries also
pose a serious risk of death.
►Operate the system with the installed safety device in the area of the reeling cable.
►Secure the working range of the device against unauthorized access.
►Wear personal protective equipment.
►Train operators and maintenance personnel about the risks associated with the reeling cable on this
device, the need for keeping limbs away from the device, and the importance of using good judgment.
Always leave two safety windings for strain relief on the device.
2.4.4 Swinging loads
Loads sometimes swing when operators lift the device. Lifting the device while the load is swinging can
pose some risk of death or personal injury.
►Keep people out of the range of swinging loads.
►Always use recommended lifting and transport gear.
2.4.5 Hot surfaces
The surfaces of drive components (gearbox, permanent magnetic coupling and motor) may reach high
temperatures during operation. Avoid touching hot surfaces, which could burn protected and unprotected
skin.
►Wear personal protective equipment.
►Allow the drive components to cool to room temperature before touching them.
2.4.6 Gear oil
Skin contact with gear oil may cause rashes and health problems.
►Wear personal protective equipment.
►Immediately wash (using water) any skin that has come into contact with gear oil.
►Observe the safety instructions of the oil manufacturer.
Leaked oil may lead to serious accidents.
►Immediately remove leaked oil with a suitable binder.
►Dispose of gear oil and any binder as required by local regulations.
Motorized Cable Reel Technical Manual
September 2021
Page 17 of 86
3 Description
The device supplies a mobile unit with electricity, and is either fixed or installed on a mobile unit. Typical
applications include:
• Ship cranes
• Container cranes
• Gripper and magnetic systems
• Hall cranes
• Light and stagecraft
3.1 Type key
The type key identifies the device and appears on the rating plate.
3.1.1 Spiral version
G2-M7-T12231-36P7-IP55 (example)
G2 bevel gear, size 2
M7 permanent magnetic coupling, size 7, 1.5 kW brake motor
T12231 reel body: 1,200 inner diameter / 2,300 external diameter / 1 winding chamber
36P7 36 A / 7-pole
IP55 protection class
3.1.2 Cylindrical version
G2-M7-T03001-36P7-IP55 (example)
G2 bevel gear, size 2
M7 permanent magnetic coupling, size 7, 1.5 kW brake motor
T03001 reel body: 300 inner diameter / 1 winding chamber
36P7 36 A / 7-pole
IP55 protection class
Motorized Cable Reel Technical Manual
September 2021
Page 18 of 86
3.2 Layout
3.2.1 Spiral version
Figure 1 Device layout, spiral version
1 Drive unit with bevel gear, permanent magnetic coupling, and motor
2 Reel body with reeling cable
3 Cable enclosure with slip ring assembly (optional with accessories)
4 Covering hood
Motorized Cable Reel Technical Manual
September 2021
Page 19 of 86
3.2.2 Cylindrical version
Figure 2 Device layout, cylindrical version
1 Drive unit with bevel gear, permanent magnetic coupling, and motor
2 Reel body with reeling cable
3 Cable enclosure with slip ring assembly (optional with accessories)
4 Covering hood
3.3 Function
The reeling cable winds onto the reel body using a motor. The reeling cable is kept under constant tensile
stress during operation. When the reeling cable unwinds from the reel body, it unwinds from the device
against the tensile stress. The motor brake prevents the reeling cable from unintentional unwinding when
the higher-level system is at a standstill or when the drive is in a voltage-free state.
3.4 Device usage types
The device supplies a mobile unit with electricity, and is either fixed or installed on a mobile unit.
INFORMATION
The arrows in the following illustrations show the directions for winding and unwinding
the reeling cable.
Motorized Cable Reel Technical Manual
September 2021
Page 20 of 86
3.4.1 Vertical power supply
• The reeling cable unwinds upwards or downwards from the fixed-mounted device.
3.4.2 Horizontal power supply
• The device is installed on a mobile unit, and the reeling cable connects to the fixed supply unit. The
cable is unwound by the mobile unit.
Figure 5 Cable unwinding, horizontal
• The device is fixed-mounted and the reeling cable unwinds in one direction by a mobile unit on which
the supply unit is located. Cable deposit occurs on cable deposit rollers.
Figure 6 Cable unwinding, horizontal with cable deposit rollers
Figure 3 Cable unwinding, vertically upwards Figure 4 Cable unwinding, vertically downwards
Table of contents
