Reelcraft L 4525 123 7a User manual

Operating Instructions

Series L 4000 Spring Driven Cord Reels

Reelcraft Industries, Inc. • 2842 E Business Hwy 30, Columbia City, IN 46725

Ph: 800-444-3134 / 260-248-8188 • Fax: 800-444-4587 / 260-248-2605

Customer Service: 855-634-9109 • [email protected] • www.reelcraft.com

Form# 542-290 Rev: 7/2021

WARNING: Even low voltage can cause irreparable damage or death!

Exercise extreme caution while operating or servicing this equipment.

IMPORTANT

Read this manual carefully before installing, operating or

servicing this equipment.

A13 1/4”

B12 5/8”

C 8”

D2 1/2”

E9 3/8”

F1 3/4”

Dimensions

Personal injury and/or equipment damage may

result if proper safety precautions are not

observed.

• Ensure that only a qualified electrician

installs/services this equipment.

• Ensure that power supply voltage does not

exceed maximum voltage rating of reel.

• Ensure that reel is properly installed before

connecting to power supply.

• All cord reels with flying leads must be hard

wired to ensure proper function.

• Ensure that all electrical power is removed

from reel before servicing.

• A high-tension spring assembly is

contained within the reel. Exercise extreme

caution.

• Check for frayed and/or broken wires before

each use. Pull electrical cord from reel by

grasping the electrical cord itself, not the

work device.

• If an electrical malfunction should occur,

remove power from reel immediately.

• Ensure that reel, electrical cord, and

equipment being serviced are properly

grounded. Use an ohmmeter to check

ground continuity.

• If reel ceases to unwind or rewind, remove

power immediately. Do not pull or jerk on

electrical cord!

• Treat and respect the reel as any other piece

of machinery, observing all common safety

practices.

Mounting

CAUTION: Unless reel was specified differently

when ordering, maximum installation height

is 16 feet. Do not exceed this distance. Ensure

that only a qualified electrician installs/services

this equipment. Installation of GFCI cord reels

should be performed by a qualified and licensed

professional in accordance with building codes

and applicable NEC standards.

1. Unpack and inspect reel for damage. Turn

by hand to check for smooth operation.

Check for completeness.

2. Configure reel for top, side or bottom-

wind (bottom-wind for constant tension

reels only) electrical cord dispensing by

removing bolts (1), securing guide arm

bracket (2). Determine new guide arm

location and remove corresponding bolts.

Position guide arm bracket to reel and

replace bolts.

3. Position reel on floor, wall, or ceiling.

Secure into place, using four (customer

supplied) screws or bolts (3).

Safety Precautions

Installation Instructions

L 4035 163 1 L 4545 123 3 L 4545 123 3BC L 4035 163 8 L 4545 123 X

L 4050 163 1 L 4545 123 3-RP L 4035 A 163 5 L 4050 163 8 L 4000

L 4035 162 2 L 4545 123 3A L 4050 A 163 5 L 4050 163 9 L 4100

L 4050 162 2 L 4545 123 3A-RP L 4545 123 7 L 4545 123 9 L 4500

L 4035 163 3 L 4545 123 3AC L 4525 123 7A L 4545 123 9G

L 4035 163 3-RP L 4525 123 3B L 4545 123 7A L 4035 163 10

L 4050 163 3 L 4525 123 3BC L 4545 123 7B L 4050 163 10

L 4050 163 3-RP L 4545 123 3B L 4545 123 7Q L 4050 163 X

Series L 4000 Spring Driven Cord Reels

Page 2 www.reelcraft.com

Installing the Input Electrical Cable

WARNING: Use only 12/3 or 16/3 cable for

input wiring. Ensure that application does not

exceed electrical rating of reel (refer to page 1

of this manual).

1. Feed input cable (1) through elbow (2)

and main shaft. Make sure that input

cable extends 6” from collector.

2. Screw elbow (2) into reel.

3. Connect input wires (3) and collector

ring wires (4) together using wire nuts

(5).

4. Take the provided zip tie (not pictured)

and zip tie the input cable wires together

closest to the slip ring.

5. Assemble cover (6) to reel.

Installing the Output

Electrical Cable

WARNING: Select output cable in accordance

with power requirement of apparatus to be

supplied. Ensure that application does not

exceed electrical rating of reel (refer to page

1 of this manual). Use extreme caution,

reel under tension. Avoid releasing latch

mechanism.

1. Manually turn sheave (1) until spring is

tight, back off 2 turns, and latch.

2. Remove access cover (2).

3. Remove 6” of output cable outer jacket

(3) and add fork terminals (4) to ends.

4. Route cable through strain relief (6), then

through cut out in spool (7).

5. Pull enough cable through for roughly

1/2 an inner wrap as shown in the

diagram.

6. Connect output wires to terminal block

(8) as shown.

7. Connect ground wire to grounding stud

(9) as shown.

8. Using Ohmmeter check for ground faults.

9. Take provided cable clamp (not pictured)

and attach it to the wire. Then take the

cable clamp and screw it down to the

brush assembly on the reel.

10. Replace cover (2).

11. Release latch and wind cable onto reel.

12. Install bumper stop (10).

Adjustments - Spring Tension

If necessary, adjust spring tension on reel by

adding or removing wraps of electrical cord

from spool, one wrap at a time, until desired

tension is obtained. Add wraps to increase

tension. Remove wraps to decrease tension.

WARNING: When adding wraps of electrical

cord, be careful not to exceed the winding

mechanism’s spring capacity. Add just enough

wraps of cord to achieve the desired tension.

Damage to the winding mechanism will result

if spring is over-tensioned. Always be aware

of spring tension on reel. Exercise extreme

caution.

Troubleshooting Instructions

Troubleshooting of the reel consists of

isolating a problem to a defective electrical

cord/work device, brush holder/brushes,

or collector assembly. Refer any other

discrepancies only to an authorized service

person or directly to Reelcraft.

WARNING: The following procedure directs

the technician to take voltage measurements.

Remember, even low voltage is dangerous and

can cause personal injury or death. Exercise

extreme caution! Ensure that only a qualified

electrician installs/services this equipment.

1. If work device is either an incandescent

or fluorescent light, replace bulb with a

known good bulb. If this does not correct

the problem, proceed to step 2. If work

device is an electrical receptacle, ensure

that tool or fixture connected to it is in

good working order. If it is, proceed to

step 2.

2. Remove power from reel.

3. Remove access cover (1).

4. Reapply power to reel.

5. Check for correct voltage (120 V AC)

at terminal strip (2). If voltage reading

is correct, replace output electrical

cord/work device (refer to Service

Instructions). If voltage reading is

incorrect, proceed to step 6.

6. Remove power from reel.

7. Using ohmmeter, check continuity of

input electrical cord. If cord checks

good, proceed to step 8. If cord is faulty,

replace it (refer to Service Instructions).

8. Remove brush holder/brushes from

reel and inspect (refer to Service

Instructions). Replace defective

components then proceed to step 9.

9. Reapply power to reel.

10. Check for correct voltage (120 V AC) at

terminal strip (2). If voltage reading is

still incorrect, replace defective collector

assembly (refer to Service Instructions).

11. Replace access cover (1).

Service Instructions

Maintain reel by following the service

instructions given below. Refer all other

repairs, other than those listed, only to

an authorized service person or directly

to Reelcraft. Failure to do so can result in

personal injury and/or equipment damage and

may void the warranty (refer to page 5 when

referencing parts).

WARNING: Remove power from reel

before performing any of the following

procedures.

Series L 4000 Spring Driven Cord Reels

www.reelcraft.com Page 3

Replacing the Output Electrical

Cord/Work Device

WARNING: Use extreme caution, reel under

tension. Avoid releasing latch mechanism.

1. Pull output electrical cord from reel until

fully extended, then latch.

2. Remove output electrical bumper stop

(7).

3. Disconnect output electrical cord/work

device (12) at terminal strip (10).

4. Remove strain relief (8). Remove output

electrical cord/work device.

5. Install replacement electrical cord/work

device by reversing steps 2 through 4.

6. Release latch and rewind electrical cord

on reel.

7. Replace access cover (1).

Replacing the Input Electrical Cord

1. Remove wire nuts (15) securing input

electrical cord to collector assembly (13).

2. Remove 90 degree elbow (9).

3. Remove input electrical cord.

4. Remove 11” of outer jacket from

replacement input electrical cord (input

electrical cord wires must protrude a

minimum of 6” from center of collector

assembly).

5. Install replacement input electrical cord

by reversing steps 1 through 3.

6. Replace access cover (1).

Replacing the Brush

Holder/Brushes

1. At terminal strip (10), remove wires

connecting brushes (11) to terminal strip.

2. Remove lock nuts (3) securing brush

holder (6) to reel. Relocate cable clamp

temporarily and remove brush holder.

3. Remove brushes (4) from brush holder

(6).

4. Install replacement brush holder/brushes

by reversing steps 1 through 3. Upon

completion of installation, adjust brush-

to-ring alignment by loosening nuts (5)

and sliding finger assembly (2).

Replacing the Collector Assembly

1. Remove wire nuts (15) securing input

electrical cord to collector assembly.

2. At terminal strip (10), disconnect wires

(11) connecting brushes (4) to terminal

strip.

3. Remove lock nuts (3) securing brush

holder (6) to reel. Relocate cable clamp

temporarily and remove brush holder.

4. Remove snap ring (14).

5. Remove collector assembly (13).

6. Install replacement collector assembly

by reversing steps 1 through 5. Upon

completion of installation, adjust brush-

to-ring alignment by loosening nuts (5)

and sliding finger assembly (2).

7. Replace access cover (1).

Autoswitch Operating Instructions

To operate Autoswitch reels, pull out and

retract cable as shown in the above diagram.

When cable is fully retracted, the reel is in the

“Off” position. As the cable is pulled out, the

guide arm pivots upward and the reel switches

to the “On” position.

Autoswitch Troubleshooting

Service Instructions

Maintain reel by following the service

instructions given below. Refer all other

repairs, other than those listed, only to

an authorized service person or directly

to Reelcraft. Failure to do so can result in

personal injury and/or equipment damage

and may void the warranty. If reel fails to

operate electrically, refer to troubleshooting

instructions on page 2. If problem persists,

check switch using the following steps.

1. Using a ohmmeter, check for continuity

between lines (1) and (2), while switch is

in the “On” or “Up” position.

2. If continuity test fails, replace switch (3).

3. If continuity test passes, check for inlet

cord (4) damage.

OFF

15 14 13 12

Series L 4000 Spring Driven Cord Reels

Page 4 www.reelcraft.com

Series L 4000 Spring Driven Cord Reels

www.reelcraft.com Page 5

Item

#Description #

Req. L 4035

163 1

L 4050

163 1

L 4035

162 2

L 4050

162 2

L 4035

163 3

L 4050

163 3

L 4545

123 3

L 4545

123 3A

L 4525

123 3B

1Incandescent Lamp/Cord

Assembly 1 600223 600212 None None None None None None None

2Fluorescent Lamp/Cord

Assembly 1 None None 600207 600211 None None None None None

3Duplex GFCI Box/Cord

Assembly 1 None None None None None None None None None

4Single Outlet 1 None None None None 600208 600209 600251 602003 602451-25

5Inlet Cord Assembly 1 260517 260517 600213 600213 260517 260517 260630 602003 602002

6Connector, 90° Cord 1 261140-1-C 261140-1-C 261140-1-C 261140-1-C 261140-1-C 261140-1-C 261140-C 261140-C 261140-C

7Screw, Set 3/8-19 x 1/2” Pin 1 300006 300006 300006 300006 300006 300006 300006 300006 300006

8Nut, Lock 10-32 Hex 22 S300011 S300011 S300011 S300011 S300011 S300011 S300011 S300011 S300011

9Snap Ring 1 300031 300031 300031 300031 300031 300031 300031 300031 300031

10 Springcase Stud 1 S261360 S261360 S261360 S261360 S261360 S261360 S261360 S261360 S261360

11 10-32 x 1/2” Screw 2 300002 300002 300002 300002 300002 300002 300002 300002 300002

12 Guide Arm Assembly 1 S400107 S400107 S400107 S400107 S400107 S400107 S400107 S400107 S400107

13 Bumper Assembly 1 600193 600193 600193 600193 600193 600193 1-HR1004-A 1-HR1004-A 1-HR1004-A

14 Spring Arbor 1 S400017 S400017 S400017 S400017 S400017 S400017 S400017 S400017 S400017

15 Latch Cam 1 S400019 S400019 S400019 S400019 S400019 S400019 S400019 S400019 S400019

16 Sheave Disc 1 400006 400006 400006 400006 400006 400006 400006 400006 400006

17 Strain Relief 1 260501 260501 260501 260501 260501 260501 260633 260633 260633

18 Plate Adapter 1 261577 261577 261577 261577 261577 261577 261577 261577 261577

19 Split Lock Washer 3 902016 902016 902016 902016 902016 902016 902016 902016 902016

20 1/4-20 x 5/8” Hex Screw 3 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42

21 Collector Ring Assembly 1 602296 602296 602296 602296 602296 602296 602296 602296 602296

22 Cover 1 261723 261723 261723 261723 261723 261723 261723 261723 261723

23 Snap Ring 1 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13

24 Wire Nut 3 260500 260500 260500 260500 260500 260500 260774 260774 260774

25 Grounding Cord Assembly 1 600241 600241 600241 600241 600241 600241 600283 600283 600283

26 Lock Washer 1 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10

27 Connect Terminal 1 260609 260609 260609 260609 260609 260609 260609 260609 260609

28 Terminal Block Assembly 1 600205 600205 600205 600205 600205 600205 600205 600205 600205

29 Sheave Assembly 1 600194 600194 600194 600194 600194 600194 600254 600254 600254

30 10-32 x 3/8” Screw 5 300001 300001 300001 300001 300001 300001 300001 300001 300001

31 Latch Plate Spring 1 S400018 S400018 S400018 S400018 S400018 S400018 S400018 S400018 S400018

32 10-24 x 3/8” Screw 1 S32-136 S32-136 S32-136 S32-136 S32-136 S32-136 S32-136 S32-136 S32-136

33 10-32 x 1” Screw 1 300035 300035 300035 300035 300035 300035 300035 300035 300035

34 Latch Bumper 1 S400021 S400021 S400021 S400021 S400021 S400021 S400021 S400021 S400021

35 Latch Plate Assembly 1 S400109 S400109 S400109 S400109 S400109 S400109 S400109 S400109 S400109

36 Latch Bushing 1 S400012 S400012 S400012 S400012 S400012 S400012 S400012 S400012 S400012

37 Base Assembly 1 400101 400101 400101 400101 400101 400101 400101 400101 400101

38 Main Shaft Kit 1 602348 602348 602348 602348 602348 602348 602348 602348 602348

39 Spacing Washer 2 300034 300034 300034 300034 300034 300034 300034 300034 300034

40 Drive Spring Assembly 1 S400030 S400030 S400030 S400030 S400030 S400030 S400030 S400030 S400030

41 Spring Case Assembly 1 S400103 S400103 S400103 S400103 S400103 S400103 S400103 S400103 S400103

42 10-32 x 3/8” Nyloc Nut 1 S82-15 S82-15 S82-15 S82-15 S82-15 S82-15 S82-15 S82-15 S82-15

43 Guide Arm Switch Assembly 1 None None None None None None None None None

44 Roller Plate Assembly 1 None None None None None None None None None

45 Switch Box 1 None None None None None None None None None

46 Autoswitch Cord 1 None None None None None None None None None

47 Switch 1 None None None None None None None None None

48 Guide Arm 1 None None None None None None None None None

49 Spring 1 None None None None None None None None None

50 Fluorescent Lamp & Single

Outlet 1 None None None None None None None None None

51 LED Lamp/Cord Assembly 1 None None None None None None None None None

52 Polycarbonate Tube Assembly 1 None None None None None None None None None

53 Triple Tap/Cord Assembly 1 None None None None None None None None None

54 Flying Leads 1 None None None None None None None None None

55 Outlet Cord Assembly w/Plug 1 None None None None None None None None None

56 Inlet Cord Assembly 1 None None None None None None None None None

Series L 4000 Spring Driven Cord Reels

Page 6 www.reelcraft.com

Item

#Description #

Req. L 4545

123 3B

L 4545

123 3AC

L 4525

123 3BC

L 4545

123 3BC

L 4035 163

3-RP

L 4050 163

3-RP

L 4545 123

3-RP

L 4545 123

3A-RP

L 4035 A

163 5

1Incandescent Lamp/Cord

Assembly 1 None None None None None None None None 600458-35

2Fluorescent Lamp/Cord

Assembly 1 None None None None None None None None None

3Duplex GFCI Box/Cord

Assembly 1 None None None None None None None None None

4Single Outlet 1 602004 602003 602451-25 602004 None None None None None

5Inlet Cord Assembly 1 602002 None None None None None None None 600472

6Connector, 90° Cord 1 261140-C S261140-C 261140-C S261140-C 261140-1-C 261140-1-C 261140-C 261140-C 261140-1-C

7Screw, Set 3/8-19 x 1/2” Pin 1 300006 300006 300006 300006 300006 300006 300006 300006 300006

8Nut, Lock 10-32 Hex 22 S300011 S300011 S300011 S300011 S300011 S300011 S300011 S300011 S300011

9Snap Ring 1 300031 300031 300031 300031 300031 300031 300031 300031 300031

10 Springcase Stud 1 S261360 S261360 S261360 S261360 S261360 S261360 S261360 S261360 S261360

11 10-32 x 1/2” Screw 2 300002 300002 300002 300002 300002 300002 300002 300002 300002

12 Guide Arm Assembly 1 S400107 S400107 S400107 S400107 S400107 S400107 S400107 S400107 600341

13 Bumper Assembly 1 1-HR1004-A 1-HR1004-A 1-HR1004-A 1-HR1004-A 600193 600193 1-HR1004-A 1-HR1004-A 600193

14 Spring Arbor 1 S400017 400017 S400017 400017 S400017 S400017 S400017 S400017 S400017

15 Latch Cam 1 S400019 S400019 S400019 S400019 S400019 S400019 S400019 S400019 S400019

16 Sheave Disc 1 400006 400006 400006 400006 400006 400006 400006 400006 400006

17 Strain Relief 1 260633 260633 260633 260633 260501 260501 260633 260633 260501

18 Plate Adapter 1 261577 261577 261577 261577 261577 261577 261577 261577 261577

19 Split Lock Washer 3 902016 902016 902016 902016 902016 902016 902016 902016 902016

20 1/4-20 x 5/8” Hex Screw 3 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42 S2-42

21 Collector Ring Assembly 1 602296 602296 602296 602296 602296 602296 602296 602296 602296

22 Cover 1 261723 261723 261723 261723 261723 261723 261723 261723 261723

23 Snap Ring 1 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13

24 Wire Nut 3 260774 260774 260774 260774 260500 260500 260774 260774 260500

25 Grounding Cord Assembly 1 600283 600283 600283 600283 600241 600241 600283 600283 600241

26 Lock Washer 1 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10

27 Connect Terminal 1 260609 260609 260609 260609 260609 260609 260609 260609 260609

28 Terminal Block Assembly 1 600205 600205 600205 600205 600205 600205 600205 600205 600205

29 Sheave Assembly 1 600254 600254 600254 600254 600194 600194 600254 600254 600194