BAL71000007E Drum body spiraldivided designon gear u.docx

BAL71000007E Drum body spiraldivided designon gear u.docx

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BAL71000007EDrumbodyspiraldivideddesignongearu

Reeltypes

ES25..,ES31..,ES20../D>6500mmongearunitK20.

CONTENTS

Page

1Generalinformation2

2Drumbodycomponents2

3Assemblyofthereelbody4

3.1Requirements4

3.2Assemblyofthereelwheel6

3.3Assemblyofthereelwheeltothegearunit13

3.4Firstalignmentofthereel（withoutcable）14

3.5Ramp16

3.6Angleforcableinsertion18

4Placingthecableonthedrumandconnectingup18

4.1Forthepreparatoryworkpriortoplacingonthedrum18

4.2Preparationofthecableendandleadingtotheslipringbody19

4.3Placingcableondrum19

4.4Reelingthecable20

4.5Connectingupthecable20

5Checkthedrumwidthandadjustifrequired20

1Generalinformation

Thefunctionofthereelbodyistotakeupareelingcable（highvoltage,lowvoltageorcontrolcable）.

Asastandardthereelbodyhasthecapacitytotakeupthewound-uplengthrequiredforthisoperationplus2windingsfortensionrelief.

Note:

Allbelownumbersinbrackets（）refertothecorrespondingpositionsonfigure1tofigure3.

2Reelbodycomponents

Thereelbodyisdelivereddismountedandiscomposedof:

-9resp.10premountedreelsegments

-1ramp

-2reelplates

-1angleforcableguidance

-1boxwithscrews,nuts,washersandlocknuts

3Assemblyofthereelbody

3.1Requirements

Theassemblyofthereelbody

-requiresanevensurface;

-requiresapprox.20elementsofanequalheight

（suggestion:

woodenblocksapprox.300mmx100mmx750mm）;

-requires2elementswithaheightdimensionreducedby24mmforthesupport（suggestion:

276mmx100mmx500mm）;

-requiresatleast2vises（spacing>350mm）;

Fortheassemblyofthereelbodytothegearunit,thegearunithastobeplacedatanappropriateheighttoguaranteeaminimumgroundclearanceofhalfareelbodyouterdiameter（D/2）.

Thereelsegmentsaresupplieddependingonthenominalcablediametersprovidedbythecustomer.

Thereelwidth„b“tobeadjusted,howeverdependsontheactualdimension„d“（cablediametertobemeasuredbythecustomer）.Choosethereelwidthassmallaspossiblebyleavingout/removingindividualwashers（16）à3mm（perspoke）.

Ifthisisrequireditshouldbedonepriortomountingthesegments.Thentightenthenutswith350Nm!

Example:

Measuredcablediameter:

48.4mm

Suppliedreelwidth:

52.0mm

Reelwidthtobeadjusted:

49.0mm

（removerespectivelyleaveoutonespacerateachjoint）

3.2Assemblyofthereelwheel

Donotyetremovethewoodenspacers（conditionupondelivery）.

Putthetworeelplateshorizontallyontothetwolowwoodenblocks.Sincetheplatesarenotsymmetrical,makesurethatthecorrectsidepointstothetop.（outerholecircledisplacedtotheleft）.

links/left

Displaywoodenblocksandjoinreelsegments.

Alwaysjoin2reelsegmentsofthesamenumber（atthefacesurface）.

2

2

Ifseveralidenticalreelsaresupplied,thesegmentsattheinsideofthejointareadditionallymarkedwiththereelnumber.

I2

I2

Example:

reelnumberjoint

Screwreelsegmentsloosewiththefollowingparts:

-countersunkscrewsM12x80DIN7991

-washers13DIN9021

-hexagonheadscrewsM12DIN934

-locknutsM12DIN7967

Thelastreelsegmentscanbeidentifiedbythe2outsidecouplingstripsandthehighestandlowestnumberatthefacesurfaces（e.g.1and10）.

Screwplatesloose（withhexagonheadscrewsM20DIN931）.

Attention!

Nutsshouldbefixedwithagapof1upto2mmtothereelplate.

Removewoodenspacers

Installassemblydistanceplatesatthefirstjointbetween2reelsegments.

Applyvisesandscrewtight.

Screwfittings（countersunkscrewsandhexagonheadscrews）tight.

Thenremovevisesanddistanceplatesandmakesurethereisnomisalignmentatthejoint（attheinside）.

Attention!

Anymisalignmentatthejointmustbeprevented.

Ifrequiredrepeatthisprocessuntilthereisnomoremisalignment（<0.5mm）.

Connectallreelsegmentstight.

Thentightenthescrewingsatthereelplate（checkwithlocknutsDIN7967）.

3.3Assemblyofthereelwheeltothegearunit

Liftreelwheelwithcrane,placeitverticallyandbringittothegearunit.

øaøcøeøf

Øc

Pushthereeloverthereelflangeintothedirectionofthemountingflange（4）.Thenboltthereelplate（5）andthemountingflange（4）ontheholecirclediameters“a”and“c”force-lockingbythe30hexagonheadscrews（6）withthecorrespondingwashers（7）andhexagonheadnuts（8）.Checkthejointswiththelocknuts（9）.（figure1.

3.4Firstalignmentofthereel（withoutcable）

1/6/11/14a/22hexagoncapscrewDIN933

2/7/24washerDIN125

3/8/20/21/23hexagonalnutDIN985

4fasteningplate

5reelpanel

6hexagonheadscrewDIN993

9lockingnutDIN7967

10firstreelplate

12（adjusting）threadbolt

13hexagonalnutDIN934or439

14threadbolt

15reelsheath

16SpacerDIN125orsleeve

17secondreelplate

18ramp

19/20/21（adjusting-）hexagonalnut

25cablelead-through（shortspokeinthesecondreelplate）

Figure1

Alignbothreelplates（10/17）inparallelrespectivelytaperingtotheoutsidebyadjustingthehexagonheadnut（19/20）.

wxyz

Dimension“b”atthereelsheathiscalculatedfromthenumberofdistancewashers/sleevesandshouldbeassmallaspossible（withreferencetotherealcablediameter）.

Dimension“b”attheouterdiameter（withemptydrum）shouldbeadjustedassmallaspossible,sothatitisonlyslightlybiggerthanthemeasuredcablediameter.

Iftheminimumadjustabledimension“b”atthereelsheathisbiggerthanthecablediameter,thereelouterdiameterhastobeadjustedtoasmallervalue.

Example:

Measuredcablediameter:

56,5mm

Adjustedreelwidthatthereelsheath:

59,0mm

Reelwidthtobeadjustedattheouterdiameter:

57,0mm

（Adjustedaccordingtoabovesketch„z“）

Theadjustmenthastobemadeseveraltimesallaroundeachpairofspokes.Makesurethatthesamevaluesareadjustedatallpairsofspokes.

Measurementsaremadeatthereelsheath“d”（innerdiameterofthereel/hole-circlediameter“f”）andattheouterdiameter“D”ofthereel.

-Tighteningthehexagonheadnut（20）tohole-circlediameter“e”increasesdimension“b”.

-Tighteningthehexagonheadnut（19）tohole-circlediameter„e“reducesdimension„b“.

Whenthereelisaligned,tightenthehexagonheadnut（21）onthehole-circlediameter“f”with350Nm（M20）andcheckwiththelocknut（9）.

Tightenthehexagonheadnuts（19/20）with350Nm（M20）onthehole-circlediameter„e“.Ithastobeobservedthatthealignmentpositionisnotchanged.

Checkoncemoretheparallelalignmentrespectivelytaperingtotheoutsideofdimension“b”allaroundandiftheresultispositivefitthelocknut（9）andcheckit.

Ifduringtighteningthehexagonheadnut（19/20）theparallelalignmentrespectivelytaperingshouldbeshiftedtotheoutside,proceedoncemoreaccordingtoitem3.4.

3.5Ramp

Fixtheramp（18）tothereelsheath（15）ofthereelsegmentbymeansofthecrossbeam（cableentry）insuchawaythatthefirstwindinglayerpassesovertothesecondwindinglayerwithoutanybreaks.Moreoverthiswillpreventthecablefrombeingcrushedintheareaofthecablelead-through.Thebreakaswellasthecrushingmustbeavoidedoncableswithfiberoptics.

Thereelsheathcontainsadrill-holefortherampassemblyfornormalunwindingrespectivelyabnormalunwinding.Dependingonthedirectionofunwindingtherampmustbemountedtotheotherdrill-holeifrequired.

Figure2

Rampfor

unwinding„abnormal“

Rampfor

unwinding„normal“

Figure3

Note:

Preventthecablefrombeingcrushedduringcableentry（25）.Theminimumbendingradiusmustbeconsidered.Steps4.1to4.3havetobecarriedoutbyaspecialistfirst.

3.6Angleforcableguidance

Mountangleforcableguidanceattheholecirclediameter„e“（displacedbyapprox.120°tothecableentry）.

4Placingandconnectingthecable

Placingandconnectingcablesmustbedonebyspecialists.

4.1Preparatoryworkforplacingcables（seeoperatinginstructions）

"Reelcable",item2

4.2Preparationofthecableendtotheslipringbody

Toestablishthelengthtostriptheinsulationofthecableitisrequiredtoopenthecoveroftheslipringbodyhousing.ThedistanceismeasuredfromthestuffingboxscrewingTL（reelcableentry）tothefinalconnectionpointoftheslipringbody.

Striptheinsulationofthecable,shortentheindividualconductorsifnecessary,consideringthedistancebetweentheringsandprovidetheendswiththecorrespondingringorpincablelug.

Note:

Highvoltagecablesaregenerallyequippedwithacablesealingend,sothattheabovedescribeddoesnotapply.

Ifacablesealingendhasnotyetbeeninstalledthismustbedonebyqualifiedpersonnel.

4.3Placingthecablesonthereel

AdjusttherubberringinthestuffingboxscrewingTLtotheactualcableouterdimension.

Thecableend,comingfromthedispatchreelordispatchring,ispushedontothereelsheathbetweenthereelshields（figure2and3）.

Whenthecableisledthroughthecableendprojectsfromthereelwheel.Fromthereleadthecabletotheguideangleandscrewitwiththecablecollar.Thenleadthecableendthroughthestuffingboxscrewing（break-outrubberring）andleadthehollowshaftofthegearunittothefarthestconnectionpointoftheslipringbody.Ifthereisarampthecablemustbeledoutofthewindingareabeforethisramp.

PriortotighteningthestuffingboxscrewingTlitisrequiredtocheckonceagainthatthenon-strippedpartofthecableisinsi