Aero Housewares TV Cables GR900 Series User Manual

Ground Fault Cable Retractor  
GR900 Series  
Service Manual  
AERO-MOTIVE COMPANY  
A Woodhead Industries, Inc. Subsidiary  
IMPORTANT SAFETY INSTRUCTIONS  
Please read this manual carefully and follow its instructions. Improper use or failure to follow these instructions could  
result in serious injury, death or property damage. Operators should be instructed in the safe and proper use and  
maintenance of this product. Keep this manual for future reference.  
The following safety precautions call attention to potentially dangerous conditions.  
DANGER:  
Immediate hazards which WILL result in severe personal injury or death.  
WARNING: Hazards or unsafe practices which COULD result in severe personal injury or death.  
Hazards or unsafe practices which MAY result in minor personal injury or product or  
property damage.  
CAUTION:  
Model GR900 retracts up to 40 feet of #1/0 or #2/0 AWG grounding cable intended to protect equipment and personnel in  
the event of a ground fault. The collector rings’ electrical path through the reel has a current carrying capacity greater  
then that of the largest cable (#2/0 AWG) to be installed on the reel.  
Failure to lock the cable drum in position with the cable fully extended as instructed, will  
WARNING:  
create an explosion hazard in the even of fault condition, and may result in property damage,  
personal injury, or death.  
The internal electrical path is not insulated from the reel frame, therefore, this reel is  
WARNING:  
unsuitable for other uses other than retracting ground cables. Use for other applications will  
create an electrical shock hazard, and could result in property damage, personal injury, or  
death.  
Failure to install, operate, and maintain the retractor in accordance with these instructions  
WARNING:  
may result in electrical shock causing property damage, personal injury, or death.  
If ground fault has occurred, return the reel to Aero-Motive Company for inspection , and  
WARNING:  
possible repair before placing back in service. Failure to do so could result in electrical  
shock hazard, and may result in property damage, personal injury, or death.  
Installation  
Misalignment of the reel and cable travel direction will cause the cable to be deflected at a  
sharp angle around the cable guide rollers  
CAUTION:  
The reel should be bolted securely to a flat metal surface of sufficient strength and rigidity to  
CAUTION:  
support it under all conditions to which it will be subjected. Mounting holes will  
accommodate 7/16” or 3/8” bolts. Nothing smaller then 3/8” or 10mm bolts should be used.  
SM3120-18D  
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SPRING TENSIONING  
Failure to test for adequate spring revolutions can cause spring damage. Hazards or  
unsafe practices MAY result in minor personal injury or product or property damage.  
CAUTION:  
NOTE: A minimum 2 pre-tension turns is required. Additional turns can added as long as one unused  
spring turn remains when cable is completely extended. If entire cable cannot be pulled out,  
decrease spring tension until full one turn remains.  
All reels require pretensioning turns to spool assembly before connecting free end of working cable. Set  
spring tension by turning fully wrapped reel through a specific number of revolutions or turns. Number of  
pretension turns depends on application and desired tension. A minimum of 2 set up turns is needed  
for most applications. Additional tension may be added by repeating above process. Failure to  
pretension reel may result in insufficient tension to retract and may shorten spring life.  
After cable is installed, apply the extra warning label (35) shipped with the reel, to the insulated cable that  
protrudes beyond the cable stop.  
Check to make sure that the cable can still be pulled out without winding the main spring to  
CAUTION:  
the end. If the cable can not be pulled out completely, too many prime turns have been  
applied and some will have to be removed. Operating the reel with too many prime turns will  
restrict the cable travel and shorten the life of the main spring.  
CONNECTING GROUND  
The ground connection cable should be as large or larger than the cable installed on the drum. It is  
attached to the reel by connecting to the ½” diameter copper rod protruding beyond the junction box  
cover  
(11), on the base (3). Connection should be made with a commercial fitting specifically intended for  
attaching this size cable to ½” diameter copper rod.  
Failure to make mechanically and electrically sound connection at both ends of the cable will  
WARNING:  
create and electrical shock hazard and could result in property damage, personal injury, or  
death.  
ADJUSTING CABLE GUIDE  
Cable guide position is set by rotating the spring pocket assembly. Loosen three clamps holding spring  
pocket assembly in place by unscrewing three hex head bolts. Unless required, do not completely  
remove bolts or clamps. Reposition guide as required, making sure clamps straddle ribs on outside  
diameter of spring pocket assembly and retighten hex head bolts.  
CAUTION:  
Pulling the cable at sharp angles to the cable guide will shorten the cable life and retard  
retraction speed.  
OPERATION  
RATCHET LOCK  
All reels are supplied with a ratchet lock to hold drum at any of several positions per drum  
revolution and prevent if from retracting. If ratchet lock is not required--constant tension--, move spring  
clip and spring to adjacent cable guide screw. To release ratchet, pull cable out until ratchet pawl  
disengages.  
GROUND FAULT CONNECTION  
When the cable is pulled out and connected to provide ground fault protection, all of the cable should be  
fully extended to provide maximum current capacity and a padlock must be installed on the reel through  
the hole provided in the flange of the spool. This padlock prevents drum rotation and assures that the  
cable remains unwound should a ground fault occur.  
SM3120-18D  
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© Aero-Motive Company Jul-01  
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Failure to unwind the full length of cable and then padlock the spool to prevent its  
inadvertent rewinding, in the event of a ground fault, will create an explosion hazard which  
could result in property damage, personal injury, or death  
WARNING:  
WARNING:  
WARNING:  
WARNING:  
Personnel should be kept at a safe distance from the Ground Fault Reel and Cable. In the  
event of a ground fault, the sudden surge of power will cause the cable to move violently and  
could cause property damage, personal injury, or death.  
This reel is intended for use in a grounding circuit only. The electrical path is not insulated  
from the reel frame. Property damage, personal injury, or death could result if retractor is  
not used in accordance with this manual.  
Check all electrical connections on retractor and ground cable terminations before use.  
Failure to do so may result in shock hazard causing property damage, personal injury, or  
death.  
SERVICE  
If ground fault condition has occurred, remove the reel from service immediately and return  
it to Aero-Motive Company for inspection and, if necessary, repair. Failure to do so could  
result in and electric shock hazard causing damage, personal injury, or death.  
WARNING:  
MAINSPRING REPLACEMENT  
If the reel will not develop tension or retract cable, the spring assembly may need to be replaced.  
To replace the mainspring:  
1. Disconnect the input grounding connection.  
2. Remove junction box cover (11) and connector (12).  
3. Remove shaft retainer screw (1) and shaft retainer (2).  
4. Remove drum and main shaft from base (3).  
5. Remove cable guide (16), spring clip (20), both screws (19), extension spring (15), shoulder screw  
(21), and ratchet pawl (22) from spring pocket assembly (14).  
6. Remove spring pocket assembly (14) from base (3) and replace with new spring pocket assembly.  
Assemble in reverse order.  
Spring pocket assemblies are sealed to prevent disassembly. Don not attempt to remove  
WARNING:  
spring from its pocket. Uncontrolled release of spring tension may occur causing property  
damage, personal injury, or death.  
Carefully inspect all wire connections after any service work is conducted. Failure to do so  
could result in property damage, personal injury, or death.  
WARNING:  
MAINTENANCE  
ELECTRICAL  
1. Inspect all cable connections at least monthly.  
2. Resistance through the reel slip ring assembly should never exceed 0.001 ohms. If so, return to  
Aero-Motive Company for inspection and repair.  
NOTE: The slip ring assembly has been designed in such manner that it cannot be disassembled  
SM3120-18D  
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REPLACEMENT PARTS  
SM3120-18D  
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Reference  
Part  
Number *  
Number  
Qty.  
1
1
Description  
SCREW; PAN HD. M5 X 12MM  
SHAFT RETAINER  
1
2
3
C03500231  
M41100003  
H22110385  
1
BASE  
4
5
6
7
8
9
3
3
1
1
1
1
1
1
1
10  
1
1
1
4
4
2
1
1
1
1
2
2
1
1
4
1
1
1
4
1
1
1
1
CLAMP-Included in clamp kit B below.  
SCREW; HEX HD. M6 -Included in clamp kit B below.  
MAIN SHAFT, ELECTRICAL WELDING REEL  
O-RING  
THREAD PLUG  
NUT; ¾” NPT LOCKING  
JUNCTION BOX GASKET  
JUNCTION BOX COVER  
STRAIN RELIEF CONNECTOR, ¾” NPT .500  
SCREW; PAN HD. M6 X 16MM – Included in roller guide kit C below.  
SPRING POCKET ASSEMBLY  
M34370006  
C47040141  
C34620105  
C71140112  
M14240007  
H82640002  
C75620419  
C03500253  
H41220076  
C60610121  
M04730007  
M24060125  
M86700006  
C03500255  
M53350002  
C15070225  
M86750002  
M70780007  
C01070517  
C03500237  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
KIT A  
KIT B  
KIT C  
EXTENSION SPRING  
CABLE GUIDE – Included in roller guide kit C below.  
ROLLER SHAFT – Included in roller guide kit C below.  
ROLLER – Included in roller guide kit C below.  
SCREW; PAN HD. M6 X 20MM  
SPRING CLIP  
SCREW; SHDR M8 X 10 X 16MM  
RATCHET PAWL  
CABLE CLAMP  
FLAT WASHER M5  
SCREW PAN HD M5  
DRUM GASKET – Included in drum kit A below.  
SLIP RING ASS’Y, ELECTRIC WELDING REEL  
SCREW – Included in drum kit A below.  
OUTER DRUM HALF – Included in drum kit A below.  
CABLE SEAL  
SEAL COVER  
SCREW PAN HD. M4 X 12MM  
INNER DRUM HALF – Included in drum kit A below.  
CABLE STOP (ST2 KIT)  
H96610001  
M86550002  
M37810027  
C03500201  
STM2  
WARNING LABEL – Included in drum kit A below.  
SLIP RING BRACKET – Included in drum kit A below.  
SCREW; PAN HD. M8 X 16MM – Included in drum kit A below.  
DRUM KIT – (GR900) Includes items #’s 26, 28, 29, 33, 35, 36 & 37  
CLAMP KIT- STAINLESS STEEL- Includes 3 each of # 4 & 5.  
ROLLER GUIDE KIT – Includes item # 13, 16, 17, and 18.  
2
H05040005  
H05040013  
H26340009  
AR  
AR  
AR  
Aero-Motive Company  
AKAPP Electro Industrie  
Woodhead Connectivity LTD.  
Woodhead Asia PTE LTD.  
Woodhead Canada LTD.  
W
A Woodhead Industries Inc. Subsidiary  
W
A Woodhead Industries Inc. Subsidiary  
Nijverheidsweg 14 Box 54  
NL-3771 ME Barneveld  
NL-3771 AB Barneveld  
Holland  
W
A Woodhead Industries Inc. Subsidiary  
W
A Woodhead Industries Inc. Subsidiary  
401 Commonwealth Drive #04-04  
Haw Par Technocentre  
Singapore 0314  
W
A Woodhead Industries Inc. Subsidiary  
1090 Brevik Place  
Mississauga Ontario  
L4W 3Y5 Canada  
PO Box 2678  
Factory No. 9  
Rassau Industrial Estate  
Kalamazoo, MI 49003-2678  
(616) 337 7700  
Ebbw Vale Gwent NP3 5SD  
United Kingdom  
(800) 999 8559  
(65) 261 6533  
(905) 624-6518  
FAX: (800) 333 6119  
(31) 34 241 4022  
FAX: (31) 34 249 2384  
(0495) 35 0436  
FAX: (0495) 35 0877  
FAX: (65) 479 3588  
FAX: (905) 624-9151  
SM3120-18D  
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© Aero-Motive Company Jul-01  
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