Power supply and crane technology

General Specification for Radial Type

Motorised Cable Reelers
Revision: A Date: 18 April 2019

Cable Motor

Drum

HV Collector
Torque Unit LV Collector

Cable Guide

Turnover
Bollard

GENERAL

 The vendor shall have expert design, commissioning and technical support services available on
a 24/365 basis in Australia.
 The vendor shall provide references of similar systems being used in Australia.

DRUM

 The cable lay type (ie. monospiral, 3-2-3, random) shall be selected to optimise the size of the
reeler system while ensuring that the lay is appropriate for the expected operating duty.
 The inner diameter of the drum is to meet the minimum bend radius requirements of the cable
while ensuring an optimal relationship between reeling torque and cable tension.

CAVOTEC METOOL Pty Ltd (ABN 34 053 865 366)

Perth Office Melbourne Office Sydney Office Newcastle Office Brisbane Office
82 Chisholm Crs 2/483 Hammond Rd PO Box 3200 28 Mitchell Rd 30 Norbury St
Kewdale WA 6105 Dandenong VIC 3175 Rouse Hill NSW 2155 Cardiff NSW 2285 Coopers Plains QLD 4108

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 Power supply and crane technology

General Specification for Radial Type

Motorised Cable Reelers
Revision: A Date: 18 April 2019

 The outer diameter of the drum shall be sized to accommodate the full cable length (including a
minimum of 2 dead turns) with an appropriate safety margin.
 The compartment width of the drum shall be calculated on the maximum cable diameter, and the
clearance applied shall be appropriate for the type of lay selected.
 The drum sides shall be made with a spoked construction to maximise cooling of the cable.
 The drum spokes shall be either mild steel or stainless steel RHS sized to accommodate all
expected static and dynamic loads while minimising weight.
 The outer rings shall be rolled from mild steel or stainless steel RHS, and shall be attached to the
spokes with full seal welds, or in the case of larger composite reels, with stainless steel fasteners.
 The inner band shall be fabricated from rolled mild steel or stainless steel plate, and spacer tubes
shall be fully seal welded to the inner face.
 The drum sides and inner band shall be assembled with appropriately sized stainless steel tie
rods.
 The outer drum side and/or the inner band shall have appropriately sized outlets through which
the cable can be fed into the drive module while at the same time maintaining the cable's
minimum bend radius.
 A clamping facility for the first turn of cable shall be provided.
 Larger drums shall be of split or composite design for ease of transportation.

TORQUE UNIT

 The torque unit bearings and gears shall have a minimum design life of 100,000 hours.
 The main drive shaft shall be designed for infinite life based on the expected overhung load and
torque parameters, and shall have a bore large enough to allow the cable (and boot if fitted) to
pass through unhindered.
 The torque unit shall have a grease purged labyrinth seal on the output shaft.
 An appropriately sized IP66 cable gland shall be fitted at the cable entry.
 Torque control shall be achieved by using a torque motor for small reels, a fluid immersed
hydrodynamic based mechanical torque regulator for small to medium reels, or a flux vector
based electronic drive system for medium to large reels.
 The rated power output of the torque unit and controller shall be at least 20% higher than the
calculated maximum to allow for on-site adjustment should cable and/or duty parameters change.

TORQUE MOTOR

 The torque motor shall have low inertia, and shall be coupled to a highly efficient and highly
reversible torque unit.
 Torque output shall be essentially constant in both directions.
 A failsafe disc brake shall be fitted to the motor shaft to prevent the cable from unwinding when
the motor is switched off.

CAVOTEC METOOL Pty Ltd (ABN 34 053 865 366)

Perth Office Melbourne Office Sydney Office Newcastle Office Brisbane Office
82 Chisholm Crs 2/483 Hammond Rd PO Box 3200 28 Mitchell Rd 30 Norbury St
Kewdale WA 6105 Dandenong VIC 3175 Rouse Hill NSW 2155 Cardiff NSW 2285 Coopers Plains QLD 4108

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 Power supply and crane technology

General Specification for Radial Type

Motorised Cable Reelers
Revision: A Date: 18 April 2019

 The motor protection rating shall be at least IP55.

MECHANICAL TORQUE REGULATOR

 The mechanical torque regulator shall be a totally enclosed, fluid immersed hydrodynamic based
system driven by an appropriately sized AC motor/DC motor/hydraulic motor/air motor.
 Torque output shall be essentially constant in both directions.
 The torque output shall be easily adjustable.
 The torque regulator shall be easily servicable by semi-skilled labour.
 Where required, a failsafe disc brake shall be fitted to the motor shaft to prevent the cable from
unwinding when the motor is switched off.
 The motor protection rating shall be at least IP55.

ELECTRONIC DRIVE

 The electonic drive system shall be based on a flux vector controlled AC motor coupled to a
highly efficient and highly reversible torque unit.
 The motor shall be oversized to ensure that it can operate indefinitely in a stalled condition
without the need for forced cooling.
 A failsafe disc brake shall be fitted to the motor shaft to prevent the cable from unwinding when
the motor is switched off.
 A friction based mechanical torque limiting coupling shall be fitted between the motor and the
torque unit, and shall be set to slip whenever the torque transmitted exceeds a prescribed
maximum.
 An incremental encoder shall be coupled to the motor shaft to provide feedback to the flux vector
controller.
 Thermistors shall be embedded into the motor stator for wiring into the flux vector controller.
 The flux vector controller shall be appropriately sized for the application and shall be user friendly,
available "off-the-shelf", and made by a reputable manufacturer.
 The flux vector controller and associated control hardware shall be mounted onto a panel suitable
for mounting inside a control room.
 The torque output shall be a) constant with two fixed torque references for payout and recovery,
or b) infinitely variable between limits with the torque reference being dependent on machine
position (good tension control)/number of turns on drum (better tension control)/actual cable
tension (exact tension control).
 Torque references shall be easily adjustable by non-specialised personel without the need for
factory programming or specialised equipment.

CAVOTEC METOOL Pty Ltd (ABN 34 053 865 366)

Perth Office Melbourne Office Sydney Office Newcastle Office Brisbane Office
82 Chisholm Crs 2/483 Hammond Rd PO Box 3200 28 Mitchell Rd 30 Norbury St
Kewdale WA 6105 Dandenong VIC 3175 Rouse Hill NSW 2155 Cardiff NSW 2285 Coopers Plains QLD 4108

Page 3 of 5
 Power supply and crane technology

General Specification for Radial Type

Motorised Cable Reelers
Revision: A Date: 18 April 2019

COLLECTOR

 Sliprings shall be rated for the expected duty, and shall have diameters large enough to allow the
cores of the reeling cable to be easily connected. Pre-tailed sliprings are to be terminated to a
terminal strip.
 Each slipring shall be separated from other sliprings and the supporting steelwork using
appropriate insulators.
 Each slipring shall have appropriately rated brushgear having a minimum of 2 spring loaded
brush tips.
 The brushgear shall be mounted to allow for easy termination of the incoming cable, and shall be
appropriately insulated.
 All airgaps shall comply with the relevent Australian Standard (AS3000 for LV installations,
AS2067 for HV).
 The housing shall be fabricated from mild steel or stainless steel sheet, and shall be fully seal
welded.
 Access into the housing shall be via a bolted cover or hinged lockable door.
 The HV housing shall be provided with a laminated glass viewing window mounted in a manner
that resists movement should an internal explosion occur.
 The HV collector assembly shall be supplied with a separate LV housing in which the pilot/control
rings, fibre optic rotary joint (if required) and geared rotary limit switch (for reel full/reel empty
detection) shall be mounted.
 HV housings shall have a self-regulating anti-condensation heater, and anti-condensation paint
shall be applied to the ceiling.
 HV housing doors/covers shall be supplied with limit switches that act to shut off the main power
should these be opened while the main power is on.
 All doors/covers shall be earthed to the main housing via an appropriately sized earthing
conductor.
 The minimum protection rating for all housings shall be IP55.
 Stainless steel fittings and fasteners shall be used throughout.

CABLE GUIDE

 The cable guide shall consist of multiple profiled rollers arranged in a radius that meets or
exceeds the minimum dynamic bend radius allowable for the cable. Sheave style guides are
unacceptable.
 Rollers shall be made from cast iron or heavy-duty UV resistant polymer, and shall be mounted
on stainless steel shafts with sealed for life bearings and Nilos seals.
 Individual rollers shall be easily removable.
 The cable guide structure shall be made from hot-dip galvanised mild steel or stainless steel.
 Overtension detection systems shall be easily calibrated on site.

CAVOTEC METOOL Pty Ltd (ABN 34 053 865 366)

Perth Office Melbourne Office Sydney Office Newcastle Office Brisbane Office
82 Chisholm Crs 2/483 Hammond Rd PO Box 3200 28 Mitchell Rd 30 Norbury St
Kewdale WA 6105 Dandenong VIC 3175 Rouse Hill NSW 2155 Cardiff NSW 2285 Coopers Plains QLD 4108

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 Power supply and crane technology

General Specification for Radial Type

Motorised Cable Reelers
Revision: A Date: 18 April 2019

 Undertension, overtension and direction detection switches shall be wired via heavy-duty conduit
to a mild steel or stainless steel junction box mounted on the guide.
 Stainless steel fittings and fasteners shall be used throughout.

TURNOVER AND BOLLARD

 The turnover radius shall meet or exceed the minimum dynamic bend radius allowable for the
cable.
 The bollard radius shall meet or exceed the minimum static bend radius allowable for the cable.
 The turnover and bollard shall be made from hot-dip galvanised mild steel or stainless steel.
 Stainless steel fittings and fasteners shall be used throughout.
 An appropriately sized lace-up stainless steel cable grip can be used in lieu of a bollard.

CAVOTEC METOOL Pty Ltd (ABN 34 053 865 366)

Perth Office Melbourne Office Sydney Office Newcastle Office Brisbane Office
82 Chisholm Crs 2/483 Hammond Rd PO Box 3200 28 Mitchell Rd 30 Norbury St
Kewdale WA 6105 Dandenong VIC 3175 Rouse Hill NSW 2155 Cardiff NSW 2285 Coopers Plains QLD 4108

Page 5 of 5