CONDUCTIX 040804 Spring Balancer Instruction Manual

CONDUCTIX 040804 Spring Balancer

Product Information

The Federzug is a retractable device used to manage cables and wires. It is available in different models that vary in terms of their maximum load capacity, cable length, and weight. The device comes with or without an automatic locking mechanism depending on the model.

Models

• 040804-1,2×2,0
• 040804-2,0×2,0
• 040813-02×2,5
• 040813-03×2,5
• 040814-02×2,5
• 040814-03×2,5
• 040823-05×3,0
• 040823-08×3,0
• 040823-10×3,0
• 040823-14×3,0
• 040824-05×3,0
• 040824-08×3,0
• 040824-10×3,0
• 040824-14×3,0

Product Specifications

Model| Maximum Load Capacity (kg)| Cable Length (m)| Weight (kg)| Automatic Locking Mechanism
---|---|---|---|---
040804-1,2×2,0| 0.5 – 1.2| 2.0| 0.6| No
040804-2,0×2,0| 1.0 – 2.0| 2.0| 0.6| No
040813-02×2,5| X| 2.5| 0.9| Yes
040813-03×2,5| X| 2.5| 0.9| Yes
040814-02×2,5| X| 2.5| 0.8| No
040814-03×2,5| X| 2.5| 0.8| No
040823-05×3,0| 2 – 5| 3.0| 3.5| Yes
040823-08×3,0| 4 – 8| 3.0| 3.8| Yes
040823-10×3,0| 7 – 10| 3.0| 3.8| Yes
040823-14×3,0| 10 – 14| 3.0| 4.0| Yes
040824-05×3,0| 2 – 5| 3.0| 3.3| No
040824-08×3,0| 4 – 8| 3.0| 3.7| No
040824-10×3,0| 7 – 10| 3.0| 3.7| No
040824-14×3,0| 10 – 14| 3.0| 3.9| No

Product Usage Instructions

Before using the Federzug, ensure that you have selected the appropriate model based on the weight and length of the cable or wire to be managed. Follow the instructions below to use the Federzug:

Installation:

1. Locate a suitable mounting point for the Federzug.
2. Attach the Federzug to the mounting point using appropriate hardware (not included).
3. Connect the cable or wire to the Federzug.

Adjusting Load Capacity:
The load capacity of the Federzug can be adjusted on certain models. Follow the instructions below to adjust the load capacity:

• For model 040804-1,2×2,0 and 040804-2,0×2,0, the load capacity is fixed and cannot be adjusted.
• For model 040813-02×2,5 and 040813-03×2,5, adjust the load capacity by turning the X screw.
• For model 040823-05×3,0, 040823-08×3,0, 040823-10×3,0, 040823-14×3,0, 040824-05×3,0, 040824-08×3,0, 040824-10×3,0, and 040824-14×3,0, adjust the load capacity by turning the X screw. The load capacity is expressed as a range (e.g., 2-5 kg).

Adjusting Cable Length:
The cable length of the Federzug can be adjusted on certain models. Follow the instructions below to adjust the cable length:

• For model 040804-1,2×2,0 and 040804-2,0×2,0, the cable length is fixed and cannot be adjusted.
• For model 040813-02×2,5, 040813-03×2,5, 040814-02×2,5, and 040814-03×2,5, the cable length is fixed and cannot be adjusted.
• For model 040823-05×3,0, 040823-08×3,0, 040823-10×3,0, 040823-14×3,0, 040824-05×3,0, 040824-08×3,0, 040824-10×3,0, and 040824-14×3,0, the cable length is fixed and cannot be adjusted.

Using the Automatic Locking Mechanism:
For models with an automatic locking mechanism (040813-02×2,5 and 040813-03×2,5), follow the instructions below to use it:

• Do not use the automatic locking mechanism for changing loads. Always change loads when the cable is fully retracted.

Order number

• 040804
• 040813
• 040814
• 040823
• 040824

Introduction

• Before commissioning the retractor the operating instructions must be carefully read and followed.
• These operating instructions contain instructions for the installation of retractors by appropriately trained technicians, as well as specifications for their operation by personnel trained in this activity.
• The original operating manual is in the German language and is legally binding. The manufacturer assumes no liability for the translated version.

Range of application

• The retractors are designed exclusively for the provision of hand-operated tools such as drills, compressed-air screwdrivers, etc.
• Any other use cannot be considered the intended use. The manufacturer/supplier cannot assume liability for any resulting damage. The user alone bears all risk.

Safety instructions

• The retractors may only be operated, installed, maintained, and repaired by personnel trained for these activities.
• The operator must train his or her personnel before they work with the retractor, and this training must correspond to the information in these operating instructions.
• Never walk, work, or stand under suspended loads.
• Attach and detach loads only when cable is fully retracted! Cables from which loads have been removed may retract suddenly, acting as whips. NEVER detach loads when the cable is extended!
• Whipping of the cable (when unloaded) can result in the anchoring of the cable being damaged (the cable may break free of the interior cable hanger). Stop work immediately, mark the retractor as defective, and inform the responsible supervisor.
• If tools are pulled beyond the permitted slant line of 10°, they may swing wide when released, injuring people.
• Never operate the retractor without its safety systems (e.g. fall protection), remove the safety systems, or disable them by means of any modification.
• Dismantling the spring housing is extremely dangerous and strictly prohibited.
•  The operation of defective retractors is strictly prohibited. This is the case, for example, when a retractor falls onto the fall protection or falls over. Continued operation of the retractor is only allowed after the replacement of the fall protection and the housing.
• The cable of the retractor must be periodically checked for damage. If the cable is damaged, the retractor may not be operated.
• Suspension, fall protection and safety chain must be continuously monitored. If damage or wear is discovered, the retractor must be replaced immediately.
• Any modification of the retractor or its accessories may only be performed with the express written consent of the manufacturer.
• Repair to and dismounting or remounting of the retractor may only be carried out by authorized personnel. Always use the manufacturer’s original replacement parts. Only they correspond to the safety criteria required.

Installation

• The installation, adjustment of the cable length, and adjustment of the loading capacity of the retractor may only be carried out by authorized, trained personnel.
• Versions with plastic housings may not be positioned in the immediate vicinity of heated air fans.
• The system on which the retractors and fall protection (4) are mounted must be designed with safety factor of at least 5 (5 x [intrinsic weight of the retractor + maximum permitted load]).
• Hang the retractor using a safety hanger (2).
• Ensure that the retractors cannot slip out of the safety hanger (2)
  • Tighten the safety nut (2.02).
• Fasten the fall protection (4) onto the hanger system:
  • The freedom of movement of the retractor may not be hindered.
  • The falling distance in case the retractor should fall may not exceed 100 mm!

Maintenance and testing

• If damage or corrosion is discovered, stop work with the retractor immediately, mark the retractor as defective, and inform the responsible supervisor.
• We recommend applying acid-free grease to all moving parts and friction points.

Carry out a daily visual inspection for corrosion and damage:

• Cable
• Safety hanger (2)
• Fall protection (4)

The retractor, and particularly the cable, must be tested at least once annually for damage by an expert (ISO 4309). In case of damage, the unit may no longer be operated.

Disposal

• All regulations for the disposal of metals, plastics, electrical and electronic parts, greases, oils, and so on valid at the time of disposal must be followed.
• Any dismounting work required may only be carried out by appropriately trained and instructed technicians.

Retractor 040804

Device elements:

1. Hanger
2. Hand wheel for adjustment of loading capacity
3. Loading hooks

Adjusting the loading capacity
The spring force can be adapted to lighter loads by reducing the spring tension, or to heavier loads by increasing the spring tension.

The spring tension may not be reduced further than the minimum load appropriate to the type/model!
The maximum spring tension in the retractor is reached by X turns of the hand wheel (2) in the “+” direction:

• 040804-1,2×2,0 X= about 2¼
• 040804-2,0×2,0 X= about 4

The spring tension may not be increased beyond this maximum!

Device specifications

Order number| Loading capacity (kg)| Cable travel (m)| Weight (kg)
---|---|---|---
040804-1,2×2,0| 0.5 – 1.2| 2.0| 0.6
040804-2,0×2,0| 1.0 – 2.0| 0.6

Retractor 040813-…, 040814

Adjusting the loading capacity

• Before adjusting the loading capacity, hang the load onto the fully retracted cable.

• Adjustment in the plus (+) direction increases the loading capacity.

• Adjustment in the minus (-) direction reduces the loading capacity.

• When the correct setting is reached, the suspended load can easily be pulled into the desired position, and returns to its original position after release.

• Retractors are shipped from the factory at the maximum load setting. Subsequent adjustments must be recorded in writing so that the maximum and minimum permitted loads are observed later. See the following model-specific specifications.
  Failure to comply with this instruction will destroy the spring inside the housing!

• When the spring ratchet (11) is pressed, the spring tension will be exerted on the adjustment tool.
  Hold the adjustment tool firmly!

• The following tool is needed for making adjustments: an Allen wrench (4 mm)

• Insert the Allen wrench into the spring ratchet (11) and push inwards (hold tight!). Using the Allen wrench, make the desired adjustment within the permitted adjustment range.

Column “X” = maximum permitted number of turns in the minus direction, starting from the factory maximum load setting

Adjusting the cable retraction limit
The maximum permitted cable extension (2.5 m) may not be exceeded.

• Hang the appropriate load and pull the cable to the desired position.
• Loosen the screws on the cable clamp (9), adjust the desired cable length, and then tighten the screws again.
• The rubber bumper (13) can be moved manually and protects the basic housing and suspended load.

Operating the retractor

Models with locking device (040813-…)

Caution:

• The automatic locking device (15) may not be used to change loads.
• Loads must always be changed with the cable fully retracted.

The suspended tool is pulled downwards and remains suspended in the extended position. To return it to the starting position, pull the suspended tool sharply downwards for a short distance, then push it quickly upwards. Slow movements will cause the locking device to engage.

Models without locking device (040814-…)
Pull the suspended tool downwards – when it is released, it will return to its original position independently.

Device specifications

Retractor with locking device

Order number| Loading capacity (kg)| Cable travel (m)| Weight (kg)
---|---|---|---
040813-02×2,5| 0.5 – 2| 2.5| 0.9
040813-03×2,5| 1.5 – 3| 2.5| 0.9

Retractor without locking device

Order number| Loading capacity (kg)| Cable travel (m)| Weight (kg)
---|---|---|---
040814-02×2,5| 0.5 – 2| 2.5| 0.8
040814-03×2,5| 1.5 – 3| 2.5| 0.8

Retractor 040823-…, 040824

Adjusting the loading capacity

• Before adjusting the loading capacity, hang the load onto the fully retracted cable,

• Adjustment in the plus (+) direction increases the loading capacity,

• Adjustment in the minus (-) direction reduces the loading capacity,

• When the correct setting is reached, the suspended load can easily be pulled into the desired position, and returns to its original position after release,

• Retractors are shipped from the factory at the maximum load setting, Subsequent adjustments must be recorded in writing so that the maximum and minimum permitted loads are observed later, See the following model-specific specifications,
  Failure to comply with this instruction will destroy the spring!

• The following tool is needed for making adjustments: an Allen wrench (6 mm)

• Insert the Allen wrench into the adjustment screw (14), Using the Allen wrench, make the desired adjustment within the permitted adjustment range, The adjustment screw (14) moves the spring ratchet (11), which has a mark on its outer side, This mark can be used to observe the adjustment,

Column “X” = maximum permitted number of turns in the minus direction, starting from the factory maximum load setting

Adjusting the cable length and cable length limit

Adjusting the cable length

The retractor is delivered from the factory with a longer cable (10), Before commissioning the desired cable extension length must be adjusted,

1. To extend the cable (10), pull it through the cable lock (7), The minimum distance of 100 mm shown between the cable lock (7) and cable clamp (9) must be observed,
2. When the desired length is reached, the pressure clamp (8) provided must press on the cable,
3. Cut off the projecting end of the cable behind the pressure clamp (8),

Adjusting the cable retraction limit
The maximum permitted cable extension (3 m) may not be exceeded,

• Hang the appropriate load and pull the cable to the desired position,
• Loosen the screws on the cable clamp (9), adjust the desired cable length, and then tighten the screws again,
• The rubber bumper (13) can be moved manually, and protects the basic housing and suspended load,

Operating the retractor

Models with locking device (040823-…)

Caution:

• The automatic locking device (15) may not be used to change loads,
• Loads must always be changed with the cable fully retracted,

The suspended tool is pulled downwards and remains suspended in the extended position, To return it to the starting position, pull the suspended tool sharply downwards for a short distance, then push it quickly upwards, Slow movements will cause the locking device to engage,

Models without locking device (040824-…)
Pull the suspended tool downwards – when it is released, it will return to its original position independently,

Device specifications

Retractor with locking device

Order number| Loading capacity (kg)| Cable travel (m)| Weight (kg)
---|---|---|---
040823-05×3,0| 2 – 5| 3| 3,5
040823-08×3,0| 4 – 8| 3| 3,8
040823-10×3,0| 7 -10| 3| 3,8
040823-14×3,0| 10 – 14| 3| 4,0

Retractor without locking device

Order number| Loading capacity (kg)| Cable travel (m)| Weight (kg)
---|---|---|---
040824-05×3,0| 2 – 5| 3| 3,3
040824-08×3,0| 4 – 8| 3| 3,7
040824-10×3,0| 7 – 10| 3| 3,7
040824-14×3,0| 10 – 14| 3| 3,9

Spare parts

Spare parts drawing 040823-… and 040824

• 040823
• 040824

Contact Information

Conductix-Wampfler GmbH
Rheinstraße 27 + 33 79576 Weil am Rhein – Märkt Germany.
Phone: +49 (0) 7621 662-0
Fax: +49 (0) 7621 662-144
info.de@conductix.com
www.conductix.com.

Importer for the United Kingdom:
Conductix-Wampfler Ltd. 1, Michigan Avenue Salford M50 2GY United Kingdom
Phone: +44 161 8480161
Fax: +44 161 8737017
info.uk@conductix.com
www.conductix.com.

www.conductix.com.

References

• Conductix Wampfler Global | We move your business

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