This article takes an in-depth look at cord reels and their configurations.
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Cord reels are used to manage and store extension cords that provide power to electrical equipment or devices situated at a distance from power outlets. They help in keeping long extension cords organized and prevent tangling or damage when not in use.
Cord reels feature a cylindrical drum designed to hold and manage extension cords. The drum is equipped with two large flanges or discs on either end to keep the cord securely wound. This drum is mounted on a frame that includes various accessories, such as brackets and bases, allowing it to be attached to floors, ceilings, posts, walls, carts, or equipment.
To use the cord reel, pull out the desired length of cord to make the necessary electrical connections; this extended position is known as the payout position. Connect the equipment plug to the receptacles on the cord reel or at the end of the cable. The excess cord remains coiled on the drum. When the cord is no longer needed, the winding mechanism will automatically retract and rewind the cord onto the drum, keeping it organized and ready for the next use.
Cord reels are widely used across various industries to extend the lifespan of power and extension cords. They help prevent tangling and nesting, protecting the cords from wear, abrasion, and damage by allowing only the required length to be exposed for electrical connections. Additionally, cord reels enhance safety by reducing tripping hazards associated with cluttered cables. By choosing the appropriate type, specifications, and installation method for a given application, cord reels provide both convenience and practicality, making them a valuable investment for efficient and safe cord management.
Cord reels are commonly constructed from materials such as plastic (e.g., PVC, ABS), fiberglass, stainless steel, and aluminum. Metal cord reels are typically used for thicker, heavier cords and often feature anti-corrosion coatings to endure outdoor and harsh conditions. Plastic cord reels, suited for lighter cords, are generally used indoors. Premium cord reels may be designed to be water-resistant, non-sparking, dust-proof, and resistant to shock and vibration, making them suitable for extreme environmental conditions.
There are various categories of cord reels available. A single cord reel can belong to multiple categories.
Commercial cord reels are optimally designed for light-duty applications. They are used in environments where corrosion is unlikely to occur. They are usually made of non-metallic material or stainless steel and are portable. They are commonly found in classrooms, offices, retail stores, and others.
Cord storage reels are designed to neatly wind and store extension cords. They typically include a reel drum and a frame with various mounting accessories, while the extension cord itself is purchased separately. Most of these reels are operated manually using a hand crank. They are ideal for keeping extension cords safe and well-maintained when not in use. However, they are meant solely for storage purposes and should not be used while the cord is energized. Always ensure the cord is fully unwound from the reel before plugging it in.
Manual cord reels are operated using a hand crank that rotates the reel drum to extend the electrical cord. To rewind the cord onto the reel, you turn the crank in the reverse direction. These reels are suited for lightweight or shorter cables, as the manual process of winding and unwinding is relatively easy. They are portable, cost-effective, and commonly used in indoor settings like homes, offices, and retail spaces.
Explosion-proof or hazardous location cord reels are engineered to prevent sparks that could cause fires or explosions. They feature a spark-resistant ratchet mechanism and an explosion-proof slip ring enclosure. These reels are certified for use in environments where flammable and explosive materials are present, such as in mining operations, grain storage facilities, and manufacturing plants that produce fuels, fertilizers, paints, or explosives.
Lighted cord reels have an attached lamp at the free end of the power cord. The light source may be an incandescent, fluorescent, or LED lamp. The cord is pulled at the desired length, and the lamp is hung on a ceiling or wall above the area being observed. The light from the lamp may be directed flexibly for optimal lighting.
Lighted cord reels are perfect for outdoor environments and locations lacking nearby power sources. They are also useful indoors, such as in service garages, where they provide additional lighting to illuminate the workspace.
Live connection cord reels enable continuous electrical flow through the cord even when part of it is still wound on the reel. These reels are equipped with connection hardware that includes electrical sockets. A crucial element for these reels is the collector ring, which ensures smooth operation while the cord remains live. The collector ring is responsible for delivering power and electrical signals necessary for the reel drum's rotation.
Medical cord reels are specifically engineered for use in healthcare environments such as hospital wards, operating theaters, emergency departments, medical labs, and radiology suites. They are also utilized in mobile clinics and portable laboratories.
These cord reels help prevent tripping hazards and ensure a stable power supply to medical equipment, which is crucial for patient safety. They usually feature a spring-driven retraction system and are housed in a robust, durable casing. The materials used in medical cord reels are selected for their ease of cleaning, waterproof properties, resistance to corrosion, and antimicrobial characteristics.
Motor-driven cord reels feature a motor to assist in winding the cord onto the reel drum. They are particularly useful when significant retraction force is required. These reels operate at slow speeds and maintain consistent tension on the cord, helping to prevent overstretching and potential damage.
Motor-driven cord reels can be powered by electric, hydraulic, or pneumatic motors. Electric motors, which use either AC or DC power from an electrical outlet, are straightforward to use, cost-effective, and efficient. Hydraulic and pneumatic motors, powered by pressurized liquids and compressed air, respectively, are ideal for environments lacking direct power sources. They are designed to avoid overheating under load and are suitable for areas with high fire and explosion risks.
These reels are commonly employed in heavy-duty scenarios, including outdoor and remote locations like mines, tunnels, refineries, construction sites, and water treatment facilities.
Open cord reels are designed without an enclosure, providing direct access to their internal parts. They are typically used in light-duty applications and are suited for environments where corrosion is not a concern.
Retractable cord reels automatically pull the cord back to the reel drum, making them easier to operate than manual cord reels. They use a spring mechanism to provide the retraction force. As the cord is uncoiled and pulled out for use, tension builds up on the steel torsion spring. Once the electrical power is no longer needed, the stored energy in the torsion spring is released, retracting the cord back to the reel.
As the cord is extended, it moves through a gap between two roller guides that steer its direction. These rollers are made from smooth materials to minimize cord wear. A ratcheting system locks the reel drum at various positions to maintain the desired length of the cord. A stopper, larger than the clearance, is positioned near the cord's end to secure it when fully retracted. Additionally, the guide arm adjusts the angle at which the cord is paid out.
Retractable cord reels are often installed centrally to streamline the workspace. They can be mounted on ceilings, walls, or workbenches. Commonly found in service garages, machine shops, and manufacturing facilities, these reels help keep the work area organized and efficient.
Stainless steel cord reels are typically made from grade 304 stainless steel, known for its superior mechanical properties, including high strength and durability, as well as excellent resistance to corrosion. These reels are ideal for use in industries such as food processing, pharmaceuticals, and healthcare, where maintaining hygiene and preventing contamination are critical. Additionally, other sectors can also take advantage of the robust performance and longevity offered by stainless steel cord reels.
The typical installation configurations for cord reels vary based on their intended use. This factor is crucial when choosing the right cord reel for your needs.
In a lift configuration, a stationary cord reel is fixed to a wall or ceiling above the work area. The cord is lowered vertically either manually or using a mechanism. The reel is built to support the weight of the cord and the outlet box, so it must be constructed from robust materials. A ratchet mechanism ensures that the cord stays in place when extended. This setup is commonly used in manufacturing environments and retail stores.
In a drag configuration, the cord reel is mounted on a wall or post slightly above the floor. The cord is pulled horizontally from the reel, either manually or by machinery, as it remains on the ground. A ratchet mechanism secures the cord once it is extended. This configuration allows for flexible extension over longer distances as the cord moves horizontally.
In a stretch configuration, the cord extends horizontally with some sag and no support. The reel can be either stationary or mobile and is typically mounted on the ceiling or high up on a wall. The cord should be 10% longer than the distance from the reel to the workstation to account for the sag.
In a retrieve configuration, the cord reel is attached to mobile equipment, with the cord’s free end secured to a stationary point. As the reel moves away from the anchor, the cord unwinds and extends. When the reel moves back towards the anchor, the cord retracts. Strong spring tension is necessary to ensure the cord retracts quickly enough to keep pace with the moving equipment.
In a vertical pick-up configuration, the cord reel is mounted on a machine component that moves up and down. The power source is located above the reel drum at the end of the cord. As the machine moves, the reel coils or releases the cord accordingly. Adequate spring tension is required to manage the cord’s upward movement into the reel.
Choosing the right cord reel can significantly boost productivity and enhance safety in your workspace. With a variety of designs available, it's important to consider the following factors to select the most suitable cord reel for your specific needs:
The first consideration when choosing a cord reel is the type and specifications of the cord it will accommodate. It's essential to determine the cord's outer diameter, length, bend radius, and gauge before selecting a reel. These dimensions impact the size of the reel required; larger and thicker cords necessitate a bigger reel. Additionally, the weight of the cord should be factored in, as heavier and longer cords may need an automatic retraction system to handle the increased effort and save time and labor.
The required cord length must be estimated in order to select the live connection cord reel, which covers the distance between the power source and the workstation. The following are the operating parameters of cord reels pertaining to the required cord length:
When purchasing live connection cord reels, ensure that the reel comes with a cord of adequate length and the necessary connection hardware. It’s crucial to verify that the reel matches the required amperage, voltage rating, and plug and socket type to ensure reliable power transmission from the mains to your equipment.
The connection hardware should provide enough electrical outlets to support all your devices. Consider safety features such as sockets with grounding terminals for added protection. Some cord reels are equipped with automatic circuit breakers to safeguard against short circuits and current surges. Additionally, certain models offer USB ports for convenient charging of devices.
Consider the operating environment of the cord reel when making your selection. A robust enclosure or casing is essential for protecting the internal components from damage caused by moisture, corrosion, dust, and debris. Enclosures help ensure the cord reel’s performance and reliability, especially in outdoor or harsh conditions. Consequently, enclosed cord reels are generally preferable to open models.
Cord reel enclosures are often rated according to standardized systems. The manufacturer usually provides the specific rating for the enclosure, which indicates its level of protection.
IP Rating System. IP (Ingress Protection) ratings are used to classify electrical enclosures based on their sealing effectiveness against unwanted intrusion of foreign bodies and moisture. They indicate the suitability of the device for use in a specific environment. IP ratings are assigned per EN 60529 or IEC 60509.
A two-digit code is assigned to each electrical enclosure. The first digit indicates the protection from foreign bodies and particulates. Meanwhile, the second digit indicates the protection from moisture and immersion in water. The digit is replaced by “X” if the enclosure is unrated or offers no protection.
Underwriters Laboratories (UL) is an independent safety organization headquartered in Northbrook, Illinois. UL’s team of experts tests and assesses various electrical products, including cord reels, to identify potential hazards.
The certification and inspection of cord reels are conducted in accordance with UL 355, also known as the UL Standard for Safety Cord Reels. A UL certification indicates that a cord reel meets stringent safety and performance standards. Cord reels that have been certified by UL often display a UL mark to signify their compliance with these rigorous criteria.
Lastly, consider your budget when selecting a cord reel. Opt for a reel that offers the necessary features and specifications while staying within your financial limits.
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