The coil looks messy, the hole is being covered up or loops fall off the sides of the coil when the endforms are removed. These issues are usually related to incorrect line tension caused by improper settings or mechanical malfunction.


Encoders are not counting properly

  • Ensure the encoders count properly via troubleshooting program.
  • See the troubleshooting manual appropriate for your machine.
  • Ensure motor to encoder couplings and rubber gear are snug and do not have excessive play.
  • Check/Swap W600 cards to ensure proper counting and operation.


Boards and Drives are not tuned properly

  • Watch the graphs on the Maintenance screen of the HMI. They should be mostly centered, if not you may need to retune the drives.
  • Ensure the control boards (W90A,W900) are tuned properly in accordance with REELEX manuals.
  • See Tune Up Procedures - REELEX Drives and Boards
  • Observe if hole issues change with machine speed to rule out certain mechanical failures.


Slipping pulleys or belts

  • If the hole is good at speed 3 but lost at speed 8, check for slippage on the belts and pulleys. 


Guide tube is too far away from mandrel, leading to poor winding control.

  • Adjust guide tube so it is 1/2 to 3/4-inches away from the outer edge of the endform.


Cable not correctly fed through guide tube or sheaves.

  • Buffer action is compromised by miss-feed, resulting in increased tension.
  • Correct wire path to resolve.


Coil or PID Parameters have been changed (D-2000/2050, G2 and G3 Equipment)

  • Revert to known reliable values.
  • Lockout screens to prevent accidental or unauthorized changes. 


Irregular or excessive tension due to improper air pressure regulation at the Dancer.

  • Check gauge at the Dancer air pressure regulator for consistent pressure. Standard REELEX Dancer with 5 over 4 (15 inch) sheaves should have no more than 15 PSI and vary no more than 2 PSI while running.
  • Adjust or replace regulator as needed. The regulator must be REELEX part # FRL-REG/NU10060 (relieving type regulator) or equivalent. 
  • Lower sheave shaft bearing may be worn causing extra friction. Replace as needed.


Mechanical failure of Buffer due to broken or worn parts. 

  • Check Buffer for worn or broken bearings and springs.
  • Sliding assembly must not be limited by friction due to buildup on rails or sticking bearings.
  • Replace parts as required. Use OEM REELEX parts.


Cable OD is less than 0.10 inch (2.54 mm) and/or the cable is slippery or highly flexible.

  • The coil may need to be stretch wrapped. One symptom is the coil will tangle at the end of the payout. (Only a few feet left in the box.)
  • A smaller diameter mandrel should be used.
  • Try using lower tension.
  • Try to get the guide tube as close to the coil as possible.


Gains set too high, causing low wind density.

  • Lower gain settings to decrease negative space in the coil.
  • Gains are too low, causing layers to sit atop one another. Consult packaging charts for minimum and maximum gains per product OD.


Tension too low, causing the layers of the coil to be loose.

  • Increase tension settings to recommended pressures. Check gauge at the Dancer air pressure regulator for consistent pressure. Standard REELEX Dancer with 5 over 4 (15 inch) sheaves should have no more than 15 PSI and vary no more than 2 PSI while running.
  • Adjust or replace regulator as needed. The regulator must be REELEX part # FRL-REG/NU10060 (relieving type regulator) or equivalent. 


Hole Size setting too large, causing the coil to be irregularly shaped.

  • Adjust the Hole Size setting so that the coil produces a hole that is only slightly larger than the payout tube diameter. This setting may vary depending on product type, diameter and coiling conditions.
  • Use higher Density setting - The Density Program works by gradually lowering the upper and lower gains as the product winds, thereby increasing weave density. This program is available as a software upgrade for G1 machines and can lower coil size by as much as 10%.