855® Smart Bender®

Transcript

855® Smart Bender® Page 1 SERVICE MANUAL 855® Smart Bender® and 01711 Optional Deluxe Pendant Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 52033652 © 2007 Greenlee Textron Inc. 11/07 Serial Code AKN Page 2 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 2 Safety Safety is essential in the use and maintenance of Greenlee tools and equipment. This service manual and any markings on the tool provide information for avoid- ing hazards and unsafe practices related to the use of this tool. Observe all of the safety information provided. Purpose of This Manual This manual is intended to familiarize authorized Greenlee service center personnel with the safe operation and maintenance procedures for the Greenlee 855 Smart Bender, Serial Code AKN. Keep this manual available to all personnel. Replacement manuals are available upon request at no charge at www.greenlee.com. Other Publications Instruction Manual: 52033651 All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Smart Bender is a registered trademark of Greenlee Textron. Loctite is a registered trademark of Loctite Corporation. Molex is a registered trademark of Molex Inc. KEEP THIS MANUAL Table of Contents Introduction ................................................................... 2 Important Safety Information .....................................3–4 Grounding Instructions .................................................. 5 Setup ..........................................................................5–6 Adjustments .................................................................. 7 Maintenance .............................................................8–10 Bender Head Disassembly .....................................11–12 Motor Disassembly ...................................................... 13 Trunnion Disassembly ................................................. 13 1/2" to 1-1/4" Side Exploded View ............................. 14 1-1/2" to 2" Side Exploded View ................................. 15 1-1/2" to 2" Roller Support Unit Exploded View ......... 16 Motor and Gearbox Exploded View and Parts List ..... 17 Main Exploded View ...............................................18–19 Main Parts List ........................................................20–21 Electrical Control System Layout and Parts List ......... 22 Power Generation Unit Schematic Diagram, Parts List, and Layout Diagram ..........................23–25 Input/Output Board Schematic Diagram, Parts List, and Layout Diagram ..........................26–28 Standard Pendant Switch Schematic Diagram, Parts List, and Layout Diagram ..........................29–30 Optional Bending Attachments Exploded View and Parts List .................................. 31 Troubleshooting ......................................................32–38 Page 3 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 3 IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for pre- venting or avoiding the hazard. Immediate hazards which, if not avoided, WILL result in severe injury or death. Hazards which, if not avoided, COULD result in severe injury or death. Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage. Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Failure to observe this warning could result in severe injury or death. Do not use this tool in a hazardous environment. Hazards include flam- mable liquids, gases, or other mate- rials. Using this tool in a hazardous environment can result in a fire or explosion. Failure to observe this warning will result in severe injury or death. Electric shock hazard: Connect the power cord to a 120 V, 20 A receptacle on a ground fault-protected circuit only. Refer to “Grounding Instructions.” Do not modify the power cord or plug. Inspect the power cord before use. Repair or replace the cord if damaged. Disconnect the unit from power before servicing. Failure to observe these warnings could result in severe injury or death. • • • • Do not expose to rain. Do not use in wet or damp locations. Do not immerse the pendant switch in water or any other liquid. Failure to observe these warnings could result in severe injury or death. • • • Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris. Do not remove guards. Failure to observe this warning could result in severe injury or death. Page 4 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 4 Extension cords: Use only three-wire, 12 AWG extension cords that have three- prong, grounding-type plugs and three-hole receptacles that accept the tool’s plug. Do not use extension cords that are longer than 30 m (100'). Repair or replace damaged exten- sion cords. Failure to observe these warnings could result in severe injury or death. • • • Pinch points: Keep hands away from bending shoe, rollers, and conduit when bender is in use. Failure to observe this warning could result in severe injury or death. Unplug the bender before changing accessories. Accidental startup could result in serious injury. Adjust fork spacing to match fork tubes on bender. Ensure caster brakes are locked and casters are straight before inserting forks into fork tubes. Forks must extend beyond ends of fork tubes a minimum of 8". Failure to observe this warning could result in severe injury or death. Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts. Failure to observe this warning could result in severe injury or death. IMPORTANT SAFETY INFORMATION Do not use tool as a step or ladder. Conduit moves rapidly as it is bent. The path of the conduit must be clear of obstructions. Be sure clearance is adequate before starting the bend. Inspect the bender before use. Replace worn, damaged, or missing parts with Greenlee replace- ment parts. A damaged or improperly assem- bled component could break and strike nearby personnel. Set the switches to the appropriate conduit size and type before bending. Select the appropriate shoe groove and support roller for the type and size of conduit before bending. Do not bend conduit over 93 degrees. Overbending could result in the other shoe hook colliding with the conduit. Some bender parts and accessories are heavy and may require more than one person to lift and assemble. Ensure that all bystanders are away from the work area when operating the bender. Ensure that the work area is clean, dry, uncluttered, and well-lit. Use this tool for the manufacturer’s intended purpose only. Use other than that which is instructed in this manual can result in injury or property damage. Failure to observe these precautions may result in injury or property damage. • • • • • • • • • Note: Keep all decals clean and legible, and replace when necessary. Page 5 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 5 Grounding Instructions Electric shock hazard: Do not modify the plug provided with the tool. Connect this tool to a grounded receptacle on a 20 A GFCI-pro- tected circuit. Failure to observe these warnings could result in severe injury or death. • • This tool must be grounded. In the event of a malfunc- tion or breakdown, an electrical ground provides a path of least resistance for the electric current. This path of least resistance is intended to reduce the risk of electric shock. This tool’s electric cord has a grounding conductor and a grounding plug as shown. Do not modify the plug. Connect the plug to a corresponding GFCI-protected receptacle that is properly installed and grounded in accordance with all national and local codes and ordinances. Do not use an adapter. NEMA L5-20 Receptacle Plug Setup Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris. Follow these steps, which are described in greater detail in this section, to set up the bender. 1. Transport the bender to the job site. 2. Lock both swivel casters. 3. Pivot the bending head to the desired position. 4. Connect the pendant to the bending head. 5. Plug the power cord into a 120 VAC, 20 A GFCI- protected receptacle. For best performance, use a dedicated circuit for this unit and do not use extension cords. 6. Turn on the power switch. Transporting the Bender Make sure that all components used to lift the bender are properly rated for the 231 kg (510 lb) weight. Use a ramp to load and unload the bender from a truck or other vehicle that is not equipped with a lift gate. To roll the bender: 1. Unlock swivel casters. 2. Pivot the bending head to the horizontal position with the 1-1/2" to 2" shoe facing up. 3. Use the transport handle to push and steer the bender. To lift the bender: 1. Pivot the bending head to the horizontal position with the 1-1/2" to 2" shoe facing up. 2. Rotate the lifting eyes so that they are accessible. 3. Loop the sling (or attach the hooks) to the lifting eyes. Make sure that each side of the sling or chain is 1 m (3') long to prevent it from rubbing against the bender. 4. Securely attach the sling or chain to the lifting device. Page 6 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 6 Setup (cont’d) Pivoting the Bending Head Do not rotate the bending head if one or more of the bending shoes is removed. The bender head pivot lock must be fully engaged in the frame hole and fully turned in the counter- clockwise direction. Failure to observe these warnings could cause the bending head to move rapidly in an unexpected direction, resulting in severe injury or death. • • The bending head can be rotated into three positions: Vertical Horizontal, 1/2" to 1-1/4" shoe facing up Horizontal, 1-1/2" to 2" shoe facing up To change the bending head position: 1. Rotate the bender head pivot lock knob clockwise until it contacts the bending head. 2. Pull out the bender head pivot lock knob. 3. Pivot the bending head to the desired position. 4. Release the bender head pivot lock knob so that the pin is fully engaged in the frame hole. 5. Turn the pivot lock knob counterclockwise until there is resistance. Do not overtighten. • • • Connecting the Standard or Deluxe Pendant Do not connect or disconnect the pendant while the power is on, or permanent damage to the pendant or bender circuitry may result. Remove the pendant control from its storage area, and plug it into the four-pin receptacle on the side of the bending head. CONDUIT TYPE DECAL NO. 500 1487.0 RIGID ALUM PVC IMC EMT CONDUIT SIZE DECAL NO. 500 8896.7 1/2 3/41 1-1/4 1-1/2 2 Page 7 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 7 Adjustments Disconnect power supply before ser- vicing bender. Servicing to be done only by trained service technician. Failure to observe this warning could result in severe injury or death. Squeeze Proper squeeze adjustment for most 1-1/2" and 2" EMT and IMC conduit is when the squeeze adjustment arm is vertical (at middle hole). But variation in conduit can result in wrinkling or side marking of conduit. If wrinkling or excessive ovalness occurs, increase squeeze one position (hole) counterclockwise. If loading conduit is difficult or if excessive side marking occurs, decrease squeeze one position (hole) clockwise. Accuracy If the accuracy of all sizes of conduit on one shoe is off in the same direction, the limit switch needs to be adjusted. Individual adjustments specific to one size and type of conduit should be made using the Accuracy Adjust mode. Refer to the “Troubleshooting” section. To adjust the limit switches, first unplug the bender. Remove the four screws that secure the top round guard and remove the guard to expose the two limit switches. The top switch controls the 1-1/2" to 2" shoe. Loosen the two screws and move it to the right side of the bender as shown in the diagram below to prevent overbending. The bottom switch controls the 1/2" to 1-1/4" shoe. Loosen the two screws and move it to the left side of the bender as shown below to prevent over- bending. Move either switch the opposite direction if the bender is underbending. Every 1/8" of switch movement approximates 1 degree of change. Tighten the screws and replace the guard. 1-1/2" and 2" Limit Switch Adj. Screws 1/2" to 1-1/4" Limit Switch Adj. Screws Less Bend Less Bend Retention Cam Loosen the screws securing the retention cam. With the bender oriented in the vertical position, rotate the round plate until the right side edge of the cam is pointed straight down or within 1/4" left of being straight down. Make sure both ends of the spring are engaged in the holes of the cam and round plate. Tighten the screws while holding the round plate in position with pliers to prevent it from rotating. 1/4" Check to make sure the roller support handle will fully engage and retract without catching on the cam holding surface. This should be done in both the vertical and horizontal bending positions. It should also be done with the cam positioned as far left and as far right as friction will allow it to stay. Cam Holding Surface Page 8 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 8 Maintenance Electric shock hazard: Disconnect the unit from power before servicing. Failure to observe this warning could result in severe injury or death. Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris. Schedule Component Maintenance Activity Maintenance Interval Chain Lubrication and Tension Adjustment Every 6 months* Roller Supports Cleaning and Lubrication Every 6 months* Commutator Brushes Replacement When drive unit performance diminishes noticeably * More often if the bender is used in dusty or corrosive environments Chain Lubrication and Tension Adjustment 1. Disconnect the bender from the power source. 2. Refer to the “1-1/2" to 2" Side Exploded View.” Remove the 1-1/2" to 2" shoe (refer to “Changing Shoes” in this section of the manual). 3. Refer to the “Main Exploded View.” Remove the screws (23) and front chain guard assembly (4). 4. Spray a motorcycle chain lubricant on the inside of the chain between the sprockets while pressing UNLOAD. Lubricate the entire length of the chain. 5. Check the amount of slack halfway between the sprockets. If the chain slack is : More than 25 mm (1"), proceed to step 6. Less than 25 mm (1"), proceed to step 10. 6. Remove 11 screws (23) and the motor guard (5). 7. Loosen the two motor mounting screws (25) on the front, the two on the back, and the nut (22). 8. Torque the eccentric locator (21) to 81 Nm (60 ft-lb). Maintain this amount of torque while tightening the nut (22) and two front screws (25). 9. Tighten the two rear screws (25). 10. Assemble in reverse order. 1/2" to 1-1/4" Roller Support 1. Disconnect the bender from the power source. 2. Remove the support pivot pin (19). Remove the roller support (7). 3. Spray a motorcycle chain lubricant through the 3 mm (1/8") diameter hole in each roller. Rotate each roller to distribute the lubricant. 4. Spray the pivot pin. 5. Wipe away any excess lubricant. 6. Replace the roller support and pivot pin. • • Page 9 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 9 Maintenance (cont’d) 1-1/2" to 2" Roller Support 1. Disconnect the bender from the power source. 2. Remove the 1-1/2" to 2" shoe (refer to “Changing Shoes” in this section of the manual). 3. Refer to the “1-1/2" to 2" Roller Support Unit Exploded View.” Use a pair of needle-nose pliers to disconnect the springs (104) from the holes in the side of the bender frame beneath the roller support unit. 4. Refer to the “Main Exploded View.” Remove the squeeze adjustment arm screw (97) and arm (74). 5. Remove the three button head cap screws (96) and adapter sleeve (92). 6. Place one hand under the support arms (71) to support the weight of the roller support unit. Remove the eccentric shaft (91). Note: You may need to rotate the eccentric shaft to remove it. Pinch points: Keep hands away from bending shoe, rollers, and conduit when bender is in use. Failure to observe this warning could result in severe injury or death. 7. Lift the roller support subassembly to the left and upward. 8. On the 1-1/2" roller group: Loosen the sleeve set screw (98) and remove the 1-1/2" pivot roller shaft (86) with grip (90). Remove the sleeve (87). Remove two hex head screws (93). Remove the outer roller plate (75). Remove the tail roller (84). Remove all components of the split roller assembly. 9. On the 2" roller group: Loosen the sleeve set screw (98) and press out the 2" pivot shaft (88). Remove the sleeve (89). Remove the hex head screw (93). Remove one retaining ring (95) from the tail roller shaft (83). Remove the outer roller plate (76). Remove the tail roller (82) and center roller (85). Remove all components of the split roller assembly. • • • • • • • • 10. Clean off all of the grease and dirt. 11. Inspect each item. Replace any worn, damaged, or missing items. 12. Lubricate all working surfaces with a high-quality grease. 13. Replace all components in reverse order, noting the following: On both roller groups: To ease the assembly of the split roller subassemblies, begin by slipping the O-rings onto the side plates. Assemble the split roller subassemblies as shown, and then slip the O-rings into their correct positions. On the 2" roller group only: After replacing any split roller components, add or remove shim washers (99, 119, or 150) as needed. On the 1-1/2" roller group: Install the two Belleville washers (100) so that the inside diam- eters contact each other. Use Loctite® 271 on the two hex head screws (93). Torque to 55 Nm to 61 Nm (40 ft-lb to 45 ft-lb). 14. Position the roller support arms (71) as shown. Assemble the roller groups to the support arms. 15. Reinstall the roller support unit to the bender. Keep one hand under the support arms so they do not drop completely below the set screw (107). 16. Insert the eccentric shaft (91). Note: You may need to rotate the eccentric shaft to get it to seat completely. 17. Install the adapter sleeve (92) and three button head cap screws (96). 18. Install the adjustment arm (74) and adjustment arm screw (97). 19. Attach the springs (104) to the holes in the side of the bender frame beneath the roller support unit. 20. Put the bender in the horizontal bending position. Adjust the set screw (107), if necessary, so that the support arms (71) are centered between the front and back plates. Engage and disengage the roller support unit to be sure that it moves freely. • • • • Page 10 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 10 Maintenance (cont’d) Changing Shoes 1. Disconnect the bender from the power source. 2. Lock the bender head in the vertical bending posi- tion (refer to “Pivoting the Bending Head” in the “Setup” section of this manual). 3. Refer to the “1/2" to 1-1/4" Side Exploded View” or the “1-1/2" to 2" Side Exploded View.” Use heavy- duty retaining ring pliers to remove the retaining ring (26) that secures the shoe. 4. Remove the shoe from the spindle. 5. Mount the replacement shoe onto the spindle. Align the slot in the shoe bore with the screw head on the spindle. Push the shoe onto the spindle until the drive lugs are fully engaged in the drive lug holes. Replace the retaining ring. Motor The motor commutator brushes should last for about 1000 hours of normal use but will eventually need to be replaced. 1. Disconnect power to the unit. 2. Remove the motor cover. 3. Remove the power cord strain relief. 4. Remove the two nuts securing the shroud to the tail of the motor and remove the shroud. 5. Push in the commutator brush retainer and move it toward the brush to release it. Unplug the brush and remove it. Replace it if the length is less than 1/4". 6. Reassemble in reverse order. Setting Roller Support Limit Switch The switch is activated by the main outer roller support arm, in the retracted position. Retract the switch from the maximum switch travel by pivoting the switch in its mounting holes and rotating it clockwise in its mounting slot. Set the squeeze adjustment at the maximum clockwise position. Move the switch in a counterclockwise direc- tion (with a 0.030" feeler gage between the roller arm and the body). When the roller, arm, gage, and switch body are in contact, tighten the mounting screws. The switch lockout circuit is normally closed. Attach alligator clips to the common and normally closed switch terminals to check switch trip operation. Do not insert meter probes into the Molex® plug. Brake Under normal circumstances the brake should not require adjustment. However, if the brake can be heard dragging while bending or if the braking performance deteriorates, brake adjustment may be necessary. Do not touch the brake if the bender has been recently used. It will be hot. Wait an hour for it to cool off before adjusting. 1. Disconnect power to the unit. 2. Remove the motor cover. 3. Loosen the two set screws on the brake rotor hub (the part that turns). 4. Slide it to a position 0.002" to 0.015" away from the mating face (about 1 to 3 page thicknesses of this manual). 5. Tighten the set screws to 4 Nm (35 in-lb). 6. Replace the motor cover. Drive lugs must engage in these holes. Page 11 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 11 Bender Head Disassembly Disconnect power supply before servicing bender. The bender head should be serviced/disassembled while on the trunnion base. Failure to observe this warning could result in severe injury or death. Electronics Note: Refer to the “Electrical Control System Layout and Parts List” for the location of key numbers. Power Generation Board (PGU) 1. Remove the four screws securing the top round cover, and remove the cover. 2. Disconnect the ground jump wire (28) and the white and black leads of the Power AC Wire Unit (21). 3. Disconnect the power cord neutral (white) wire (3). 4. Disconnect the power lead (black) from the switch (1). 5. Disconnect the PGU-I/O cable (13). 6. Disconnect the motor leads (2). 7. Remove the four screws securing the PGU subplate and remove the assembly. 8. Assemble in reverse order, noting the proper polarity of all wires as shown. Rectifier 1. Remove the PGU subplate by following steps 1 to 7 under “Power Generation Board” disassembly above. 2. Disconnect the red, black, and two yellow wires to the rectifier (18, 19, 20). 3. Remove the screw, lock washer, and nut securing the rectifier. 4. Assemble in reverse order, using heat transfer grease between the rectifier and subplate. Relay 1. Remove the PGU subplate by following steps 1 to 7 under “Power Generation Board” disassembly above. 2. Disconnect the red and black PGU-relay wires (11, 12). 3. Disconnect the relay wire unit (8). 4. Remove the red and black relay wires (9, 10). 5. Remove the two screws, lock washers, and nuts, and then remove the relay. 6. Assemble in reverse order. Input/Output Board (I/O) 1. Remove the four screws securing the top cover and remove the cover. 2. Disconnect the receptacle unit (4). 3. Disconnect the selector switch (22). 4. Disconnect the unload lockout switch (7). 5. Disconnect the limit switch (5). 6. Disconnect the optical encoder (23). 7. Disconnect the brake wire (6). 8. Disconnect the PGU-I/O cable (13). 9. Disconnect the Power AC Wire Unit (21). 10. Remove the four screws securing the I/O subplate and remove the assembly. 11. Assemble in reverse order, noting the proper polarity of all wires as shown. Chain If the chain breaks, replace it with new chain (90542509)—not another master link. Because of the high stress on the chain, the addition of a second master link will only weaken the chain further. If the master link breaks, replace it with a new master link (90542517). 1. Remove the four screws securing the top cover and remove the top cover. 2. Remove the 1-1/2" to 2" shoe (refer to “Changing Shoes” in the “Maintenance” section of this manual). 3. Remove the seven screws securing the front guard and remove the guard. 4. Remove the nine screws securing the motor cover and remove the motor cover. 5. Rotate the motor until the chain master link is accessible at the top of the bender. 6. With the bender head in the horizontal position, loosen the four bolts and nut securing the motor and turn the eccentric adjusting bolt to allow chain slack. 7. Tap the motor toward the spindle to slack the chain, taking care not to allow the encoder to contact the frame. 8. Remove the cotter pins, master link, and chain. 9. Reassemble in reverse order, noting the following: Torque the eccentric adjusting bolt to 81 Nm (60 ft-lb) while tightening the two front bolts and nut to maintain chain tension. Use a new master link and cotter pins. • • See Electrical Control System Layout for location of key numbers. Page 12 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 12 Bender Head Disassembly (cont’d) Spindle 1. Remove the chain (refer to “Chain” disassembly). 2. Remove the 1/2" to 1-1/4" shoe (refer to “Changing Shoes” in the “Maintenance” section of this manual). 3. Loosen the 1/2" to 1-1/4" drive plate hub set screw. 4. Remove the socket head screw in the 1/2" to 1-1/4" spindle. 5. Remove the drive plate and key. 6. Use a file to remove any raised edges from the spindle to prevent bearing damage. 7. Remove the spindle/sprocket. 8. Reassemble in reverse order. Limit Switch Bracket 1. Remove the spindle (refer to “Spindle” disassembly). 2. Remove the four screws securing the two limit switches, and remove the switches. 3. Remove the two screws securing the bracket and remove the bracket. 4. Reassemble in reverse order, noting the following: The limit switch with red wires goes on top. Install the top switch so that the trip roller is as far left as possible, as viewed with the switch behind the bracket. Install the bottom switch (black wires) with the trip roller as far right as possible, as viewed with the switch behind the bracket. Temporarily install both shoes before installing the chain. Place 2" IMC in the bender and rotate the shoe until the conduit locks up against tail roller. (Do not raise the support rollers as is normal for IMC.) Slide the top limit switch until the contacts trip and tighten in that position. Place 1/2" rigid in the bender and rotate the shoe until the conduit locks up against the support roller. Slide the bottom switch until the contacts trip and tighten in that position. Rotate the spindle, checking that the limit switch trip bolts do not snag the trip rollers. Readjust the bracket mounting, if necessary. 1-1/2" and 2" Limit Switch Adj. Screws 1/2" to 1-1/4" Limit Switch Adj. Screws Less Bend Less Bend • • • • • • • • • Brake 1. Remove the eleven screws securing the motor cover, and remove the cover. 2. Loosen the two set screws securing the brake rotor, and remove the rotor. 3. Remove the power supply leads. 4. Remove the four screws securing the brake housing, and remove the housing. 5. Reassemble the brake housing and power leads. 6. Use shims to set the brake rotor gap at 0.002" to 0.015" and tighten. 7. Replace the motor cover. Optical Encoder 1. Remove the four screws securing the top cover, and remove the cover. 2. Remove the seven screws securing the front guard, and remove the guard. 3. Remove the nine screws securing the motor cover, and remove the cover. 4. Rotate the motor until both hub set screws are accessible. 5. Loosen the two set screws in the drive hub. 6. Unplug the encoder from the I/O board. 7. Remove the two mounting screws and round plastic spacers securing the encoder, and pull off the encoder. Note: Attach a wire or string to the encoder plug at the I/O board to serve as a retrieval line to pull the new wire and plug up through the unit. 8. Reassemble in reverse order, noting the following: Torque the hub set screws to 0.16 Nm (22 in-oz). Jog the motor and check Quad 1 and Quad 2 LEDs for on/off pulsing. • • Page 13 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 13 Motor Disassembly 1. Remove the optical encoder (refer to “Optical Encoder” disassembly in the “Bender Head Disassembly” section). 2. Remove the chain (refer to “Chain” disassembly ). 3. Remove the brake (refer to “Brake” disassembly ). 4. Loosen the motor sprocket set screws, and remove the sprocket and key. 5. Disconnect the motor leads at the relay and the ground wire. 6. Remove the five motor mounting bolts and nut. 7. Remove the motor. Note: Attach a wire or string to the motor leads at the power generation board to serve as a retrieval line to pull the new wire through the unit. 8. Assemble in reverse order. Trunnion Disassembly 1. Support the bender’s entire weight, which is approximately 230 kg (500 lb), at the lifting eyes, but do not lift above the floor. Note: Lifting slings must attach to the lifting mecha- nism within the width boundaries of the bender to prevent the lifting eyes from sliding off once the retaining rings are removed. CORRECT INCORRECT 2. Remove the support tower on the rotary selector switch side. Remove the two bolts and two nuts at the side of the tower. Remove the outer retaining ring on each side of the bender. Slide the tower off the pivot spindle. 3. Slide the remainder of the trunnion assembly off the opposite pivot spindle. Bender head may rotate a bit when locking detent pin is disengaged. Keep hands clear. 4. Remove the remaining support tower from the base. 5. Pull out the detent pin, knob, and spring. 6. Remove the four bolts and swivel casters on each side. 7. Remove the stationary wheels. Remove the retaining rings on the axle. Press out the axle. Remove the wheel and washers from each side. 8. Assemble in reverse order, but leave out the detent pin, knob, and spring. After all else is assembled, rotate the bender head so that the top of the bender is pointed toward the kickstand, and insert the detent pin assembly. Hold the detent pin in while rotating the bender head back to one of its normal positions. • • • • • • Page 14 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 14 1/2" to 1-1/4" Side Exploded View Note: Refer to the “Main Parts List” to identify the parts in this illustration. 7 19 204 5 26 23 223 225 224 222 225 221 43 Shoe Unit 1/2" to 1-1/4" consists of 221, 222, 223, 224 and 225 205 205 206 206 Page 15 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 15 1-1/2" to 2" Side Exploded View Note: Refer to the “Main Parts List” to identify the parts in this illustration. 3 74 213 97 207 96 91 92 26 224 226 226 227 228 229 44 Shoe Unit 1-1/2" to 2" consists of 224, 226, 227, 228 and 229 The Roller Support Unit exploded view is on the following page. Page 16 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 16 1-1/2" to 2" Roller Support Unit (50005740) Exploded View Note: Refer to the “Main Parts List” to identify the parts in this illustration. 95 118 89 73 98 117 80 71 104 84 72 115 86 116 78 77 100* 77 78 98 116 87 94 75 93151 101 90 93 99, 119 or 150 Note: Torque to 54 to 61 Nm (40 to 45 ft-lb) 93 88 76 117 95 104 83 85 105 82 80 79 81 79 *Two required Page 17 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 17 Motor and Gearbox Exploded View and Parts List 22 23 10 4 6 5 2 1 20 21 16 15 13 14 17 19 18 12 22 8 1 2 9 23 8 11 8A 3 25 24 26 27 Bolt Tightening Sequence for Gearbox Cover 6 4 3 1 2 5 1. Torque gearbox bolts to 11/9 Nm (100/80 in-lb) in sequence shown. 2. Assemble all Belleville washers so that I.D.’s butt and O.D.’s contact bearings. 3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 4. Insert commutator brushes before connecting push-on terminals. UPC No. Key 78-3310- Part No. Description 1 86705 91867053 Commutator Brushes 2 86706 91867061 Commutator Brush Retention Springs 3 86707 91867070 Tail Housing 4 86708 91867088 Brush Assembly Plate 5 86709 91867096 Cord 6 39092 50390929 Shroud 8 02863 52028638 Armature/Housing Set 8A 86071 91860717 Bearing 9 54348 90543483 Belleville Washers 10 39073 50390732 Rear Gear Housing 11 39074 50390740 Gasket 12 39075 50390759 Front Gear Housing 13 39076 50390767 Output Gear Shaft 14 39077 50390775 Short Spacer 15 39078 50390783 Long Spacer 16 39079 50390791 2nd Reduction Pinion Shaft w/ BRGs 17 53323 90533232 Wave Washer 18 39080 50390805 3rd Reduction Pinion Shaft w/ BRGs 19 54248 90542487 Belleville Washer 20 39081 50390813 4th Reduction Pinion Shaft 21 39082 50390821 Small Spacer 22 54043 90540433 1/2-20 x 2-1/2 Screw 23 02298 50022989 1/4-28 x 9-1/4" Stud 24 51705 90517059 1/4-28 Hex Nut 25 50749 90507495 1/4" Internal Tooth Lockwasher 26 07208 50072080 Oil Seal 27 07209 50072099 Oil Seal Page 18 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 18 Main Exploded View 19 205 206 205 206 204 213 13 17 12 11 16 10 27 7 3 5 23 26 14, 28 8 201 6 202 240 208 208 30 231 18 15 45 46 47 2 34 31 36 58 15 15 25 33 48 49 21 57C 57A 57B 57D 57H 57F 57G 57E 57 209, 211, 212 221 225 223 225 224 23 55 60 53 20 59 51 52 50 22 20A 43 23 179 37 170 233 233 177 34 31 178 29 178 207 Page 19 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 19 12 1 26 9 176 , 28 203 208 240 54 231 15 228 226 224 229 226 44 4C 4B 4, 4A 23 35 32 15 18 07 If the chain breaks, replace it with new chain (90542509)—not another master link. Because of the high stress on the chain, the addition of a second master link will only weaken the chain further. If the master link breaks, replace it with a new master link (90542517). = Cam Repair Kit (50079395) 95 118 89 73 98 117 80 71 104 84 72 115 86 116 78 77 100 77 78 98 116 87 94 75 93 151101 90 93 99, 119 or 150 Note: Torque to 54 to 61 Nm (40 to 45 ft-lb) 93 88 76 117 95 104 83 85 105 82 80 79 81 79 21 6 91 74 92 96 97 111 114 106 107 109 108 112 113 Page 20 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 20 Main Parts List UPC No. Key 78-3310- Part No. Description Qty UPC No. Key 78-3310- Part No. Description Qty 2 01622 50016229 Frame weldment ..............................................1 3 38217 50382179 Guard weldment, top chain ...............................1 4 38983 50389831 Guard assembly, front chain .............................1 4A 38236 50382365 Guard, front ......................................................1 4B 38244 50382446 Retainer ...........................................................1 4C 50160 90501608 Rivet, 3/16" pop ...............................................2 5 38232 50382322 Guard weldment, motor ....................................1 6 01607 50016075 Guard, bottom ..................................................1 7 38199 50381997 Sppt wldt, 1/2" to 1-1/4" RLR ...........................1 8 38250 50382500 Drive unit ..........................................................1 9 01702 50017020 Spindle weldment, main ...................................1 10 38193 50381938 Plate weldment, drive .......................................1 11 54253 90542533 Sprocket, #60 14T ............................................1 12 38267 50382675 Key, drive sprocket ...........................................1 13 54255 90542550 Bearing, sleeve #48DU40 .................................2 14 54250 90542509 Chain, #60 92P .................................................1 15 54462 90544625 Ring, rtng Truarc #5100-200 ............................4 16 38265 50382659 Washer, main spindle ........................................2 17 38268 50382683 Key, shoe drive .................................................1 18 38457 50384570 Plate, hoist .......................................................2 19 55204 90552040 Pin, 1/2" to 1-1/4" sprt pvt ...............................1 20 38257 50382578 Spacer, motor mount ........................................1 20A 39488 50394886 Spacer, thin motor mount .................................1 21 38228 50382284 Locator weldment, eccentric .............................1 22 54265 90542568 Nut, 1/2-13 lock ...............................................1 23 51655 90516559 Screw, #10-16 x .50 hex head ........................31 25 53903 90539036 Screw, cap 1/2-13 x 1.00 .................................4 26 52501 90525019 Ring, rtng Truarc #5100-287 ............................2 27 54345 90543459 Screw, set 1/2"-20 x .75 socket .......................1 28 54251 90542517 Link, connecting #60 chain ...............................1 29 54240 90542409 Screw, #6-32 x 1.00 sltd mach .........................4 30 38246 50382462 Bracket, limit switch .........................................1 31 38248 50382489 Back-plate, switch ............................................3 32 50226 90502264 Screw, 5/16-18 x 1.25 skt. cap .........................2 33 52597 90525973 Washer, flat .56 x 1.37 x .109 ...........................4 34 85822 91858224 Switch, limit #BZ-2RW822-A2 ..........................4 35 50645 90506456 Nut, hex 5/16-18 reg jam .................................2 36 01708 50017080 Receptacle unit, pendant ..................................1 37 54124 90541243 Strain relief .......................................................1 43 38780 50387804 Shoe unit, 1/2" to 1-1/4" ..................................1 44 38148 50381482 Shoe unit, 1-1/2" to 2" .....................................1 45 52203 90522036 Screw, mach #6-32 x .25 .................................2 46 29708 50297082 Guard, breaker switch ......................................1 47 86385 91863856 Breaker, circuit 20 amp ....................................1 48 54619 90546199 Screw, cap #4-40 x .62 skt ...............................2 49 38646 50386468 Encoder unit, optical .........................................1 50 50572 90505727 Screw, cap #8-32 x .50 skt ...............................4 51 86646 91866464 Brake, motor ....................................................1 52 38807 50388070 Key, brake ........................................................1 53 54616 90546164 Spacer, round plastic ........................................2 54 54151 90541510 Knob, plastic w/set screw ................................2 55 54335 90543351 Screw, flng 1/4 x .37 thd ..................................2 57 01648 50016482 Switch, pendant ...............................................1 57A 01305 50013050 Board, circuit ....................................................1 57B 33476 50334760 Cover................................................................1 57C 33472 50334727 Housing, lower..................................................1 57D 38649 50386492 Switch, membrane ...........................................1 57E 34342 50343424 Screw #4-20 ....................................................3 57F 33580 50335804 Screw #6-32 ....................................................3 57G 01666 50016660 Cord, pendant ...................................................1 58 35012 50350129 Screw, #4 x 1/2" flat head or 06683 50066838 rivet, pop 3/32 ..................................................2 59 51751 90517512 Screw, drive .....................................................4 60 38868 50388681 Nameplate ........................................................1 71 38221 50382217 Support weldment, roller ..................................1 72 00528 50005286 Support weldment, 1-1/2" ................................1 73 00601 50006010 Support weldment, 2".......................................1 74 38225 50382250 Arm weldment, adjustment ...............................1 75 00543 50005430 Plate, 1-1/2" outer roller ...................................1 76 00604 50006045 Plate, 2" outer roller .........................................1 77 38254 50382543 Rol, 1-1/2 .........................................................2 78 38264 50382640 Ball, 1-1/2 ........................................................2 79 38255 50382551 Rol, 2 ................................................................2 80 38263 50382632 Ball, 2 ...............................................................2 81 38262 50382624 Spacer, 2 roller .................................................1 82 00599 50005995 Roller unit, 2" ...................................................1 83 00493 50004930 Shaft, 2" rear roller ...........................................1 84 38252 50382527 Roller, 1-1/2 I.M.C.............................................1 85 38253 50382535 Roller, 2 tail ......................................................1 86 38260 50382608 Shaft, 1-1/2 pivot roller.....................................1 87 32027 50320270 Sleeve, 1-1/2 ....................................................1 88 31728 50317288 Shaft, 2 pivot ....................................................1 89 38151 50381512 Sleeve, 2 ..........................................................1 90 23258 50232584 Grip ..................................................................1 91 38256 50382560 Shaft, eccentric ................................................1 92 38251 50382519 Sleeve, adaptor.................................................1 93 50540 90505409 Screw, 7/16-14 x 1.00 hex hd ..........................3 94 00860 50008609 Shaft, 1-1/2" support .......................................1 95 54819 90548191 Ring, retaining #5100-87 ..................................2 96 54242 90542428 Screw, cap 1/4-20 x .37 btn hd ........................3 97 50224 90502248 Screw, 5/16-18 x 1.00 skt hd ...........................1 98 50881 90508815 Screw, 1/4-28 x .25 set ....................................2 99 53018 90539184 Washer, 1.00 x 1.37 x .03 shim ........................1 100 54248 90542487 Washer, Belleville 1.362 x .803 .........................2 101 39440 50394401 Washer, .62 x 2.00 x .06 flat .............................1 104 54243 90542436 Spring, extension .75 x 3.50 .............................2 Page 21 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 21 Main Parts List (cont’d) 105 54252 90542525 Clamp, loop-type ..............................................1 106 52108 90521080 Nut, hex 1/4-20 ................................................1 107 54239 90542398 Screw, 1/4-20 x 3/4 ovl pt set ..........................1 108 39851 50398512 Cam, retention ..................................................1 109 38463 50384635 Shaft, cam retention .........................................1 111 38544 50385445 Plate, cam retention .........................................1 112 38566 50385666 Spring, cam retention .......................................1 113 54268 90542681 Screw, 1/4-20 x 1-3/8 skt cap ..........................1 114 50458 90504585 Rollpin, 1/8 x .375 ............................................1 115 38592 50385925 Guide, spring ....................................................1 116 51130 90511301 O-ring, 1.50 x 1.62 x .062 ................................2 117 51537 90515374 O-ring, 1.75 x 1.87 x .062 ................................2 118 38657 50386573 Shaft, 2 middle roller ........................................1 119 52644 90526449 Washer, 1/32 shim ............................................1 150 52645 90526457 Washer, 1/16 shim ............................................1 151 53216 90532163 Ring, retaining ..................................................1 170 86263 91862639 Nut, 1/2" conduit lock .......................................1 176 54911 90549112 Screw, 1/4-28 x 3/8" socket head cap..............2 177 55302 90553020 Screw, #6-32 x 1.25 socket head .....................2 178 54355 90543556 Washer, #6 .......................................................6 179 07912 50079123 Power cord .......................................................1 201 52031175 Base assembly ................................................1 202 52031167 Tower assembly, trunnion, L.H. ........................1 203 52031170 Tower assembly, trunnion, R.H. ........................1 204 53390 90533909 Wheel ...............................................................2 205 38613 50386131 Axle, short ........................................................2 206 51528 90515285 Ring, retaining #5160-75 ..................................4 207 54237 90542371 Screw, flange 3/8-16 x 1.00 hex .......................8 208 52646 90526465 Nut, 3/8-16 Esna hex ........................................4 209 38167 50381679 Pin, trunnion lock ..............................................1 211 54244 90542444 Spring, trunnion lock ........................................1 212 38168 50381687 Knob.................................................................1 213 52031172 Caster, w/side lock ...........................................2 221 31710 50317105 1/2" to 1-1/4" IMC, Rigid hook .........................1 223 31712 50317121 1/2" to 1-1/4" EMT hook ..................................1 224 52479 90524799 Drive bolt, 1/2-13 x .62 socket head cap screw .....................................6 225 51088 90510887 1/2" to 1-1/4" Hook bolts, 3/8-16 x 1-1/4 socket head cap screw .............8 226 53396 90533968 1-1/2, 2" Hook shoulder bolts, 3/4 x 1-1/2 ......................................................6 228 31716 50317164 1-1/2, 2" EMT hook ..........................................1 229 38779 50387790 1-1/2, 2" IMC & Rigid hook ...............................1 231 10299 50102990 Selector switch unit w/o knobs .........................1 240 52031173 Flange, screw ...................................................4 Decals (not shown) 38893 50078852 Decal, lifting eye ...............................................2 01445 50014455 Decal, deluxe pendant instr. ..............................1 38896 50388967 Decal, Slct switch size ......................................1 01487 50014870 Decal, Slct switch type .....................................1 38898 50388983 Decal, bender pivot lock ...................................1 38899 50388991 Decal, roller adjustment ....................................1 02263 50022636 Decal, roller engagement ..................................1 01568 50015680 Decal, operation ...............................................3 38974 50389742 Decal, circuit breaker........................................1 01453 50014536 Decal, shoe orientation .....................................2 52025721 Decal, warning .................................................1 52031174 Decal, warning .................................................2 Optional 01711 50017110 Deluxe pendant control 38962 50389629 Vinyl cover (not shown) 01700 50017004 1/2" to 2" PVC shoe group Service Only 05586 50055860 Frame unit (includes bearings) ..........................1 50079395 Cam repair kit ...................................................1 57H 52020832 Stripping, magnetic - replacement ....................1 52033403 Service kit (includes base and LH & RH trunnions) ...............................1 233 UPC No. Key 78-3310- Part No. Description Qty UPC No. Key 78-3310- Part No. Description Qty Page 22 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 22 Electrical Control System Layout and Parts List BLACK RED WHITE WHITE TO RELAY BLACK RED TO I/O BLACK WHITE BLACK WHITE GREEN GREEN GREEN BLACK WHITE YELLOW TO DRIVE UNIT YELLOW BLACK RED RED BLACK FROM RECTIFIER YELLOW YELLOW CN1 CN2 NC BLACK WHITE NO COM X Locate under roller support. AC –HV AC +HV JP1 5 23 13 10 12 31 29 24 1 32 3 30 8 11 6 26 9 28 21 18 27 33 2 20 19 25 15 17 7 16 4 22 14 Key Part No. Description 1 50389416 PGU Power Wire 2 50382500 Motor 3 50079123 Power Cord 4 50017080 Receptacle Unit 5 50386360 Limit Switch Wire Unit 6 50386379 Brake Wire Unit 7 50102354 Unload Lockout Switch Wire Unit 8 50060473 Relay Wire Unit 9 50060481 Red Relay Wire 10 50060490 Black Relay Wire 11 50060341 Red Relay–PGU Wire 12 50060350 Black Relay–PGU Wire 13 50386484 I/O–PGU Wire Unit 14 91858224 Limit Switch 15 50060309 Input/Output Control Unit 16 Directional Test Toggle Switch 17 Test Pushbutton Switch 18 50060503 Yellow Rectifier Wires 19 50060384 Red Rectifier Wire 20 50060422 Black Rectifier Wire 21 50060368 Wire Unit, Power AC 22 50081519 Selector Switch Unit w/o knobs 23 50386468 Optical Encoder 24 50054678 Power Generation Board Assembly 25 50060376 Wire Unit, Power DC 26 Test Terminal (Troubleshooting) 27 90543297 Screw, #8-18 x 3/8 Ground 28 50060406 Wire Unit, Ground 29 Test Terminal (Troubleshooting) 30 Test Pushbutton (Troubleshooting) 31 90516559 Screw, #10-16 x .5 Hex 32 91863856 Circuit Breaker, 20 A 33 91859972 Rectifier, 600 V, 35 A Key Part No. Description Page 23 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 23 Power Generation Unit (50054678) Schematic Diagram Do not trim insula tor. in hea t sink. Q1 should mount to upper hole in hea t sink. D8 should mount to lo wer hole Tighten Q1 and D8 to 5 in-lb #4-40 Phillips Screw #4-40 Nut #4-40 Lock W asher: #4-40 Fla t W asher (x2) KA-118-094 Po wer Devices, Inc Insula tor: THM7023B-MT Thermallo y Inc. Hea tsink: Mounting Hardware for Q1 and D8 7 5 4 8 1 6 2 MIC4422BN U2 100K R10 -+ 12 3 1 6 7 LM339 U1A 10K/1% R16 20K/1% R7 4.75K/1% R6 1.5K/1% R26 +15 V 20K/1% R24 10K/1% R25 -+ 12 3 13 10 11 LM339 U1D +170 V 1N5245B D3 21 TO RELA Y (Contacts 5 and 8) BLACK J11 21 TO RELA Y (Contacts 6 and 7) RED J10 DSEI30-06A D8 IXFK73N30 Q1 C10 +15 V .1uF/50V .1uF/50V C9 VCC GREEN LED D4 DIRECTION YELLOW LED D1 PWM RED LED D2 2K R8 2K R1 6 5 4 3 2 1 TEST CONNECTOR Molex 39-28-1063 J1 EVQ-P AC09K S1 -+ 12 3 2 4 5 LM339 U1B 100K R13 1N4148 D6 1M R12 1N4148 D7 1M R14 .01uF/50V C3 150K R4 1M R2 1M R3 12K/1% R5 +15 V 27.4K/1% R27 1.5K/1% R28 .1uF/50V C12 10K/1% R23 -+ 12 3 14 8 9 LM339 U1C 100/1% R22 .040/5W/1% R15 2 3 56 7 8 2 1 TO RELA Y COIL (Contacts 1 and 2) Molex 39-28-1023 J4 UF1001DI D9 HCPL4502 U3 6 5 4 3 2 1 TO I/O Molex 39-28-1063 J2 PN2222A Q2 1K R19 1K R21 +15 V .1uF/50V C13 .1uF/50V C1 1uF/63V C2 1N4148 D5 22 R9 22 R11 RECTIFIER TO BRIDGE +170 V +15 V 1N4007 D13 1N4007 D14 21 AC YELLOW J8 4.7K/10W R17 21 DC- BLACK J9 21 DC+ RED J6 21 AC YELLOW J5 POWER GREEN LED D11 1N5245B D10 20K/2W/1% R18 680uF/25V C7 1000uF/250V C6 .010uF/500V AC C4 .010uF/500V AC C11 GROUND NEUTRAL LINE .0047uF/500V AC C5 .0047uF/500V AC C8 470uH L1 1.5M R20 3 2 1 AC POWER IN Beau 72503-C J7 Notes: • Bend leads on R17 to mount a t least 0.25" off-board. • All resistors 5% 1/4W unless noted. R29 68.1K Page 24 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 24 Power Generation Unit (50054678) Parts List C1,C9,C10,C12,C13 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 5 AVX SA115C104KAA KEMET C420C104K5R5CA C2 WIMA MKS21.06310 Capacitor, film, 1 uF, 63 volts 1 C3 Philips A103M15Z5UFVVWA Capacitor, .01 uF, 50 volts 1 AVX SA105E103ZAA C4,C11 Sprague 440LS10 Capacitor, .010 uF, 500 volts AC 2 C5,C8 Sprague 440LD47 Capacitor, .0047 uF, 500 volts AC 2 C6 Panasonic ECE-S2EU102Z Capacitor, 1000 uF, 250 volts 1 Cornell Dubilier 380LX102M250K052 C7 Panasonic EEU-FC1E681 Capacitor, 680 uF, 25 volts 1 D1 Panasonic LN48YP LED, T1, amber 1 Liteon LTL-4251 D2 Panasonic LN28RP LED, T1, red 1 Liteon LTL-4221 D3,D10 Motorola 1N5245B Zener diode, 15 volts, 500 milliwatts 2 D4,D11 Panasonic LN38GP LED, T1, green 2 Liteon LTL-4231 D5,D6,D7 Generic 1N4148 Diode 3 D8 IXYS DSEI 30-06A Diode, fast recovery, 30A, 400-600V, TO-247 (see Note 1) 1 Adv Pwr Tech APT30D40B Adv Pwr Tech APT30D60B D9 Vishay UF1001DI Diode, ultra-fast switching, 1A, 50V, 50ns, DO-41 1 D13,D14 Generic 1N4007 Diode 2 J1,J2 Molex 39-29-0063 Connector, Minifit Jr., 6-position, gold 2 J4 Molex 39-29-0023 Connector, Minifit Jr., 2-position, gold 1 J5,J6,J8,J9,J10,J11 Keystone 1287 Connector, tab, .250 x .032 6 J7 Beau 72503-C Connector, terminal block, 3-position, no mount holes 1 Magnum A202203 L1 Renco RL-1328-22-470 Choke, common mode 1 Q1 IXYS IXFK73N30 MOSFET, N channel, 73-76A, 300V, TO-264 (see Note 2) 1 Adv Pwr Tech APT30M40LVFR Q2 Generic PN2222A Transistor, NPN 1 R1,R8 Generic Resistor, 2 kΩ, 1/4 watt, 5% 2 R2,R3,R12,R14 Generic Resistor, 1 MΩ, 1/4 watt, 5% 4 R4 Generic Resistor, 150 kΩ, 1/4 watt, 5% 1 R5 Generic Resistor, 12.1 kΩ, 1/4 watt, 1% 1 R6 Generic Resistor, 4.75 kΩ, 1/4 watt, 1% 1 R7,R24 Generic Resistor, 20 kΩ, 1/4 watt, 1% 2 R9,R11 Generic Resistor, 22 Ω, 1/4 watt, 5% 2 R10,R13 Generic Resistor, 100 kΩ, 1/4 watt, 5% 2 R15 Dale LVR-5 .04W Resistor, .040 Ω, 5 watt, 1% 1 KRL NP-5A .04W Riedon MT-5 .04W R16,R23,R25 Generic Resistor, 10 kΩ, 1/4 watt, 1% 3 R17 Dale CW-10 4.7K Resistor, 4.7 kΩ, 10 watt, 5% (see Note 3) 1 KRL C-10A 4.7K Riedon UT-10 4.7K R18 Dale RS-2B-20K Resistor, 20 kΩ, 2 watt, 1% 1 KRL C-2A 20K Reference Supplier Part Number Description Qty Page 25 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 25 Power Generation Unit (50054678) Parts List (cont’d) Reference Supplier Part Number Description Qty. Riedon UT-2B 20K R19,R21 Generic Resistor, 1 kΩ, 1/4 watt, 5% 2 R20 Generic Resistor, 1.5 MΩ, 1/4 watt, 5% 1 R22 Generic Resistor, 100 Ω, 1/4 watt, 1% 1 R26,R28 Generic Resistor, 1.5 kΩ, 1/4 watt, 1% 2 R27 Generic Resistor, 27.4 kΩ, 1/4 watt, 1% 1 R29 Generic Resistor, 68.1 kΩ, 1/4 watt, 1% 1 S1 Panasonic EVQ-PAC09K Switch, momentary pushbutton 1 U1 Motorola LM339AN IC, low power quad comparitor 1 U2 Micrel MIC4422BN IC, 9-A peak low-side non-inverting MOSFET driver 1 U3 HP HCPL4502 IC, opto-isolator 1 QT-Opto HCPL4502 Siemens 6N136 Note 1: Mount D8 to bottom hole of heat sink. Note 2: Mount Q1 to top hole of heat sink. Note 3: Bend leads and mount 0.25" off-board. Power Generation Unit (50054678) Layout Diagram R18 L1 J7 Q1 + C6 D8 C13 C12 C10 C3 C1 C9 C2 U1 J6 Yellow Yellow Red Black TEST DIR PWM VCC GREENLEE TEXTRON POWER R17 6 5 4 3 2 1 D2 R8 R1 D1 J8 J5 J9 D4 R15 D11 D13 Red Black TO RELAY FROM RECTIFIER ©2000 TO I/O Ground Neutral Line R28 R12 R4 R22 R2 R27 R3 6 5 4 3 2 1 J2 C4 2 1 J4 R7 D3 R16 R6 R23 R10 Q2 U3 R13 R14 D6 D7 U2 R26 D5 R9 R11 R5 R24 R25 R19 R21 C5 C8 R20 C11 + C7 S1 D9 D10 J10 J11 D14 Page 26 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 26 Input/Output Board (50060309) Schematic Diagram Deluxe Terminal I/O Pin Term Pin 1 6 2 1 3 4 4 5 Standard Pendant I/O Pin Term Pin 1 1 2 2 3 3 4 4 SW SIZE 0 SW SIZE 1 SW SIZE 2 SW SIZE 3 SW SIZE 4 SW SIZE 5 SW HOME 1 SW HOME 2 SW TYPE 0 SW TYPE 1 SW TYPE 2 LOCKOUT EECLK/SCL EEDI EECS SW TYPE 0 SW TYPE 1 SW TYPE 2 TXD RXD T2UD PWM SW SIZE 4 SW SIZE 3 SW SIZE 2 SW SIZE 0 SW SIZE 1 SW SIZE 5 SW TYPE 1 SW TYPE 0 EECS EEDI EECLK/SCL LOCKOUT SW TYPE 2 SW SIZE 2 SW SIZE 3 SW SIZE 4 SW SIZE 5 SW HOME 1 SW HOME 2 EECLK/SCL EEDI EECS HSI.0 HSI.1 HSI.2/HSO.4 HSI.3/HSO.5 HSI.1 HSO.1 HSI.3/HSO.5 HSI.0 HSO.2 HSI.2/HSO.4 SW HOME 2 SW HOME 2 SW SIZE 1 SW SIZE 0 T2UD PWM HSO.2 BRAKE D0 A0 A0 D0 A0 D0 D0 D3 A11 A3 A6 A6 D6 D4 A9 A3 D6 A14 A14 D5 A7 A2 A8 A13 A9 D5 D4 D2 A14 A10 D4 D5 D7 A2 A12 D1 A15 A15 D2 A13 A11 A6 D2 D7 A10 A8 D3 D3 A7 A9 A2 A4 A10 D5 A14 A8 D7 A5 D1 D6 D6 A5 D2 A1 D4 A12 A13 D7 A13 A1 A5 D1 A3 A4 A12 D3 A11 A7 D1 A4 A1 A15 LOCKOUT LOCKOUT HSO.3 HSO.3 WATCHDOG TIMER HSO.3 RESET EECLK/SCL RXD TXD HSO.1 DIRECTION HSO.1 HSO.2 TXD RXD HSO.0 Pendant Select HSO.0 Pendent Select HSO.0 TXD/SCL RXD/SDA EEDO/SDA EEDO/SDA EEDO/SDA EEDO/SDA VCC T2CLK VCC VS T2CLK SW HOME 1 SW HOME 1 T2CAP T2RST T2CAP EXTINT T2RST EXTINT 12 1 2 3 4 1 16 2 15 3 14 4 13 5 12 6 11 7 10 8 9 1 2 3 4 CS 1 CLK 2 DI 3 DO 4 VSS 5 VCC 8 ORG 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 RST 1 TD 2 TOL 3 ST 7 RST 5 RST 6 VCC 8 GND 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 A0 10 A1 9 A2 8 A3 7 A4 6 A5 5 A6 4 A7 3 A8 25 A9 24 A10 21 A11 23 A12 2 A13 26 A14 27 A15 1 CE 20 OE 22 O0 11 O1 12 O2 13 O3 15 O4 16 O5 17 O6 18 O7 19 VCC 28 GND 14 D0 3 D1 4 D2 7 D3 8 D4 13 D5 14 D6 17 D7 18 OC 1 G 11 Q0 2 Q1 5 Q2 6 Q3 9 Q4 12 Q5 15 Q6 16 Q7 19 VCC 20 GND 10 B 15 C 16 K 1 B 6 C 8 K 9 B 11 C 10 K 9 B 3 C 2 GND 4 K 1 VS 14 P3.0/AD0 60 P3.1/AD1 59 P3.2/AD2 58 P3.3/AD3 57 P3.4/AD4 56 P3.5/AD5 55 P3.6/AD6 54 P3.7/AD7 53 ALE 62 P4.0/AD8 52 P4.1/AD9 51 P4.2/AD10 50 P4.3/AD11 49 P4.4/AD12 48 P4.5/AD13 47 P4.6/AD14 46 P4.7/AD15 45 INST 63 /BHE 41 /WR 40 /RD 61 CLKOUT 65 HSI.0 24 HSI.1 25 HSO.0 28 HSO.1 29 HSO.2 34 HSO.3 35 HSI.2/HSO.4 26 HSI.3/HSO.5 27 VREF 13 VPP 37 VCC 1 X1 67 X2 66 BUSWIDTH 64 /EA 2 /RESET 16 READY 43 P0.0/AIN0 6 P0.1/AIN1 5 P0.2/AIN2 7 P0.3/AIN3 4 P0.4/AIN4 11 P0.5/AIN5 10 P0.6/AIN6 8 P0.7/AIN7 9 NMI 3 P1.0 19 P1.1 20 P1.2 21 P1.3 22 P1.4 23 P1.5 30 P1.6 31 P1.7 32 P2.0/TXD 18 P2.1/RXD 17 P2.2/EXINT 15 P2.3/T2CLK 44 P2.4/T2RST 42 P2.5/PWM 39 P2.6/T2UD 33 P2.7/T2CAP 38 AGND 12 VSS 36 VSS 68 VSS 14 1 2 14 7 3 4 14 7 5 6 14 7 9 8 14 7 13 12 14 7 3 4 5 6 14 7 9 10 11 8 14 7 1 2 13 12 14 7 IN1 1 IN2 16 IN3 9 IN4 8 D1 2 D2 15 D3 10 D4 7 S1 3 S2 14 S3 11 S4 6 V- 4 GND 5 VL 12 V+ 13 1 2 3 4 5 A0 10 A1 9 A2 8 A3 7 A4 6 A5 5 A6 4 A7 3 A8 25 A9 24 A10 21 A11 23 A12 2 A13 26 A14 1 D0 11 D1 12 D2 13 D3 15 D4 16 D5 17 D6 18 D7 19 CE 20 OE 22 WE 27 VCC 28 GND 14 1 2 3 4 5 6 11 10 14 7 1 2 3 4 JP5 MOLEX 39-28-1023 BRAKE JP4 MOLEX 39-28-1043 PENDANT/TERMINAL R3 100 X1 10MHz C1 22p C2 22p R2 100 R5 2.2K C24 .1u/50V R29 100 R30 100 JP8 MOLEX 39-28-1043 HOME SWITCHES C22 .1u/50V C23 .1u/50V U5 93LC56(B) R11 560 R23 100/.5W RP3 10K R22 1K R20 100/.5W R21 1K C8 .1u/50V RP1 10K R8 100 C21 .1u/50V C9 .1u/50V R27 100/.5W C3 .1u/50V R9 560 RP2 10K R10 100 R17 2.2K R18 2.2K R12 2.2K C10 10u/25V R4 100 U8 DS1232 C11 .1u/50V C13 .1u/50V C12 .1u/50V C14 .1u/50V C16 .1u/50V C19 .1u/50V C20 .1u/50V C15 .1u/50V C18 .1u/50V JP3 3M 2510-6002UB SWITCHES JP7 MOLEX 39-28-1063 TEST TO PGU R31 68 R26 330 R19 1K R24 68 JP6 MOLEX 39-28-1063 SIGNAL TO PGU R25 2.2K S1 EVQ-PAC09K TEST SWITCH S2 ESWITCH E1218 TEST DIRECTION R6 1K R7 1K R16 100 R15 100 R13 10K R14 10K C7 .1u/50V C5 .1u/50V C6 .1u/50V U4 27C512 C4 .1u/50V U2 74HC373 U11D ULN2068B U11B ULN2068B U11C ULN2068B U11A ULN2068B U1 N80C196KB D1 RED TEST D7 RED BRAKE D15 RED HOME2 D14 RED HOME1 D5 RED QUAD1 D4 RED QUAD2 D10 RED PWM D3 RED DELUXE D2 RED STANDARD D8 RED DIR D12 RED TEST 2 D11 1N4148 D9 1N4148 D6 UF1001DI D16 1N4148 D13 1N4148 U10A 74HC04 U10B 74HC04 U10C 74HC04 U10D 74HC04 U10F 74HC04 U6B 74HC10 U6C 74HC10 U6A 74HC10 R32 10K R33 10K U9 MAX4613 C17 .1u/50V JP1 Molex 26-60-4050 DC POWER IN U3 KM68512 JP2 MOLEX 39-28-1063 QUAD ENCODER U10E 74HC04 C25 .001u/50V D17 1N4148 R28 100 JP9 MOLEX 39-30-2037 LOCKOUT SWITCH Alternate Connection +5V +5V +5V +5V +5V +5V +5V +5V +5V +12V +12V +5V +12V +5V +12V +5V +5V +5V +5V +12V +5V +5V +12V +5V Page 27 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 27 Input/Output Board (50060309) Parts List C1,C2 Murata RPE110COG220J050V Capacitor, 22 pF, 50 volts 2 Murata RPE110COG220J0100V C3,C4,C5,C6,C7,C8,C9, Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 21 C11,C12,C13,C14,C15, AVX SA115C104KAA C16,C17,C18,C19,C20, KEMET C420C104K5R5CA C21,C22,C23,C24 C10 Nichicon UVZ1E100MDH Capacitor, 10 uF, 25 volts 1 C25 Philips A102K15X7RHVVWA Capacitor, .001 uF, 100 volts 1 D1,D2,D3,D4,D5,D7,D8, Panasonic LN28RP LED, T1, red 11 D10,D12,D14,D15 Liteon LTL-4221 D9,D11,D13,D16,D17 Generic 1N4148 Diode 5 D6 VISHAY UF1001DI Diode, ultra-fast switching, 1A, 50V, 50ns, DO-41 1 JP1 Molex 26-60-4050 Connector, locking, .156" center, 5-position 1 JP4,JP8 Molex 39-28-1043 Connector, Minifit Jr., 4-position 2 JP2,JP6,JP7 Molex 39-28-1063 Connector, Minifit Jr., 6-position 3 JP3 3M 2510-6002UB Connector, dual row, 10-position 1 JP5 Molex 39-28-1023 Connector, Minifit Jr., 2-position 1 JP9 Molex 39-30-2037 Connector, Minifit Jr., 3-position 1 RP1,RP2,RP3 Bourns 4610X-101-103 Resistor pack, 10KWx8 with common, 1/4 watt, 5% 3 R13,R14,R32,R33 Generic Resistor, 10K, 1/4 watt, 5% 4 R6,R7,R19,R21,R22 Generic Resistor, 1K, 1/4 watt, 5% 5 R3 Dale MDP1603-101G Resistor pack, 100Wx8, individual, 1/4 watt, 5% 1 R2,R4,R8,R10,R15,R16, Generic Resistor, 100, 1/4 watt, 5% 9 R28,R29,R30 R5,R12,R17,R18,R25 Generic Resistor, 2.2K, 1/4 watt, 5% 5 R11,R9 Generic Resistor, 560, 1/4 watt, 5% 2 R26 Generic Resistor, 330, 1/4 watt, 5% 1 R20,R23,R27 Generic Resistor, 100, 1/2 watt, 5% 3 R31,R24 Generic Resistor, 68, 1/4 watt, 5% 2 S1 Panasonic EVQ-PAC09K Momentary pushbutton switch 1 S2 Eswitch EG1218 Slide switch, SPDT 1 U1 Intel N80C196KB Integrated circuit, microcontroller 1 U1 AMP 821689-1 68-pin socket, PLCC 1 U2 Generic 74HC373 Integrated circuit, buffer 1 U3 Samsung KM62256DLP-7L IC, SRAM, 32K x 8, 70ns, 28-pin x .6" DIP 1 U4 Generic 27C256 IC, EPROM, 120 nsec, 28-pin x .6" DIP 1 U3,U4 Robinson Nugent ICO-286-S8A-T 28-pin socket, dual wipe 2 U5 Microchip 93LC56 Integrated circuit, EEPROM,128 x 16 bit 1 Microchip 93LC56B U5 Robinson Nugent ICO-083-S8A-T 8-pin socket, dual wipe 1 U6 Generic 74HC10 Integrated circuit, NAND 1 U8 Dallas DS1232 Integrated circuit, timer/reset control 1 Dallas DS1232LP U9 Maxim MAX4613 IC, analog switch, 16 pin x .3" DIP 1 U10 Generic 74HC04 Integrated circuit, inverter 1 U11 Generic ULN2068B Integrated circuit, buffer/driver 1 X1 Fox FOX 100-20, Crystal, 10MHz, HC49U case, mylar spacer 1 HC49U-10.000-MS Reference Supplier Part Number Description Qty. Page 28 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 28 Input/Output Board (50060309) Layout Diagram D9 D16 D13 U4 U5 DC POWER IN JP1 JP9 2 1 3 2 TEST PENDANT PGU TEST1 RED SWITCHES HOME ENCODER BRAKE HOME2 DLX HOME1 QUAD2 STD C15 C18 C7 C8 C13 C12 C14 C16 R19 R20 R21 S1 S2 R6 R7 R16 R15 R13 R14 C4 D14 R29 R30 R23 R22 R12 D6 R28 R27 R5 RP3 RP1 R17 C10 + C11 U9 D1 QUAD1 BRAKE PWM C24 R11 R8 R10 C1 C2 R9 R24 D5 D4 U6 C23 JP3 10 1 2 9 U3 c2001 GREENLEE TEXTRON LOCKOUT C22 R18 JP2 1 2 3 4 5 6 R31 R26 D8 DIR R32 TEST2 JP51 2 JP4 1 2 3 4 X1 JP8 1 2 3 4 JP7 1 2 3 4 5 6 JP6 1 2 3 4 5 6 C5 C6 D17 D11 D15 R4 U8 C17 U11 D7 D2 R3 C21 C9 C3 R25 U2 D10 D3 D12 U11 10 27 44 R2 RP2 U10 C25 R33 C19 C20 Page 29 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 29 Standard Pendant Switch (50013050) Schematic Diagram SDA GND SCL +12V 1 2 3 4 5 6 7 8 9 10 E1 1 D1 2 C1 3 P1 4 E2 5 D2 6 G2 7 C2 8 P2 9 B2 10 A2 11 F2 12 AN2 13 AN1 14 B1 15 A1 16 G1 17 F1 18 12345678910 1234 VSS 8 A0 1 A1 2 A2 3 P0 4 P1 5 P2 6 P3 7 P4 9 P5 10 P6 11 P7 12 /INT 13 SCL 14 SDA 15 VDD 16 IN 1 OUT 3 GND 2 ADDR 1 CEXT 2 P8 3 P7 4 P6 5 P5 6 P4 7 P3 8 P2 9 P1 10 P9 15 P10 16 P11 17 P12 18 P13 19 P14 20 P15 21 P16 22 SDA 23 SCL 24 MPX1 11 MPX2 14 VCC 13 VEE 12 RN1 10K/.25W DS1 MAN-6910 C1 .1uF C5 .1uF C6 .1uF J1 BERG 78541-1104 C7 .1uF P1 MOLEX 70553-0038 U1 PCF8574 VR1 MIC2940A-5.0BT U2 SAA1064 D3 1N4007 D1 1N4007 D2 1N4007 D4 1N4007 D5 1N4007 +5V +5V +5V +5V +5V +5V +5V Page 30 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 30 Standard Pendant Switch (50013050) Parts List Standard Pendant Switch (50013050) Layout Diagram Reference Supplier Part Number Description Qty. C1,C5,C6,C7 Vishay 1C20X7R104K050B Capacitor, ceramic, .1 uF, 50 volts (minimum), radial, 4 or Equal or Equal .2 cc, X7R D1,D2,D3,D4,D5,D6 Generic 1N400x (x=1 to 7) Diode 5 DS1 QT Opto MAN-6910 LED display, common anode, 2 digit x .56, 7 seg + dec, 1 Agilent Tech HDSP-5521 18-lead .6" DIL or Equal or Equal J1 BERG 78541-110H Connector, .100" cc x .318 mating, 10-position, right angle, 1 or Equal or Equal single row, 30 micro-in gold over 50 micro-in nickel P1 MOLEX 70553-0038 Connector, locking, “SL” series, .100" cc, 4-position 1 RN1 Generic Resistor pack, 10KWx10 with common, 1/4 watt, 5% 1 U1 Philips PCF8574P Integrated circuit, I2C, 8-bit I/O expander, 16-lead .3" DIL 1 U2 Philips SAA1064 Integrated circuit, I2C, LED display driver, 24-lead .6" DIL 1 VR1 Micrel MIC2940A-5.0BT Voltage regulator, fixed 5V, low dropout 1 Mounting Hardware for VR1 Generic #4-40 Hex Nut ZN steel or stainless, nylon insert, 1/4 x 9/64 1 Generic #4-40 Phillips Screw ZN steel or stainless, machine, pan head, #4-40 x 0.25" 1 D2 D1 D3 C7 C6 C5 C1 P1 4 3 2 VR1 10 1 J1 RN1 D4 U2 U1 DS1 D5 1 GREENLEE TEXTRON c2001 Page 31 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 31 4 1 2 3 UPC No. Key 78-3310- Part No. Description Qty 00572 50005723 Shoe unit, 1/2" to 1-1/4" PVC-coated Rigid (includes items 1–4) ................................1 31919 50319191 Shoe unit, 1-1/2" to 2" PVC-coated Rigid (includes items 4–7) ................................1 00934 50009346 Support unit, 1/2" to 1-1/4" PVC-coated Rigid (includes items 8–17) ..............................1 1 00567 50005677 1/2" to 1-1/4" PVC-coated Rigid shoe ..............1 2 00570 50005707 1/2" to 1-1/4" PVC-coated Rigid hook ..............1 3 51088 90510887 3/8-16 x 1-1/4" Socket head cap screw ...........4 4 52479 90524799 1/2-13 x 5/8" Socket head cap screw ..............5 5 31918 50319183 1-1/2" to 2" PVC-coated Rigid shoe .................1 6 31916 50319167 1-1/2" to 2" PVC-coated Rigid hook .................1 7 53396 90533968 3/4" x 1-1/2" Shoulder screw...........................3 8 00933 50009338 Support weldment, PVC-coated Rigid roller .......1 9 51353 90513533 Retaining ring ...................................................5 10 00923 50009230 1/2" Roller axle ................................................1 11 00924 50009249 3/4" Roller axle ................................................1 12 00925 50009257 1" Roller axle ....................................................1 13 00926 50009265 1-1/4" Roller axle .............................................1 14 00927 50009273 1/2" Roller ........................................................1 15 00928 50009281 3/4" Roller ........................................................1 16 00929 50009290 1" Roller ...........................................................1 17 00930 50009303 1-1/4" Roller ....................................................1 18 54910 90549104 Retaining ring pliers (not shown).......................1 19 23818 50238183 Metal storage box (not shown) ..........................1 Optional Bending Attachments for 1/2" to 2" 40 Mil PVC-coated Rigid (50017004) Exploded View and Parts List 4 5 6 7 15 16 10 11 12 13 17 9 8 14 Page 32 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 32 Troubleshooting Problem Probable Cause Probable Remedy Bender does not operate. No voltage. Check supply voltage circuit operation. Check that switch is on. Check that pendant is fully plugged in. Bender operates, but display is blank. Insufficient voltage. Use shorter or larger gauge extension cord. Check supply voltage (80 VAC minimum). Pendant was plugged in while bender was on. Turn bender switch off and on. Display comes on, but bender does not bend. Bender was advanced 93 degrees. UNLOAD to desired position. Display comes on, but does not count during bend. Bender turned on while conduit was fully loaded. Remove conduit and initialize home position per “Setting the Home Position” under “Operation” in the instruction manual. Bender operates in wrong direction. Wrong conduit size and/or type selected. Set selector switches properly. Bends are overbent a few degrees. Wrong conduit size and/or type selected. Set selector switches properly. Too much squeeze on 1-1/2" or 2" EMT, IMC, or rigid aluminum conduit. Back squeeze off per adjustment instructions. Unusual conduit characteristics. Refer to “Accuracy” in the “Adjustments” section or bend to a smaller angle to compensate. Bends are underbent a few degrees. Wrong conduit size and/or type selected. Set selector switches properly. Too little squeeze on 1-1/2" or 2" EMT, IMC, or rigid aluminum conduit. Increase squeeze per adjustment instructions. Unusual conduit characteristics. Refer to “Accuracy” in the “Adjustments” section or bend to a larger angle to compensate. Page 33 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 33 Troubleshooting (cont’d) Problem Probable Cause Probable Remedy UNLOAD key does not work. Roller support is not all the way down. Release the roller support. Unloaded to the starting position. Release and press UNLOAD again. Locking cam does not engage. Too much squeeze on 1-1/2" or 2" EMT, IMC, or rigid aluminum conduit. Back squeeze off per adjustment instructions. Shoe rotated too far in unload direction. Rotate shoe with BEND key until locking cam engages. Bend key does not work for 1/2" to 1-1/4" conduit. Roller support is not all the way down. Release the roller support. Message “E6” or “CONDUIT SUPPORT UP” appears. Power was turned off while bending 1-1/2" or 2" EMT, IMC, or rigid aluminum conduit. Press UNLOAD. Bending shoe will slowly unload until roller support retracts. Roller support lockout switch or wire harness is bad or poorly adjusted. Adjust switch. Check for pinched wires and shorts to frame. Roller support is locked or jammed. Twist roller support handle counterclockwise. Deluxe pendant displays: “BENDER CANNOT MAKE BENDS THAT CLOSE.” Due to the geometry of the bend, the shoe hook would end up interfering with the first bend while making the second. Follow the suggestions on the display to adjust the HEIGHT, ANGLE, or STRAIGHT section value. Deluxe pendant displays: “LENGTH IS TOO SHORT” or “HEIGHT IS TOO SHORT.” The first mark must be at least one pipe diameter away from the end of the conduit to prevent damage to the conduit. Follow the suggestions on the display to adjust the LENGTH or HEIGHT value. Page 34 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 34 Troubleshooting (cont’d) The following flow charts show some of the most likely areas to look at for certain problems. They by no means encompass all the possible problems or the only possible solutions. YES NO YES NO YES NO YES NO YES NO YES Replace transformer unit. Does bender work with different (good) pendant? Is fuse blown? Is 115 VAC measured at PGU board input? Do any of the 8 LEDs on the I/O board light? Turn switch off and then back on. Bad pendant board, bad pendant cord or plug inside pendant is unplugged. Bent pin connector in receptacle or bad recep- tacle unit? Replace fuse. Plugged into dead circuit, bad power cord, or switch is bad or off. Was pendant plugged in after the bender was turned on? NO YES NO Does PWM LED light when BEND is pressed? Disconnect I/O-PGU cable on the I/O board and reconnect to test terminal. Disconnect brake wire unit. Restore power and push test switch. Does shoe move? (The toggle switch, located next to the push button switch, controls the direction the shoe moves.) Replace PGU. Won’t bend – display blank Replace receptacle. Replace PGU. NO YES Replace I/O board. Will bend – won’t count NO YES Is bending shoe on in the proper orientation? Does bender count with different (good) pendant? Do both Quad 1 and Quad 2 LEDs light when bend or unload is pressed? YES NO YES NO YES When jog is pressed, does the bender continue to run slowly with- out stopping after 1/2 degree? YES Install shoe per instructions in this manual. Replace optical encoder. Replace pendant board. Replace or adjust limit switches or wire unit. NO NO Do Home 1 and Home 2 LEDs light when the shoe is run past the Start position? YES Will bend – display blank Is at least 80 volts measured at the power cord? NO Find 120 VAC power source. Replace pendant board. Replace optical encoder. Replace I/O board. Page 35 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 35 Troubleshooting (cont’d) YES NO YES NO YES NO YES YES NO Bender runs backwards for bend and unload Rotary switch cable is backwards or rotary switch unit is bad. Select proper size. Is proper size of conduit selected? Does bender run backwards when using deluxe pendant or does bender run backward when a conduit size for the shoe not being used is selected? Are polarity of rectifier, relay, and motor connections correct? (Refer to “Electrical Control System Layout and Parts List.”) On 1-1/2" or 2" setting, does white motor lead receive positive voltage? Replace PGU. NO Replace I/O board. Disconnect I/O-PGU cable on the I/O board and reconnect to test terminal. Disconnect brake wire unit. Restore power and push test switch. Does shoe move? (The toggle switch, located next to the push button switch controls the direction the shoe moves.) Connect wires correctly. Motor is wired wrong internally. YES YES Does bender work with different (good) pendant? Jump #2 & #4 terminals in pendant. Does bender run? Bad pendant board. Bad membrane switch. YES NO YES NO NO YES NO Replace I/O board. NO YES YES NO Does BEND work when set to 1-1/2" or 2" size? Does PWM LED light when BEND or UNLOAD is pressed? Can an angle be programmed? Is 100+ VDC measured at the motor leads when BEND or UNLOAD is pressed? Are all pin connections making contact on 6-wire cable connecting the I/O board to the PGU board? Refer to “Won’t Unload – Display On” in this section. Replace I/O board. Replace motor. Replace or repair the interconnecting cable. YES NO Won’t bend – display on Disconnect I/O-PGU cable on the I/O board and reconnect to test terminal. Disconnect brake wire unit. Restore power and push test switch. Does shoe move? (The toggle switch, located next to the push button switch controls the direction the shoe moves.) Replace PGU. NO Replace I/O board. Page 36 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 36 Troubleshooting (cont’d) YES Use 120 VAC. NO YES NO Replace pendant membrane switch. Does bender stop when the pendant is unplugged? Is the supply line voltage low? Replace PGU. Won’t stop NO YES YES On 1-1/2" or 2" size setting, is the DIR LED on the I/O Board on when BEND is pressed? Replace I/O board. Replace 91866456 relay. NO When DIR LED is on, is 12 VDC measured at large relay coil (where relay wire unit connects)? Bender only runs in one direction NO Replace I/O. Move 6-wire connector on PGU from “TO I/O” to “TEST.” Alter- nately press BEND and UNLOAD. Does yellow “DIRECTION” LED on PGU turn on and off? YES Replace PGU. Won’t unload – display on YES NO NO YES Lower the roller support assembly. Is the retention cam engaged with the roller support? Is the roller support assembly completely disengaged? Adjust the roller support limit switch. Lower the roller support assembly. YES YES NO YES NO Are the proper support rollers and shoe groove being used for the type and size of conduit being bent? Is the current on the 115 VAC line exceeding 20 amps? Is the DC current to the motor exceeding 17 amps? When BEND is pressed, is the voltage sent to the motor 20 to 50 volts over the AC line voltage? Are connectors corroded? Replace PGU. Follow directions in instruction manual. Replace circuit breaker. Replace motor. Replace bridge rectifier. Clean. NO NO YES NO YES Trips circuit breaker Page 37 855 Smart Bender® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 37 Makes inaccurate bends Press BEND to rotate shoe and stop it when the pendant displays between 1°-6°. Note the shoe position. Press BEND and continue past 90°. Unload to angle first stopped at (between 1°-6°) without passing it. Note shoe position. Is shoe within 1° of first position stopped at? YES YES Consistently bends all sizes of one shoe a few degrees over or bends all the sizes a few degrees under. YES Adjust the limit switch for that shoe. YES Bender coasts to a stop. YES NO NO Replace optical encoder. No-load motor speed is greater than 4400 rpm. YES NO NO NO NO NO YES Indicates variations in the conduit. Use Accuracy Adjustment to compensate. Limit switch arm is bent or switch is mounted backwards. Adjust motor brake. Replace motor field. Replace I/O board. Replace optical encoder. Clean and tighten all ground connections at frame. Consistently underbends by a few degrees and can’t be adjusted correctly. Bends some sizes of one shoe 1° or 2° over and other sizes of the same shoe 1° or 2° under. Isolate motor leads from cables that plug into the I/O board. Are set screws tight in drive hub on optical encoder? Isolate motor leads from all cables that go to I/O board. Replace optical encoder. YES Consistently overbends by more than 5° and can’t be properly adjusted. NO NO Tighten to 0.16 Nm (22 in-oz) torque. NO NO NO Troubleshooting (cont’d) Page 38 855 Smart Bender® USA 800-435-0786 Fax: 800-451-2632 Troubleshooting (cont’d) Accuracy Adjustment Due to variations in conduit, you may notice that the bender consistently over- or underbends a particular size and type of conduit. Programmed adjustments can be made to compensate for over- and underbend- ing conduit. Each size and type of conduit can have a unique adjustment ranging from plus 9 degrees to minus 9 degrees. Standard Pendant 1. Press and hold CLEAR, and then press and hold BEND until “Pr” is displayed. 2. Use the side switches to select the size and type of conduit to compensate. The display shows the current adjust value (“0” is factory default). 3. Compensate the angle: Press ANGLE SELECT to increase the bend to compensate for underbending. Press ANGLE SELECT to decrease the bend to compensate for overbending. Press CLEAR to reset the compensation to the factory default (“0”). 4. Press BEND to save the adjust angle and exit the adjust mode. The bender retains the new adjust value even if power is turned off. The only way to change the adjust value is to repeat this procedure. The pendant displays “oP” as it returns to operating mode. • • • • • • Deluxe Pendant 1. Press RESET. 2. Press the 0 key three times. “PROGRAMMING MODE” appears on the display. 3. Key in the desired size and type of conduit to compensate. The display shows the current adjust value (“0” is factory default). 4. When the display prompts “ENTER NUMBER OF DEGREES (USE • FOR NEGATIVE),” use the numerical keys to enter a number from 0 to 9. Use the • (decimal) key to toggle the negative sign. Enter positive numbers to increase the bend to compensate for underbending. Enter negative numbers to decrease the bend to compensate for overbending. Press CLEAR to reset the compensation to the factory default (“0”). Press RESET to exit the adjust mode without changing any values. 5. Press ENTER to save the adjust angle and exit the adjust mode. The bender retains the new adjust value even if power is turned off. The only way to change the adjust value is to repeat this procedure. Note: Once in the adjust mode, the pendant can display any compensation value by selecting the size or type. However, only the values of the last size and type viewed are saved to memory when exiting adjust mode. • • • • • •

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