Troubleshooting Guide

ManualsBrandsGardner Bender ManualsConduit Benders1/2 in. - 2 in. Cyclone Electric-Powered Complete EMT, Rigid, IMC Conduit Bender

GAR_TL_045_0515

B2000 Cyclone

Bender

SERVICE INSTRUCTIONS

These Service instructions are intended for use by a qualified personal at Authorized Gardner Bender Service

Centers. Users of Gardner Bender equipment should see the bender instruction sheet for installation, operation and

maintenance information.

SAFETY ISSUES

1.0 Troubleshooting Guide ............................................ 2

2.0 Pendant Troubleshooting ........................................ 4

3.0 Disassemble Instructions ....................................... 5

Limit Switch ........................................................ 5

Roller Housing .................................................... 5

Bender Shoe ....................................................... 5

Circuit Board ....................................................... 5

Electric Motor ..................................................... 5

Drive Sprocket Assembly ................................... 6

4.0 Reassembly Instructions ........................................ 6

Drive Belt and Sprockets ................................... 6

Motor Assembly ................................................. 7

Shoe Shaft .......................................................... 7

Roller Housing .................................................... 7

Prinited Circuit Board ......................................... 7

Limit Switch Assem/Wiring 7

5.0 Zero Adjustment ...................................................... 8

6.0 Parts Breakdown ..................................................... 9

B2000 Bender ..................................................... 9

Bottom of Electric Motor ................................. 10

Shoe .................................................................. 11

Limit Switch ...................................................... 12

Roller Housing .................................................. 13

Upper Roller / Handle ...................................... 14

Sprocket Housing ............................................. 15

Handle / Control Circuit ................................... 16

7.0 Wiring Schematic .................................................. 17

8.0 B2000 Wiring Diagram .......................................... 18

9.0 Maintenance .......................................................... 19

REQUIRE TOOLS AND TEST EQUIPMENT

• Torque Wrench

• Allen Wrench

• Open Wrench ½ “ and 9/16 “

• Sockets

• White Assembly Grease

• Soft Head Mallet

• 2” EMT and Rigid Conduit

• Silicone

• Multi-meter

• Strap Wrench

• Repair Parts Sheet

• Instructions Manual

TABLE OF CONTENTS

WARNING: Do not locate the bender on damp or wet surfaces. Do not stand on damp or wet surfaces

when repairing or operating the bender.

WARNING: To avoid electrical shock, always unplug the bender power cord before removing end plates,

motor or any electrical wiring.

CAUTION: To avoid physical injury, use two people to remove and install the bending shoe or to move

it from place to place.

CAUTION: Keep hands, clothing and electrical power cords away from moving rollers, bending shoe and

exposed gears.

IMPORTANT: Prior to installation: apply a coat of molycoat or equivalent to all shafts. When installing

shafts, use soft head mallets to seat in position.

Summary of content (19 pages)

PAGE 1
Troubleshooting Guide B2000 Cyclone® Bender GAR_TL_045_0515 SERVICE INSTRUCTIONS These Service instructions are intended for use by a qualified personal at Authorized Gardner Bender Service Centers. Users of Gardner Bender equipment should see the bender instruction sheet for installation, operation and maintenance information. SAFETY ISSUES WARNING: Do not locate the bender on damp or wet surfaces. Do not stand on damp or wet surfaces when repairing or operating the bender.
PAGE 2
1.0 TROUBLESHOTTING GUIDE PROBLEM POSSIBLE CAUSE ACTION Bending shoe does not move when switch is in bend or return position. No power to bender Check power cord. Use 110 VAC, 15 amp outlet. 12V DC power supply failed Unplug bender power cord. On P.C. board, remove cover on plug. Connect positive meter lead on black wire and negative lead on green wire. Plug in the power cord. Meter should indicate 12V DC. If not, replace P.C. board. Power circuit on P.C.
PAGE 3
PROBLEM POSSIBLE CAUSE ACTION Bender does not stop at selected bend size (angle). Bend limit switch is not being actuated by shoe post Remove shoe indicator plate. Observe the tabs as they pass the bend limit switch. Adjust switch until tabs correctly contact the posts. Bend limit switch is not functioning Unplug the bender power cord. Attach leads to orange and green wires at the switch. Continuity should exist. Push the actuator tab (on the switch). Continuity should be broken.
PAGE 4
2.0 PENDANT (P05C) TROUBLESHOOTING 1. Verify continuity for both wires traveling from the zero limit switch down to the wire harness. Wiring Schematic ZERO STOP SWITCH BEND LIMIT SWITCH RETURN LIMIT SWITCH BLACK GREEN RED (OPEN) COMMON (OPEN) BLOCK MOUNTING ORANGE Typical Switch Contacts WHITE NORMALLY OPEN BLUE (OPEN) BLACK OVER MOUNTING ONLY NORMALLY CLOSED BOTTOM OF MOTOR 2.
PAGE 5
3.0 DISASSEMBLY INSTRUCTIONS Bender Shoe (Figure 1 & 2) 1. Prior to removing the bending shoe, the limit switch assembly must be removed. Refer to “LIMIT SWITCH” in the disassembly procedures. 2. Remove the four bolts (Figure 1 Item #9) and washers (Figure 1 Item #10) located on the flat portion of each side of the shoe (Figure 2 Item # 1). 3. Two people are required to lift the bending shoe. Lift at two places (180° apart) and pull the shoe straight up until it clears the shoe shaft. 4.
PAGE 6
4.0 RE-ASSEMBLY INSTRUCTIONS elbow and pull the wires out. 6. Remove the rear access plate by removing 4 cap screws and washers. 7. Remove the four cap screws and washers (Figure 6 Item #18 & 19) securing the motor to the sprocket housing, Remove the motor, unhook the drive belt from the motor shaft. 8. Remove the belt tensioner (Figure 6 Item #2) by removing nut and washer. The tensioner shaft is spring loaded. Remove the tensioner assembly spring and shaft from inside the sprocket housing.
PAGE 7
Motor Assembly (Figure 6 / Insert A) 1. Remove restraint from drive belt. 2. Place gasket (#1) on motor flange. Insert motor into the sprocket housing. Install one mounting screws and washers into mounting hole closer to the belt 3. Position the drive belt over the motor pulley. Align the belt to ride at the same height on the motor pulley and grooved sprocket. 4. Using a strap tool put it around the motor to help align the mounting holes with the motor. Install the 3 mounting screws and washers. 5.
PAGE 8
5.0 ZERO SET ADJUSTMENT TO ENSURE ACCURATE BENDS, THE BENDER ZERO ADJUSTMENT MUST BE ACCOMPLISHED AFTER RE-ASSEMBLY. 1. Plugs bend power cord into 110/115V outlet. Push upper roller assembly against the stop on the sprocket housing (Figure 19). 2. Press and hold “ADVANCE” on pendant switch until RIGID side of shoe is facing the upper roller housing. 3. Place a straight edge against the shoe (clamp surface) and toward the upper roller shaft. 4.
PAGE 9
Figure Figure11 B2000 Bender Assembly B2000 Bender Assembly 2 3 9 9 23 24 12 10 10 1 21 38 22 20 7 36 8 5 4 6 35 27 (See Fig. 7) 34 34 35 37 35 26 17 34 25 14 SEE INSERT A Page 3 & Fig.
PAGE 10
INSERT A 28 30 33 31 32 29 31 30 B2000 Bender Assembly, cont. B2000 Bender Assembly Item # Part # # Req’d Description Item # Part # # Req’d Description 20 CU295900K 1 Roller Housing Assm (Figure 4) 1 Figure 2, pg. 4 1 Shoe Sub Assm 21 CK696108 1 Washer 2 Figure 3, pg.
PAGE 11
Figure 2 Shoe Subassembly 8 2 10 11 4 9 3 1 GB 4 6 5 7 7 8 Shoe Subassembly Item # Part # # Req’d Description 1 CL199809K 1 Shoe Bending (Incl. items 7, 8, 9 and 10) 2 CN542005 1 Clamp, IMC (Incl. items 4, 5, 6) 3 CN541005 1 Clamp, EMT (Incl. items 4, 5, 6) 4 Common 6 Replaceable Part 5 Common 6 Common 6 Shoe Subassembly, cont.
PAGE 12
Figure 3 Limit Switch Assembly 1 1 2 B2000CK ItemCM802950N # Part # 1 Clamp kit Limit Switch Assembly Description Knob Sub Assembly Kit B2000HCK Clamp Kit 3 CM767108 Washer ZCM793055N Thread Locker (for #1) not pictured 4 2 CM801950 Upper Plate Assembly CM802950N Knob Sub Assembly Kit 2 #10 CM767108 Washer 5 3 B2000-TRK Trip Ring Assembly Kit (Incl. & #11) 4 CM801950 Upper Plate Assembly 6 CM803950N Actuator Kit 5 B2000-TRK Trip Ring Assembly Kit (Incl.
PAGE 13
Figure 4 Roller Housing Assembly – CU295900K 11 3 13 9 2 12 3 6 9 7 NOTE: Item 11 is a separate 2 assembly not included with the roller housing (Figure 5). 1 8 7 5 4 5 10 10 7 7 Roller Housing Assembly-CU295900K Item # 1 2 3 Part # CL61107 10 CU297104 2 Shaft, Roller Upper Roller Assm (see Figure 5) 12 DC694104 1 Axle Bearing 13 CL343550 1 Grip, Handle CU299281 1 1 ⁄2” Roller 5 CU298281 2 2” Roller (Set of 2) 6 CN452104K 1 Shaft, Roller Common Repl.
PAGE 14
Figure 5 Upper Roller and Handle Assembly – CK994900 4 1 2 3 10 4 11 9 5 6 12 7 13 Upper Roller and Handle Assembly-CK994900 Item # Part # 1 # Req’d Description Common Repl. Part 1 1” External Retaining Ring 2 CK569108 1 Washer 3 ∗ CK575281K 1 1 CK295107 2 Bearing (Set of 2) CL30900 1 Roller Axle Assembly Common Repl. Part 1 3 CL662950KW 1 Cam Shaft CK693107 2 Bearing (Set of 2) 4 5 6 7 8 ∗ ⁄2”-1” Roller Common Repl.
PAGE 15
Figure 6 33 31 Sprocket Housing Assembly - DA7058900 11 36 32 2 19 42 43 21 44 45 35 34 23 48 28 30 47 37 26 12 47 39 23 41 19 13 15 20 27 22 40 38 10 46 24 18 14 29 22 16 1 25 20 17 Sprocket Housing Assembly - DA7058900 Sprocket Housing Assembly - DA7058900, cont.
PAGE 16
Figure 7 Handle and Control Circuit Assembly – HC12 7, 8 3, 4 14 1 16 19 15 10 6 18 9 5 11 6 17 12 15 13 HC12 Contents Item # Part # # Req’d Description 1 CJ458885 1 Locknut 2 CM178647SR 1 Plug Assembly 3 CM32006 1 Receptacle, Power Cord 4 CM25061 2 Pin, Cord Receptacle 5 PO5C 1 Pendant Station Assm 2 6 Common Repl. 3 #6 -32 X 3⁄8” LG. Button Hd.
PAGE 17
Wiring Schematic ZERO STOP SWITCH BEND LIMIT SWITCH RETURN LIMIT SWITCH BLACK GREEN RED (OPEN) COMMON (OPEN) BLOCK MOUNTING ORANGE Typical Switch Contacts WHITE NORMALLY OPEN BLUE (OPEN) BLACK NOTE: 2-LONG STUDS FOR COVER MOUNTING ONLY NORMALLY CLOSED BOTTOM OF MOTOR WHITE AZ YELLOW ORANGE (42) (43) RED BLACK (45) (46) YELLOW (48) GREEN (41) BLUE (44) GREY CONNECTOR TO CIRUIT BOARD (47) RED BLACK GREY POWER CORD FEMALE CONNECTOR RED BLACK WHITE BLACK MALE CONNECTOR RED B
PAGE 18
PAGE 19
9.0 MAINTENANCE A troubleshooting aid exists on the printed circuit board mounted to the inside of the operating handle. A white L.E.D. will flash once every two seconds after power up. The L.E.D. indicates all systems functional. See Figure 13. Error codes consist of different light patterns. 1. Blink twice, pause, blink twice = the motor is over heated. 2. Blink 3 times, short pause, blink three times, long pause = limit switch has failed. 3.