Gardner Bender B2000 Troubleshooting Guide

Troubleshooting Guide
B2000 Cyclone® Bender
GAR_TL_045_0717
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 is reserved for conditions and actions that can cause serious or fatal injury. CAUTION is reserved for conditions and actions that can cause injury or instrument damage.
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.
• 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.
• Keep hands, clothing and electrical power cords away from moving rollers, bending shoe and exposed gears.
• Prior to installation: apply a coat of molycoat or equivalent to all shafts. When installing shafts, use soft head mallets to seat in position.
REQUIRE TOOLS AND TEST EQUIPMENT
Torque Wrench
Allen Wrench
Open Wrench ½" and 9/16"
Sockets
Lithium Grease
Soft Head Mallet
TABLE OF CONTENTS
1.0 Troubleshooting Guide .........................................2-6
2.0 Pendant Troubleshooting ........................................ 6
3.0 Disassemble Instructions ....................................... 7
Limit Switch ..................................................... 7
Roller Housing ................................................. 7
Bender Shoe .................................................... 7
Circuit Board .................................................... 7
Electric Motor .................................................. 7
Drive Sprocket Assembly ................................ 8
4.0 Reassembly Instructions ........................................ 8
Drive Belt and Sprockets ................................ 8
Motor Assembly .............................................. 9
Shoe Shaft ....................................................... 9
Roller Housing ................................................. 9
Prinited Circuit Board ...................................... 9
Limit Switch Assem/Wiring ............................. 9
2" EMT and Rigid Conduit
Silicone sealant
Multimeter
Strap Wrench
Repair Parts Sheet
Instructions Manual
5.0 Zero Adjustment .................................................... 10
6.0 Parts Breakdown ................................................... 11
B2000 Bender ................................................ 11
Bottom of Electric Motor .............................. 12
Shoe ............................................................... 13
Limit Switch ................................................... 14
Roller Housing ............................................... 15
Upper Roller / Handle ................................... 16
Sprocket Housing .......................................... 17
Handle / Control Circuit ................................18
7.0 Wiring Schematic .................................................. 19
8.0 Limit Switch Wiring Diagram ................................ 20
9.0 Maintenance .......................................................... 21
10.0 Interchangeable Part Compatibility ..............21-23
1
1.0 TROUBLESHOTTING GUIDE
*Note: Troubleshooting or maintenance that requires the B2000 to be disassembled in any way should be done by a professional indicated by Gardner Bender to avoid permanent damage to the machine. Contact nearest Gardner Bender Service Center for guidance.
PROBLEM POSSIBLE CAUSE ACTION
Bending shoe does not move when switch is in bend or return position.
Roller Housing and Upper Roller do not properly lock the conduit into place.
Circuit break / power switch in the off position.
No power to bender. Check for voltage at power source. Use 110 VAC, 15 amp outlet.
Blown Fuse.* *THIS PROBLEM WILL NOT OCCUR ON MODELS B2000-5 THROUGH
12V DC power supply failed.
Remote pendant wiring harness is malfunctioning.
Power circuit on P.C. board is malfunctioning.
Motor overload or/ overheated.
Upper Roller pivot is in incorrect position.
Incorrect rollers used. If the Roller Housing (Part Number – CU295900K) has been disassembled in
Rollers are damaged Replace damaged rollers.
Check that power switch (Part Number – CB25) is in the “ON” position. When the bender is ON, the two LEDs on the Rear Handle End Plate (Part Number – HC12) will flash red, then green to indicate normal function. The green power light on the control pendant (Part Number – PO5C) should be lit.
B2000-7 (SERIAL NUMBERS BEGINNING WITH LETTERS “F” - “K” OR BENDERS MANUFACTURED BETWEEN 2001 AND 2007). THESE MODELS DO NOT HAVE A FUSE.
Inspect 15 amp fuse and perform continuity check for a short.
If no continuity, replace fuse with new 15 amp, 125 volt fuse.
Fuse located behind handle mounting plate in the left corner of the control panel. Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
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, Part Number- EC2006 or HC12
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Remote pendant wiring in the harness may be pinched or cut in a way that causes bending to malfunction despite the indicator LEDs on Rear Handle End Plate and Remote Pendant illuminating.
Replace wire harness. (Refer to Repair Parts List for illustration and additional part numbers).
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Control circuit is not activating bender.
Replace P.C. board, Part Number- EC2006 or HC12
Allow time for motor to cool. Activate bender.
If motor will not run, perform continuity check. If there is continuity, motor is damaged and must be replaced, Part Number – CL43259
Refer to “Electric Motor” in “DISASSEMBLY” section (page 7) for instructions.
If the Upper Roller has been disassembled in the past, the pivot may be in the wrong position.
While facing the B2000 push handles, remove the Upper Roller (Part Number – CK994900) and look down the bearing shaft. There will be an off-center hole at the bottom of the bearing. If the Upper Roller is correctly installed facing to the right, this hole should be closer to you to ensure that the pivot is in the right position.
Refer to “Roller Housing” in “DISASSEMBLY” section (page 7) for instructions.
the past, the rollers may have been incorrectly reassembled. The middle set of 1½" nylon rollers (Part Numbers – CU299281 and CU319281) must be placed in the correct position and are not interchangeable. The upper set of 1¼" rollers (Part Number – CU300281) can be swapped and the lower set of 2" rollers (Part Number – CU298281) can be swapped.
Refer to “Roller Housing” in “DISASSEMBLY” section (page 7) and “Roller Housing” in “RE-ASSEMBLY” section (page 9) for instructions on assembling the rollers.
Refer to “Roller Housing” in “DISASSEMBLY” section (page 7) for instructions.
2
Drive belt tensioning seems loose.
Bend switch does not function, return switch functions.
Bend function works, return switch does not.
Belt is worn out. Belt may be worn or damaged and must be replaced,
Part Number – CL310014.
Refer to “Drive Sprocket Assembly” in “DISASSEMBLY” section (page 8) for instructions.
Tensioner failure. Tensioner may be damaged and must be replaced, Part Number – CL306900.
The motor must be removed in order to remove the tensioner. Refer to “Electric Motor” in “DISASSEMBLY” section (page 5) for instructions.
Motor pulley is lose. If the motor has been disassembled in the past, thread-locking fluid may
not have applied to the containing screw of the motor pulley (Part Number – CL311019) when reassembling the motor assembly (Part Number – CL43259).
Apply thread-locking fluid on containing screw and assemble it to the motor pulley.
Refer to “Electric Motor” in “DISASSEMBLY” section (pages 7 & 8) for instructions.
Remote pendant bend switch or wiring inoperative.
Unplug bender power cord, test for continuity at hard¬ness to pendant. Attach leads to black and white wires. Press bend switch. If no continuity, check switch under pendant cover. Place ohm meter on leads for black wire and white wire. Depress bend switch.
If continuity exists, replace switch, Part Number - DA9687372.
If no continuity, wire harness is faulty.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Bend limit switch or harness to limit switch is malfunctioning.
Unplug bender power cord. Perform continuity check on green and orange wires. Press bend limit switch actu¬ator tab.
If continuity exists, replace switch, Part Number - DA9687372.
If no continuity, check wiring harness. (Refer to Repair Parts List for illustration and additional part numbers).
If no continuity exists on wire harness, it must be replaced.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions
Plunger on bend limit switch is not being tripped by the shoe post.
Remove shoe indicator plate (Part Number – CM801950). Observe the shoe post as it passes the bend limit switch (Part Number - DA9687372). The shoe post should trip the plunger on the bend limit switch as it passes over the limit switch.
If the shoe post is not tripping the plunger, replace the limit switch, Part Number- DA9687372.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Printed circuit board malfunctioning.
Pendant return switch is malfunctioning.
Replace P.C. board, Part Number- EC2006 or HC12
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Unplug bender power cord. Perform continuity check on pendant return switch. Attach leads to black wire and white wire, depress return switch.
*The colors described here are not present on the model B2000-7 and B2000­8 pendant harness (B2000 SERIAL NUMBERS BEGINNING WITH LETTERS “J” - “N” OR BENDERS MANUFACTURED AFTER 2007). However, the same troubleshooting actions should be taken.
If continuity exists, replace switch, Part Number - DA9687372.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Wiring is malfunctioning. If no continuity, check wire harness. Attach ohm meter leads to orange
and blue wires. Depress return switch.
If no continuity; replace wire harness, Part Number – CL¬712647SR.
Refer to “Drive Sprocket Assembly” in “DISASSEMBLY” section (page 8) for instructions.
3
Bender shoe will not return when pressing return and jog button.
Bender shoe successfully returns to zero, indicator light on top of Pendant Control malfunctions and does not light.
Bender consistently develops over bends.
Jog button malfunctioning.
Wire harness to pendant damaged.
Pendant damaged or malfunctioning.
Zero limit switch is malfunctioning and is not receiving voltage.
Harness to switch is malfunctioning and is not receiving voltage.
Bend angle is not correctly indicated.
Bender zero adjustments are necessary.
Bender angle adjustments are necessary.
Unplug bender power cord. Perform continuity check on wire harness. Attach leads to red and green wires, Depress override (jog) button.
*The colors described here are not present on the model B2000-7 and B2000-8 pendant harness (B2000 SERIAL NUMBERS BEGINNING WITH LETTERS “J” - “N” OR BENDERS MANUFACTURED AFTER 2007). However, the same troubleshooting actions should be taken.
If continuity exists, check jog switch in pendant control, (Parts Not Available). Remove cover, place leads on red and green wires at switch. Depress jog switch. If there is continuity, replace switch (Parts Not Available).
Refer to “Circuit Board” in “DISASSEMBLY” section (page 8) for instructions
If no continuity exists, fault lies in wire harness.
Replace wire harness. (Refer to Repair Parts List for illustration and additional part numbers).
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Replace pendant switch, Part Number – PO5C
If model B2000-4 or older (SERIAL NUMBERS BEGINNING WITH LETTERS “A” - “E” OR BENDERS MANUFACTURED BEFORE 2001), customer may need to upgrade to current model B2000. Older model pendant switch is no longer available.
For models B2000-5 and B2000-6 (SERIAL NUMBERS BEGINNING WITH LETTERS “F” - “H” OR BENDERS MANUFACTURED BETWEEN 2001 AND
2004), customer may be able to adapt new pendant (P05C) to older models.
Unplug bender power cord. Perform continuity check on harness from pendant control. Attach leads to black and red wires.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 5) for instructions.
If continuity exists, check the zero limit switch (see illustration in Repair Parts List).
Attach the leads to black and red wires at the limit switch. Depress limit switch actuator tab. If continuity exists, replace switch, Part Number- DA9687372.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Unplug bender power cord. Perform continuity check on wire harness from limit switch.
If no continuity exists, the wire harness is malfunctioning.
Remove and strip wire harness wire ends, crimp on female terminals (Part Number – 21-161F), and reconnect terminals to limit switches. If problem continues, replace wire harness.
In order to replace the limit switch wire harness, the following components need to be disassembled: bender shoe (item #1), sprocket (item #8), end plate (item #26), and handle (item #38). Please refer to Figure 1 to identify listed parts.
Refer to “Bender Shoe”, “Drive Sprocket”, and “Limit Switch” in “DISASSEMBLY” section (pages 7 & 8) for instructions.
Ensure that the flat edge of the pointer (Part Number – 802950N) is on a line indicating the exact degree of bend desired, not the angled edge. Failure to do this will lead to inaccurate bends.
Refer to Instruction Sheet for operation instructions.
Ensure bender zero adjustment has been performed. This is required after every re-assembly.
Refer to “ZERO SET ADJUSTMENT” section (page 10) for mechanical adjustment instructions.
Differences in conduit characteristics and other variations can lead to incorrect scale indications. Loosen the size scale (for type material being bent) mounting screws. Slide the scale clockwise as many degrees as the over bend (if bend is 5° over, move indicator 5° clockwise). The degree of movement is observed by watching one of the size marks as it moves past the angle disc scale. Tighten the mounting screws.
Refer to Instruction Sheet for more Angle Adjustment instructions.
4
Bender consistently develops over bends
Bender does not stop at selected bend angle.
During return function, bender shoe does not stop at zero point.
Bender shoe does not stop rotating in both the return and bend directions.
Braking resistor on P.C. board is malfunctioning.
P.C. board circuit is malfunctioning.
Bender is incorrectly set up.
Bend limit switch is not being actuated by shoe post.
Bend limit switch is malfunctioning.
Braking resistor is malfunctioning.
Brake circuit (P.C. board) is malfunctioning.
Plunger on return limit switch is not being tripped by the trip ring tab.
Bend limit switch is malfunctioning.
Return limit switch is malfunctioning.
Brake resistors are malfunctioning.
Limit switches assembled incorrectly on the switch arm.
Unplug bender power cord. Perform resistance measurements on braking resistor. Remove chassis from rear of bender. Attach ohm meter across to brown and gray wires.
If meter reads above 11 ohms, replace resistor.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Remove and replace P.C. Board, Part Number- EC2006 or HC12.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Ensure bender angle adjustment and zero adjustment has been performed. This is required after every re-assembly.
Refer to “ZERO SET ADJUSTMENT” section (page 10) for mechanical adjustment instructions. Refer to Instruction Sheet for Angle Adjustment instructions and correct set up instructions.
Remove shoe indicator plate. Observe the tabs as they pass the bend limit switch.
Adjust switch until tabs correctly contact the posts.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
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. If not, replace the switch.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Unplug the bender power cord. Perform resistance measurement on braking resistor. Attach leads across terminals.
A 9-11 ohms (+ 1 ohm) resistance is normal. Other readings are unacceptable. Replace braking resistor, Part Number – RA19.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
If all other tests are positive, replace P.C. board, Part Number– EC2006 or HC12.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Remove limit switch assembly. Observe tab to return limit switch contact.
If switch is not contacting tab, adjust switch position.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
If post to switch is correct, perform bend limit switch continuity check. Attach leads to orange and green wires. Press limit switch tab.
Continuity should result. If not, replace switch.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Unplug the bender power cord. Perform return limit switch continuity check. Attach leads to white and blue wires.
Continuity should be broken. If not, replace return limit switch.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Unplug the bender power cord. Perform resistance measurement on each resistor. Place ohm meter leads on gray and brown wires.
Meter should read 9-11 ohms. If reading is over 11 ohms, replace resistor.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
If the Limit Switch has been disassembled in the past, the switches may have been reassembled incorrectly on the switch arm. The switch arm must have two limit switches (blue face, facing away from arm) on the long side of the arm, and one limit switch (black face, facing away from arm) on the short side of the arm.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
5
Bend function works,
Wiring Schematic
return function results in bending direction.
Return function works, bend function results in shoe moving in return
Direction circuit on P.C. board is malfunctioning.
Brake circuit on P.C. board is malfunctioning.
Replace P.C. board.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
If all other tests are positive, replace P.C. board.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
direction.
Return function works. Depressing bend switch, shoe moves
Direction circuit on P.C. board is malfunctioning.
Replace P.C. board.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
in return.
2.0 PENDANT (P05C) TROUBLESHOOTING
1. Verify continuity for both wires traveling from the zero limit switch down to the wire harness.
GREEN
(OPEN)
ORANGE
BEND LIMIT SWITCH
BLOCK MOUNTING
(OPEN)
BLACK
RED
ZERO STOP SWITCH
WHITE
(OPEN)
BLUE
K
RETURN LIMIT SWITCH Typical Switch Contacts
COMMON
NORMALLY OPEN
NORMALLY CLOSED
2. Verify that the black wire goes to the pin on the limit switch that is separate from the other two, and that the red wire is connected to the middle pin.
3. Test Zero Light - Take a multimeter and set it to the diode (
) function and place the red lead on the orange wire
in the harness and the black lead to the red (pink) wire in the harness. This should illuminate the green Zero LED
4. Test Power LED - Take a multimeter and set it to the diode (
) function and place the red lead on the orange wire
and black lead on the yellow wire. This should illuminate the red Power LED.
5. Test Bend Button - Set a multimeter to the continuity or ohms function. Place one meter lead to the pin of the Black wire in the pendant wire harness, and place the other lead on the pin for the Blue with Black strip wire. While the probe tips are making contact with the pins in the harness, press the bend button. When the button is pressed, 0 Ohms and/or the continuity buzzer should go off.
6. Test Return Button - Set a multimeter to continuity or ohms function. Place one meter lead on the pin of the Black wire in the pendant wire harness. Place the other meter lead to the pin of the Blue wire in the harness. With the probes still making contact with the pins, press the Return button. When the button is pressed, 0 Ohms and/or the continuity buzzer should go off.
7. Test Jog Button - Set a multimeter to the continuity or Ohms function. Place one meter lead to the pin of the Black wire in the pendant wire harness, and place the other lead on the pin for the Brown wire. While the probe tips are making contact with the pins in the harness, press the bend button. When the button is pressed, 0 Ohms and/or the continuity buzzer should go off.
6
3.0 DISASSEMBLY INSTRUCTIONS
IMPORTANT: To avoid unnecessary service, the bender should be tested prior to any service work. Please refer to the maintenance section in the instructions manual and Troubleshooting section.
Limit Switch (Figure 3)
1. Prior to removing components of the limit switch and angle adjustments, the bending shoe, trip ring and sprocket housing must be marked to aid in re-assembly.
2. Position the bending shoe to the zero point by pressing the pendant in “RETURN. Continue holding the switch until the shoe stops and the zero light comes on.
3. Unplug the bender power cord.
4. Scribe a mark on the side of the trip ring (Figure 1) and a matching mark on the bending shoe.
5. Scribe a mark on the lower portion of the bending shoe and on the sprocket housing (Figure 1).
6. Remove the silicone packing from the trip ring mounting screws (Figure 3). Remove the mounting screws and the top plate assembly (Figure 3), the size indicator plates must not be removed.
7. Remove and tag the wires attached to the limit switches (Figure 3). Leave the switches (Figure 3) attached unless they require replacement.
8. Remove the springs and the three screws from the plate assembly (Figure 3).
9. Leave actuator and clamp attached to upper plate assembly unless damaged.
10. Examine all components for signs of wear or damage. Use troubleshooting procedures to electrically check switches. Repair or replace items that are worn, damaged or non-functional.
11. Refer to “RE-ASSEMBLY” section of this manual.
Roller Housing (Figure 4 & 5)
1. Remove the pin (Figure 5 Item #6) securing the upper roller arm (#5). Remove the nut (Figure 5 Item #10) and remove the cap screw (Figure 5 #9) securing the arm in the Cam Shaft (Figure 5 Item #7).
2. Remove the cap screw (Figure 5 Item #12) and the washer (Figure 5 Item #13). Lift the roller housing (Figure 4 Item #1) from the shaft. Remove the thrust washers (Figure 1 Item #21) and the shims (Figure 1 Item #22).
3. Inspect all rollers, the housing and shaft for wear and damage. Replace worn or damaged items.
4. All nylon rollers should be secured in the housing by retaining rings around the roller shafts (Figure 4). Be sure that the correct rollers are reassembled in the exact location they were in originally. All new rollers contain factory installed bearing.
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. Inspect the shoe for worn grooves, cracks or other damage. Each conduit groove should be checked for wear by placing a piece of conduit (of correct size and material) into the groove. It should fit easily without excessive gaps above, below or behind it.
5. If shoe damage is suspected, a dye penetrate may be required to locate cracks in the casting.
6. Refer to Re-Assembly procedures.
Circuit Board (Figures 7 / Insert B)
1. The printed circuit board is mounted inside of the sprocket housing. Access is gained by removing the handle assembly.
WARNING: To avoid electrical shock, unplug the bender power cord prior to removing the handle and access plate.
2. Remove the four screws and washers (Figure 7 Items #13 & 17).
3. Remove the handle assembly (Figure 1 Item# 38) NOTE: Hold the handle to prevent it from falling and
causing damage to electrical connectors inside the sprocket housing.
4. Lower the handle and plate assembly. Unplug the power cord receptacle (Figure 7 Item #3) from the P.C. board plug. Unplug the pendant receptacle (Fig. 7 Item #7) from the P.C. board plug.
5. Conduct testing procedures described in the “Troubleshooting” section. See Insert B for wiring diagram.
Electric Motor (Figure 6) WARNING: Unplug bender power cord prior to removing
motor or wiring.
1. Remove acorn nuts securing the motor bottom cover.
2. Remove electrical wires from bottom of motor. Refer to (Page 14 Insert A).
3. Remove bolt and washer (Figure 6 Item #26 & 27) which secures the locking plate (Figure 6 Item #37) to the bottom of the sprocket housing. Remove bolt (Figure 6 Item #38), lock washer (Figure 6 Item #39) and washer (Figure 6 Item #40) which secures the sprocket shaft in the locking place.
4. Rotate the sprocket shaft by placing the locking plate over the shaft flats. Turn the shaft until the sprocket belts and chains are loose.
5. Remove the conduit nut (Figure 6 Item #15) from the motor connection. Slide the flexible conduit out of the
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