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Table of Contents
Related Manuals for Greenlee 855
Summary of Contents for Greenlee 855
- Page 1 SMART BENDER and 01711 Optional Deluxe Pendant Serial Code ABL Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 999 2168.5 © 2001 Greenlee Textron IM 1266 REV 15 6/01...
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Page 2: Table Of Contents
Troubleshooting ... 50–62 Greenlee Textron / Subsidiary of Textron Inc. Description The 855 Smart Bender™ is designed to bend 1/2" through 2" EMT, IMC, rigid steel and rigid aluminum conduit from 0 through 90 degrees. 1/2" through 2" 40 Mil PVC-coated rigid steel conduit can also be bent with optional 01700 shoe group attachment. -
Page 3: Important Safety Information
Failure to observe this warning will result in severe injury or death. Greenlee Textron / Subsidiary of Textron Inc. Electric shock hazard: • Connect the power cord to a 120 volt, 20 amp receptacle on a ground fault protected circuit only. -
Page 4: Safety
Failure to observe this warning can result in severe injury or death. Greenlee Textron / Subsidiary of Textron Inc. Do not use 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. -
Page 5: Grounding Instructions
Failure to observe these warnings can result in severe injury or death. Greenlee Textron / Subsidiary of Textron Inc. 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. -
Page 6: Specifications
Temperature ... 0 C to 38 C (32 F to 100 F) Relative Humidity ... 0 to 98% Capacity ... 1/2" to 2" conduit Greenlee Textron / Subsidiary of Textron Inc. Balanced bending head pivots easily as it is changed from the vertical bending position to the horizontal bending table position. -
Page 7: Identification
5. 1-1/2" to 2" support roller system 6. Support roller engagement handle Features The 855 bender is designed to make high quality bends of up to 90 degrees in 1/2" to 2" EMT, IMC, rigid steel, and rigid aluminum conduit. It incorporates a number of features to make bending easier and faster. -
Page 8: Transportation
To take the bender off the stand, push down on the lever below the crossbar and pull the bender toward you until it rolls off the stand. Greenlee Textron / Subsidiary of Textron Inc. Setup When you reach your destination, lower at least two jackscrews to prevent the unit from rolling. -
Page 9: Operation Standard Pendant
Clear Key: sets the display to 00 and eliminates any angle from memory. It will not reset the actual present bend angle to zero. Greenlee Textron / Subsidiary of Textron Inc. Display: shows the actual angle the conduit has been bent in degrees. Counting does not start until the conduit actually starts to bend. -
Page 10: Operation
STUB LENGTH MARK START OF BEND BENDING CENTER TO CENTER MARK 1 START OF BEND BENDING MARK 1 Greenlee Textron / Subsidiary of Textron Inc. STUB IMC, RIGID & PVC MARK OFFSET BENDING MARK 2 BENDING MARK 2 CONDUIT SIZE... -
Page 11: Deluxe Pendant
SET HOME POSITION prompt will be skipped if the home switch was previously tripped.) Greenlee Textron / Subsidiary of Textron Inc. 00o to 99o (Bend angle is displayed when BEND is pressed and after the home switch has been tripped.) -
Page 12: Deluxe Pendant
All numeric displays will be limited to two decimal places, except as noted above. Greenlee Textron / Subsidiary of Textron Inc. 11. Pressing BEND: a. if the conduit size and type have not been selected, will display the SELECT CONDUIT SIZE screen but will not start the bender. -
Page 13: Installing And Bending Conduit
Failure to observe these warnings can result in severe injury or death. Greenlee Textron / Subsidiary of Textron Inc. Note: Variations for deluxe pendant operation are included within brackets […]. [On the deluxe terminal, select the size and type of conduit with the six conduit size keys and the one conduit type key. -
Page 14: Operation
JOG key to advance the bend in 1/2-degree increments to prevent overbending. Greenlee Textron / Subsidiary of Textron Inc. 1-1/2" and 2" Rigid and 40 Mil PVC-Coated Rigid Conduit Make sure that the rollers are in the fully retracted position to the right. -
Page 15: Operation
Always use the UNLOAD key to rotate the shoe to the desired position. Greenlee Textron / Subsidiary of Textron Inc. Accuracy Adjustments Due to variations in conduit, you may notice the bender consistently over or under bending a particular size and type of conduit. -
Page 16: Operation
The bender will proceed to unload. Release the UNLOAD key when the shoe has rotated to the desired position. Greenlee Textron / Subsidiary of Textron Inc. MAKING ANOTHER BEND To make another manual bend, proceed as you did with the first one. -
Page 17: Operation
2 with the hook, rotate conduit 180 degrees, and make the next bend(s) as before. Greenlee Textron / Subsidiary of Textron Inc. 1-1/2" and 2" EMT, IMC and Aluminum Rigid Conduit Note: For aluminum rigid conduit, set squeeze to the minimum position. -
Page 18: Installing And Bending Conduit
Proceed to bend the conduit as a normal offset except do not rotate the conduit between bends. Greenlee Textron / Subsidiary of Textron Inc. Four-Bend Saddles To make a four-bend saddle, program it as a saddle and bend it as two offsets. -
Page 19: Special Bending Information
4. Place a mark this distance from the end of the conduit. 5. Make your bend after positioning the front edge of the hook on your mark. Greenlee Textron / Subsidiary of Textron Inc. Offsets (controlling the start of the first bend) START OF FIRST BEND... - Page 20 8. Make your first bend after placing the front edge of the hook on the first mark and your second bend after placing the front edge of the hook on the second mark. Greenlee Textron / Subsidiary of Textron Inc. Three-Bend Saddle LENGTH TO CENTER LENGTH – Z MARK 2 1.
- Page 21 12. Place a fourth mark this distance from your third mark. 13. Make your four bends by placing the front edge of the hook on the respective marks for each bend. Greenlee Textron / Subsidiary of Textron Inc. U-Bends ANGLE BENDING...
- Page 22 MINIMUM H = 1.20 22.5 22.5 22.5 22.5 MINIMUM H = 2.06 MINIMUM H = 3.08 MINIMUM H = 5.53 MINIMUM H = 8.38 MINIMUM H= 14.47 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 3.28 11.01 18.73 26.45 34.18...
- Page 23 22.5 22.5 22.5 22.5 MINIMUM H = 2.89 MINIMUM H = 4.40 MINIMUM H = 8.10 MINIMUM H = 12.49 MINIMUM H = 22.10 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 1.35 9.07 16.80 24.53 32.26...
- Page 24 MINIMUM H = 2.09 22.5 22.5 22.5 22.5 MINIMUM H = 3.59 MINIMUM H = 5.37 MINIMUM H = 9.61 MINIMUM H = 14.54 MINIMUM H= 25.06 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 5.56 13.29 21.01 28.74 7.71...
- Page 25 22.5 22.5 22.5 22.5 MINIMUM H = 2.05 MINIMUM H = 3.06 MINIMUM H = 5.49 MINIMUM H = 8.31 MINIMUM H = 14.33 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 3.03 10.76 18.48 26.21 33.94...
- Page 26 22.5 22.5 22.5 22.5 MINIMUM H = 2.88 MINIMUM H = 4.38 MINIMUM H = 8.06 MINIMUM H = 12.42 MINIMUM H = 21.96 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 1.08 8.81 16.52 24.25 31.97...
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Page 27: Special Bending Information
22.5 22.5 22.5 22.5 MINIMUM H = 3.53 MINIMUM H = 5.26 MINIMUM H = 9.38 MINIMUM H = 14.14 MINIMUM H = 24.25 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 5.30 13.03 20.75 28.48 7.71... -
Page 28: Assembly For 40 Mil Pvc-Coated Rigid Bending Accessories
Replace the retaining ring. Greenlee Textron / Subsidiary of Textron Inc. 6. Remove the retaining ring securing the 1/2" to 1-1/4" shoe and remove the shoe. -
Page 29: Adjustments
Failure to observe this warning can result in severe injury or death. This section of the manual describes how to disas- semble and replace parts in the Greenlee 855 Smart Bender™. Parts must be ordered from Greenlee Textron. Service of this bender should only be done by qualified personnel who are familiar with handling of electronic components. -
Page 30: Maintenance
If you cannot move the switch enough to get it to trip properly, use needlenose pliers to slightly bend the arm. Greenlee Textron / Subsidiary of Textron Inc. Maintenance Chain Lubrication Lubrication of the drive chain is recommended every six months (more often if used in dusty or corrosive environments). -
Page 31: Greenlee Textron
Greenlee Textron / Subsidiary of Textron Inc. Rear rollers: The rear rollers should be lubricated every six months (more often if used in a dusty environ- ment). -
Page 32: Bender Head Disassembly
3. Assemble in reverse order, using heat transfer grease between rectifier and subplate. See Electrical Control System Layout for location of key numbers. Greenlee Textron / Subsidiary of Textron Inc. Relay 1. Remove PGU subplate (follow instructions 1-10 above). -
Page 33: Greenlee Textron
2. Unplug receptacle unit (4). 3. Remove two screws securing receptacle and remove receptacle. 4. Reassemble in reverse order. Greenlee Textron / Subsidiary of Textron Inc. SHOES Removing and Installing Shoes 1. Disconnect power to unit. 2. Remove the retaining ring securing the shoe to be removed with retaining ring pliers. -
Page 34: Supports
O-ring, roller, two Belleville washers, roller, O-ring and pivot ball (84) (94) (115) (78) (116) (77) (100) (77) (116) (78). Greenlee Textron / Subsidiary of Textron Inc. 93 151 11. Loosen the set screw securing the collar to the pivot pin on the 2"... -
Page 35: Greenlee Textron
I/O board to serve as a retrieval line to pull the new wire and plug up through the unit. Greenlee Textron / Subsidiary of Textron Inc. 7. Reassemble in reverse order noting the following: • With the bender oriented in the vertical position,... -
Page 36: Greenlee Textron
3. Remove two screws securing bracket and remove bracket. Greenlee Textron / Subsidiary of Textron Inc. 4. Reassemble in reverse order, noting the following: • Limit switch with red wires goes on top. • Install top switch so that trip roller is as far left as possible, as viewed with the switch behind the bracket. -
Page 37: Motor Disassembly
8. Reassemble in reverse order, noting the following: • Torque hub set screws to 22 inch-ounces. • Jog motor and check Quad 1 and Quad 2 LEDs for ON/OFF pulsing. Greenlee Textron / Subsidiary of Textron Inc. Motor Disassembly 1. Remove optical encoder (see optical encoder removal). -
Page 38: Trunnion Disassembly
CORRECT INCORRECT Greenlee Textron / Subsidiary of Textron Inc. 2. Remove support tower on the rotary selector switch side. a. Remove four bolts, two nuts and crossbar at base of tower. -
Page 39: Exploded Views, Parts Lists, Schematics And Wiring Diagrams
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. Greenlee Textron / Subsidiary of Textron Inc. UPC No. Key 78-3310- 86705 86706... - Page 40 855 Smart Bender™ 1/2" to 1-1/4" Side Exploded View Greenlee Textron / Subsidiary of Textron Inc. See page 43 for parts list. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 43 Shoe Unit 1/2" to 1-1/4" consists of 221, 222, 223, 224 and 225...
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Page 41: Greenlee Textron
855 Smart Bender™ 1-1/2" to 2" Side Exploded View Greenlee Textron / Subsidiary of Textron Inc. See page 43 for parts list. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 The Roller Support Unit exploded view is on the following page. -
Page 42: Greenlee Textron
855 Smart Bender™ 1-1/2" to 2" Roller Support Unit (500 0574.0) Exploded View 100* *Two required Greenlee Textron / Subsidiary of Textron Inc. 93 151 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 99, 119 or 150 Note: Torque to 54 to 61 Nm... - Page 43 905 0540.9 Screw, 7/16-14 x 1.00 Hex Hd ... 3 00860 500 0860.9 Shaft, 1-1/2" Support ... 1 54819 905 4819.1 Retaining Ring #5100-87 ... 2 Greenlee Textron / Subsidiary of Textron Inc. UPC No. Qty. Key 78-3310- Part No.
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Page 44: Greenlee Textron
855 Smart Bender™ Main Exploded View Power Cord 209, 211, 212 Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 14, 28 Optional Kit... -
Page 45: Greenlee Textron
855 Smart Bender™ 4, 4A Greenlee Textron / Subsidiary of Textron Inc. 93 151 99, 119 or 150 Note: Torque to 54 to 61 Nm (40 to 45 ft-lb) = Cam Repair Kit #500 7939.5 If the chain breaks, replace it with a new chain —... -
Page 46: Greenlee Textron
503 8148.2 Shoe Unit, 1-1/2" to 2" ... 1 52203 905 2203.6 Screw, Mach #6-32 x .25 ... 2 29708 502 9708.2 Guard, Breaker Switch ... 1 Greenlee Textron / Subsidiary of Textron Inc. UPC No. Qty. Key 78-3310- Part No. -
Page 47: Greenlee Textron
503 8168.7 Knob ... 1 38464 503 8464.3 Pad Weldment, Jack Bolt ... 4 54276 905 4276.2 Caster, Swivel ... 2 38156 503 8156.3 Block, Reinforcement ... 2 Greenlee Textron / Subsidiary of Textron Inc. UPC No. Qty. Key 78-3310- Part No. Description 31710 503 1710.5 1/2"... -
Page 48: Greenlee Textron
855 Smart Bender™ Optional Bending Attachments for 1/2" to 2" 40 Mil PVC-Coated Rigid (500 1700.4) Exploded View and Parts List Greenlee Textron / Subsidiary of Textron Inc. UPC No. Key 78-3310- 00572 31919 00934 00567 00570 51088 52479 31918... -
Page 49: Greenlee Textron
503 8175.0 Black Relay Wire 503 8961.0 Red Relay–PGU Wire 503 8960.2 Black Relay–PGU Wire 503 8648.4 I/O–PGU Wire Unit 500 1741.1 I/O to Power Wire Unit Greenlee Textron / Subsidiary of Textron Inc. GREEN GREEN BLACK BLACK Part No. -
Page 50: Greenlee Textron
503 8270.5 Off Board – – – J3, J7 – – J5, J6 918 6693.6 Greenlee Textron / Subsidiary of Textron Inc. Description Value Resistor 4.7 K / 1/4 w / 5% Resistor 10 K / 1/4 w / 5% Resistor... -
Page 51: Greenlee Textron
855 Smart Bender™ Power Generation Unit Schematic Diagram 330u/25V 1N4744 1N4744 1000u/250V 10uF/250VAC Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070... -
Page 52: Greenlee Textron
855 Smart Bender™ Power Generation Board Layout Diagram ANODE GREENLEE/ TEXTRON INC. BLK (-) RED (+) Greenlee Textron / Subsidiary of Textron Inc. TO I/O TO RELAY 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 LINE NEUTRAL 120VAC 0VAC... -
Page 53: Greenlee Textron
R16, 40, 41, 44-47 R32, 43 R28, 37 R17, 24 MDP1603-102G R21, 33 4610X-101-103 V150LA20A Greenlee Textron / Subsidiary of Textron Inc. Description EEPROM EPROM, Programmed - 855M2 Quad Driver Microcontroller Watchdog IC SPST Toggle Switch SPST/No Push MOM Switch Capacitor 22pF Capacitor, Decouple .1uF... -
Page 54: Greenlee Textron
855 Smart Bender™ Input/Output Board Schematic Diagram 74HC86 U1:A .1uf 10Mhz .1uf Greenlee Textron / Subsidiary of Textron Inc. 1N4001 MFJ2M 10u/25v STROBE WATCHDOG P0.7 SW.HOME.2 P0.6 SW.HOME.1 P0.5 SW.SIZE.5 P0.4 SW.SIZE.4 P0.3 SW.SIZE.3 P0.2 SW.SIZE.2 P0.1 SW.SIZE.1 P0.0 SW.SIZE.0 HSO.5... -
Page 55: Greenlee Textron
.25A/ 250V LINE SIGNAL TO PGU ENCODER HOME BRAKE TEST Pendant Board Layout Diagram Greenlee Textron / Subsidiary of Textron Inc. TEST1 BRAKE TEST2 QUAD 1 QUAD 2 HOME 1 HOME 2 LOCKOUT GREENLEE/TEXTRON INC. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 GREENLEE/ TEXTRON INC. -
Page 56: Greenlee Textron
+12V IDC1X4M Reference Part Number PCF8574P SAA1064 705-53-0003 C1, 3, 4, 5, 6 R1, 3 MAN-6910 7806 78L05 Greenlee Textron / Subsidiary of Textron Inc. PCF8574 ADDR CEXT .0027 MPX1 MPX2 SAA1064 7806 LM78L05 Description I.C. 16 Pin Dip I.C. 24 Pin Dip 4 Pin Right Angle Header 10 Pin .100"... -
Page 57: Troubleshooting
Too little squeeze on 1-1/2" or 2" EMT or IMC conduit. Unusual conduit characteristics. Greenlee Textron / Subsidiary of Textron Inc. PROBABLE CAUSE Check supply voltage circuit operation. Check that switch is ON. Pendant not fully plugged in. -
Page 58: Greenlee Textron
Shoe rotated too far in unload direction. Bend key does not work for Roller support locking cam is engaged. 1/2 - 1-1/4" conduit. Greenlee Textron / Subsidiary of Textron Inc. PROBABLE CAUSE Release the roller support or adjust retension cam. Release and repress UNLOAD. -
Page 59: Greenlee Textron
Replace PGU. Greenlee Textron / Subsidiary of Textron Inc. WILL BEND – WON’T COUNT Is bending shoe on in the proper orientation? When jog is pressed, does the... -
Page 60: Greenlee Textron
Replace PGU. Greenlee Textron / Subsidiary of Textron Inc. BENDER RUNS BACKWARDS FOR BEND & UNLOAD Jump #2 & #4 termi- Is proper size of conduit selected? nals in pendant. -
Page 61: Greenlee Textron
Greenlee Textron / Subsidiary of Textron Inc. TRIPS CIRCUIT BREAKER Are the proper support rollers and shoe groove being used for... -
Page 62: Greenlee Textron
I/O board. Replace optical encoder? Replace I/O board. Greenlee Textron / Subsidiary of Textron Inc. Customer Service (International): 815/397-7070 • Fax: 815/397-9247 Customer Service (North America): 800/435-0786 • Fax: 800/451-2632, 815/397-1865 Greenlee Textron / Subsidiary of Textron Inc.