Greenlee 854 Reference manual

SERVICE BULLETIN
999 3841.3 © 2000 Greenlee Textron SB 284 11/00
500 6018.0 I/O Control
Retrofit to 854 Bender with
500 3050.7 I/O Control
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
500 6018.0 I/O Control Retrofit
Wiring
Refer to the Wiring Diagram.
1. Completely remove and discard I/O to PGU Wire
Unit (124) and I/O to Power Wire Unit (125).
2. Unplug Brake and Pendant.
3. Disconnect red jumper wire, white motor-drive wire,
and white resistor wire.
4. Remove four 5/16" hex drive screws (23) that retain
assembly in bender, and remove old assembly.
5. Insert new assembly in bender and secure with four
5/16" hex drive screws (23).
6. Connect the green wire provided (strapped to base
plate of I/O) between the center ground screw
(shared with ground wire of the drive unit) and the
ground terminal on the PGU assembly.
7. Find the power wires on the new control assembly.
They are connected to the small brown power
supply circuit board.
• Connect the ring terminal of the black wire to the
line connection of the PGU.
• Connect the ring terminal of the white wire to the
neutral connection of the PGU.
Note: The rest of the connections are similar to the
500 3050.7 board.
8. Plug in the Direction Selector Switch Unit (127) to
JP4 “Selector”on circuit board.
9. Plug in the Brake (51) to JP2 “Brake”on circuit
board.
10. Plug in the (supplied) six-wire harness from the I/O
from JP5 “TO PGU”to the PGU board “TO I/O”
connector.
11. Connect the white motor-drive wire to relay
Common (terminal #4) shared by short black jumper
across relay common.
12. Connect the red jumper wire to relay Normally Open
(terminal #6) shared by short red jumper across
relay NO.
13. Connect the white resistor wire to the relay Normally
Closed on the PGU (terminal #7) with black motor-
drive wire.
Connection Check
Leave the crescent-shaped shroud off the top of the 854
to perform some checks. Be careful not to contact the
circuit boards or moving parts when the cover is
off. Do not bend conduit with shroud off. Only
observe the shoe movement and LEDs as described
below.
1. Plug in and turn on the 854.
The green LED on the PGU should come on, and
the green LED on the Control Board should come
on.
2. Switch the selector to 1-1/2" –2".
3. Press BEND. Observe the direction of rotation.
If the bender goes in the wrong direction, turn off
and unplug the bender. Swap the black and white
wires of the drive unit and repeat Connection
Check.
4. Press and hold BEND. 854 shoes should turn
180 degrees in 10 to 15 seconds.
5. Press UNLOAD. Observe the direction of rotation.
6. Switch the selector to 1/2" –1-1/4". Press BEND.
Release. Press UNLOAD. Observe the direction of
rotation.
7. Turn off and unplug the 854 bender.
8. Check that the circuit board assembly is firmly
mounted with four 5/16" hex drive screws (23).
9. Replace the crescent-shaped shroud and firmly
mount with four 5/16" hex drive screws (23).
10. The bender is now ready for normal usage.
Troubleshooting
If you encounter any difficulty connecting or using this
circuit board assembly, please contact Greenlee
Textron.
Read and understand all of the
instructions and safety information
in IM 1301 before operating
or servicing this tool.
Electric shock hazard:
Always turn off and unplug bender
before performing any repair.
Failure to observe this warning can
result in severe injury or death.
The I/O control is a static-sensitive device. Handle
only at a static-safe work station.
Important Safety Information

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
500 6018.0 I/O Control Retrofit
Wiring Diagram
23
47 126
122
123
121
120A
120B
120 120C
120D
BLACK
GREEN
JP1
CN1
CN2
YELLOW
YELLOW
YELLOW
AC
AC
-HV
+HV
WHITE
WHITE
RED
BLACK
YELLOW
FROM RECTIFIER
RED BLACK
BLACK
TO RELAY
TO I/O
RED
BLACK
WHITE
BLACK BLACK WHITE
GREEN
TO DRIVE UNIT
BLACK
WHITE
GREEN
TO BRAKE (ITEM #51) TO SELECTOR SWITCH UNIT (ITEM #127)
RED
Parts List
120 500 6018.0 854 I/O Control Assembly............................... 1
120A 500 6037.6 Wire Unit, Power —DC .................................. 1
120B 500 6036.8 Wire Unit, Power —AC .................................. 1
120C 503 8648.4 Wire Unit, I/O —PGU ..................................... 1
120D 500 6040.6 Wire Unit, Ground ........................................... 1
121 500 5467.8 PGU2 Assembly.............................................. 1
122 503 8941.6 Wire Unit, PGU to Breaker.............................. 1
123 918 6839.4 Wire Unit, I/O to PGU ..................................... 1
126 503 8603.4 Cord Unit, Power............................................. 1
127 500 3052.3 Switch, PCB Direction..................................... 1
128 905 4279.7 Tie, Cable (not shown).................................... 3
Key Part No. Description Qty.

Printed in the U.S.A.
Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
Customer Service (International): 815/397-7070 •Fax: [phone]
Customer Service (North America): 800/435-0786 •Fax: [phone]
Canada Fax: [phone]