Greenlee 855GX Intellibender Electric Bender Manual Manuel utilisateur

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INSTRUCTION MANUAL
855GX IntelliBENDER
®
Electric Bender
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
52055798 REV 5 © 2019 Greenlee Tools, Inc. 8/19
Patents Pending
Español ............... 33
Français .............. 61
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
All specications are nominal and may change as design
improvements occur. Greenlee Tools, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
IntelliBENDER and BendWorks are registered trademarks of
Greenlee Tools, Inc.
KEEP THIS MANUAL
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information .....................................3–5
Grounding Instructions .................................................. 6
Specications ................................................................ 6
Identication .................................................................. 7
Features ......................................................................... 8
Transporting Bender and
Pivoting Bending Head .................................................. 9
Setup ........................................................................... 10
Operation ................................................................ 10–19
Manually Selecting Conduit Type and Size.............. 12
Basic Programmed Bending .................................... 12
Fully Programmed Bending ................................13–15
Load File from USB ................................................. 16
BendWorks™ Software Troubleshooting ............17–18
Squeeze Adjustment ................................................ 19
Optional PVC-Coated Conduit Bending .................. 19
Illustrated Bending Glossary ....................................... 20
Bending Instructions ..............................................21–22
Additional Bending Instructions .............................23–25
Additional Bending Tables ......................................26–29
Maintenance ...........................................................30–32
Description
The Greenlee 855GX IntelliBENDER
®
Electric Bender is
intended to bend 1" to 2" conduit and pipe. This bender
has the capability to accommodate the following types
of conduit and pipe:
Electrical Metallic Tubing
Intermediate Metallic Conduit
Rigid Conduit
Aluminum Rigid
PVC-Coated Rigid Conduit
Schedule 40 Pipe
Stainless Steel Rigid
The 855GX includes a shoe to bend EMT, IMC, and
rigid conduit. In addition, shoes and roller supports are
available for bending PVC-coated conduit.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information
for avoiding 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 all personnel with
the safe operation and maintenance procedures for the
Greenlee 855GX Electric Bender.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
Do not discard this product or throw away!
For recycling information, go to www.greenlee.com.
855GX Electric Bender
Greenlee Tools, Inc. 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, dened 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 will
result in severe injury or death.
Do not use this tool in a hazardous
environment. Hazards include am-
mable liquids, gases, or other materi-
als. Using this tool in a hazardous
environment can result in a re or
explosion.
Failure to observe this warning will
result in severe injury or death.
Electric shock hazard:
Inspect the power cord before
use. Repair or replace the cord if
damaged.
Connect the power cord to a
120 volt, 20 amp receptacle on a
ground fault protected circuit only.
Refer to “Grounding Instructions.”
Do not modify the power cord or
plug.
Disconnect the unit from power
before servicing.
Failure to observe this warning could
result in severe injury or death.
For continued protection against risk of re and
electric shock, replace ONLY with same manufacturer,
type, and rating of fuse. Refer to the “Maintenance”
section of this manual.
Failure to observe this warning could result in severe
injury or death.
Do not use in dangerous environ-
ment. Do not use power tools in
damp or wet locations, or expose
them to rain. Keep work area well
lighted.
Do not immerse the pendant switch
in water or any other liquid.
Failure to observe these warnings
could result in severe injury or death.
Always use safety glasses. Everyday
glasses only have impact resistant
lenses; they are NOT safety glasses.
When using in dusty environment, use
face or dust mask.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
Keep guards in place and in
working order.
Remove any tools from bender
before operating. Form habit of
checking to see that all tools are
removed from bender before
turning it on.
Failure to observe these warnings
could result in severe injury or death.
Extension cords:
Use only three-wire, 12 AWG exten-
sion 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.
Support conduit when unloading.
Conduit can become loose and fall
if not properly supported.
Failure to observe these warnings
could result in severe injury or death.
Reduce the risk of unintentional starting. Make sure
switch is in off position before plugging in.
Never leave tool running unattended. Turn power
off. Do not leave tool until it comes to a complete
stop.
Disconnect tools before servicing and when chang-
ing accessories such as shoes, rollers, and the like.
Accidental start-up could result in serious injury.
Failure to observe these warnings could result in
severe injury or death.
Never stand on tool. Serious injury could occur if
the tool is tipped.
Do not overreach. Keep proper footing and balance
at all times.
Failure to observe these warnings could result in
severe injury or death.
Adjust fork spacing to match fork tubes on bender.
Ensure brake is engaged before inserting forks into
fork tubes.
Failure to observe this warning could result in severe
injury or death.
Select 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 96 degrees. Overbending
could result in the other shoe hook colliding with
the conduit.
Failure to observe these precautions may result in
injury or property damage.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
IMPORTANT SAFETY INFORMATION
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.
Wear proper apparel. Do not wear loose clothing,
gloves, neckties, rings, bracelets, or other jewelry
which may get caught in moving parts. Nonslip
footwear is recommended. Wear protective hair
covering to contain long hair.
Do not force rollers or alter tool. It will do the
job better and safer at the rate for which it was
designed.
Use right tool. Do not force tool or attachment to do
a job for which it was not designed.
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.
Keep work area clean. Cluttered areas and benches
invite accidents.
Keep children away. All visitors should be kept safe
distance from work area.
Make workshop kid proof with padlocks, master
switches, or by removing starter keys.
Failure to observe these precautions may result in
injury or property damage.
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.
Maintain tools with care. Keep tool clean for best
and safest performance. Follow instructions for
lubricating and changing accessories.
Check damaged parts. Before further use of the
tool, a guard or other part that is damaged should
be carefully checked to determine that it will
operate properly and perform its intended func-
tion. Check for alignment of moving parts, binding
of moving parts, breakage of parts, mounting, and
any other conditions that may affect its operation.
A guard or other part that is damaged should be
properly repaired or replaced.
Use recommended accessories. Consult the
instruction manual for recommended accessories.
The use of improper accessories may cause risk of
injury to persons.
Some bender parts and accessories are heavy
and may require more than one person to lift and
assemble.
Failure to observe these precautions may result in
injury or property damage.
Note: Keep all decals clean and legible, and replace
when necessary.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Grounding Instructions
Electric shock hazard:
Do not modify the plug provided
with the tool.
Connect this tool to a grounded
receptacle on a 20 amp ground
fault protected 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.
20 Amp/120 Volt
Plug and Receptacle
ReceptaclePlug
Plug Receptacle
Do not modify the plug provided. If it will not t the
outlet, have the proper outlet installed by a qualied
electrician. Improper connection of the equipment-
grounding conductor can result in a risk of electric
shock. The conductor with insulation having an outer
surface that is green with or without yellow stripes
is the equipment-grounding conductor. If repair or
replacement of the electric cord or plug is necessary,
do not connect the equipment-grounding conductor
to a live terminal. Check with a qualied electrician or
service personnel if the grounding instructions are not
completely understood, or if in doubt as to whether the
tool is properly grounded.
Specifications
Height (vertical bending position) ........................................................117.1 cm (46.1")
Width .....................................................................................................74.7 cm (29.4")
Depth (vertical bending position) ..............................................................84 cm (33.0")
Mass/Weight (bender with shoes and roller supports) ...........................230 kg (507 lb)
Power Supply .................................................................................... 120 VAC, 20 amp
GFCI-protected receptacle
Operating Conditions
Temperature .......................................................... –20 °C to 49 °C (–5 °F to 120 °F)
Relative Humidity ....................................................................................0% to 98%
Capacity ..................................................................1" to 2" conduit, schedule 40 pipe
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Identification
Features
1. 1" to 2" shoe for EMT/IMC/rigid conduit
2. Main power (On-Off) switch/circuit breaker
3. Programmable bending selector buttons
4. LCD backlit display
5. 2" roller support
6. Conduit size determination trip lever
7. Bending head pivoting detent lock
8. Storage area
9. Fork tube
10. Transport handle
11. Swivel casters
12. Roller support retainer
13. 1" roller support
14. Roller engagement handle
15. 1-1/4" roller support
16. 1-1/2" roller support
17. Shoe retainer
18. Lower pivot handle
19. Hoist lifting bar
20. Motor
21. Roller support
22. Squeeze adjuster
23. Rear wheels
24. Storage lid
25. Storage lock tab
26. Bending head pivot
27. Power cord with tie strap
28. Pendent receptacle
29. Brake
30. USB port
31. Upper pivot handle
32. LCD shield
33. Motor debris guard
34. Gearbox
35. Absolute encoder
36. Squeeze roller release lever
37. Fuse holder
Decals
A. Bending
B. Circuit breaker
C. Engage rollers
D. 1" EMT/IMC roller
E. Brake
F. Fork tube
G. Pivot
H. Squeeze
I. Identication
J. Instruction
K. Lifting
L. Warning
M. Support release
N. Fuse warning
O. Raise rollers
1
17
16
35
15
14
12
D
13
C
O
30
A
7
G
B
8
3
32
N
4
2
5
6
9
29
11
18
F
E
10
26
22
23
H
27
21
36
34
M
33
20
24
25
28
L
J
I
K
19
31
37
Squeeze rollers
illustrated in
raised/engaged
position.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Features
Single shoe bending of 1" to 2" EMT, IMC, and rigid
conduit.
1/2" to 2" PVC-coated conduit bending capability with
optional shoe group.
Four large wheels for easy transportability.
Waist level working height.
Patented roller system automatically adjusts between
IMC and EMT conduit.
Patent pending conduit size and type sensing system
allows for quick loading and bending to desired angle.
No homing or initial setup required—just load conduit
and bend.
Bender automatically compensates for springback—
simply bend to the desired angle.
Squeeze adjustment allows for variations in conduit.
Bright, adjustable contrast LCD display for easy
programmable bending input and dimensional illustra-
tions for making marks on conduit.
Programmable memory will stop bender at any pro-
grammed angle.
Common angles preset with one-touch selection.
Digital display shows bend angle on pendant.
Computer will provide alignment mark dimensions for
stubs, kicks, offsets, three- and four-bend saddles,
and U-bends for any height, length, and angle.
Programmed for transfer to other 855GX benders.
Programmed bends can also be uploaded to bender
from bends programmed on a computer. Bends can
be saved on thumb drive through USB port.
Programmed for transfer to other 855GX benders.
Programmed bends can also be uploaded to bender
from bends programmed on a computer.
Bends can be saved on thumb drive through
USB port.
Removable patent pending pendant prevents
unauthorized use of bender. Pendant includes cord
strain relief and strong rare earth magnets for holding
on steel surfaces.
Lockable storage area for pendant, instruction
manual, etc.
Lifting bar provided for easy hoisting.
Fork tubes provided for easy forklift mobility.
Adjustable height handle for easy and comfortable
mobility.
Rear wheel brake to securely keep bender in place
during use.
Quick release retainers for bending shoe and rollers.
Quick release lock pin to easily pivot bender between
vertical and horizontal positions.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Refer to the “Identication” section of this manual.
To transport the bender on the ground:
1. Pivot the bending head to the horizontal bending
position.
2. Push down on the lower pivot handle (18) to remove
the preload from the detent pin while pulling the
detent pin (7) out.
3. Rotate the bending head as shown below until it
locks in the horizontal position.
4. Remove the handle locking pins and raise the
handle to the desired height.
5. Reverse steps 1 through 4 to return the bending
head to its vertical position.
To transport the bender with a forklift:
Insert the forks into the fork tubes (9) and lift.
Adjust fork spacing to match fork tubes on bender.
Ensure brake is engaged before inserting forks into
fork tubes.
Failure to observe this warning could result in severe
injury or death.
To transport the bender with a crane:
1. Pivot the bending head to the vertical bending
position.
2. Conrm that the shoe and roller support retainers
(12, 17) are in place and locked.
3. Use a sling around the lifting bar (19) to support the
full weight. DO NOT USE HANDLES. Lift only with
the head in the vertical position.
To transport the bender on a trailer
1. Pivot the bender to the horizontal bending position.
2. Position the bender on the trailer so the bender
wheels are parallel to the trailer axle. By doing so,
the bender will resist movement if the trailer has
sudden starts and stops.
3. Place blocks against the bender wheels to resist
movement.
4. Attach straps around the bender shoe and hooks to
secure the bender to the trailer. Tighten the straps
to secure the bender from moving.
NOTE: the bender wheel brake will not adequately
secure the bender for transportation.
Transporting Bender and Pivoting Bending Head
Vertical bending position Horizontal bending position
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Setup
Always use safety glasses. Everyday
glasses only have impact resistant
lenses; they are NOT safety glasses.
When using in dusty environment, use
face or dust mask.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Refer to the “Identication” section of this manual.
1. Position the bender so that there is room to load
conduit and engage the rear wheel brake bar.
2. Place the bender in the desired vertical or horizontal
bending position.
3. Plug the bender into a grounded 20 amp outlet.
4. Plug the pendant switch into the pendant receptacle
(28).
Operation
Do not use this tool in a hazardous
environment. Hazards include am-
mable liquids, gases, or other materi-
als. Using this tool in a hazardous
environment can result in a re or
explosion.
Failure to observe this warning will
result in severe injury or death.
Electric shock hazard:
Inspect the power cord before
use. Repair or replace the cord if
damaged.
Connect the power cord to a
120 volt, 20 amp receptacle on a
ground fault protected circuit only.
Refer to “Grounding Instructions.”
Do not modify the power cord or
plug.
Disconnect the unit from power
before servicing.
Failure to observe this warning could
result in severe injury or death.
Pinch points:
Keep hands away from bending
shoe, rollers, and conduit when
bender is in use.
Support conduit when unloading.
Conduit can become loose and fall
if not properly supported.
Failure to observe these warnings
could result in severe injury or death.
Disconnect tools before servicing and when chang-
ing accessories such as shoes, rollers, and the like.
Accidental start-up could result in serious injury.
Failure to observe this warning could result in severe
injury or death.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Wear proper apparel. Do not wear loose clothing,
gloves, neckties, rings, bracelets, or other jewelry
which may get caught in moving parts. Nonslip foot-
wear is recommended. Wear protective hair covering
to contain long hair.
Failure to observe this precaution may result in injury
or property damage.
Refer to the “Identication” section of this manual.
1. Turn on the main power switch (2).
2. Use the BEND or UNLOAD button to
orient the shoe so that the hooks of the
conduit type to be bent are around the
7o’clock (approximately –5°) position.
(Silver hooks are for EMT; green hooks are
for IMC and rigid.)
The bender automatically stops at the load
position (approximately –5°). To continue
past the load position, release the BEND
or UNLOAD button, and then repress the
BEND or UNLOAD button as needed.
The bender actively prevents operation at
certain angles while the roller supports are up. This
is done to prevent the shoe hooks from damaging
the roller supports. When the roller supports are
up and the hooks are close to or within the roller
supports, the pendant will blink “UP” twice. When
the pendant blinks “UP”, the bender can often be
moved in the opposite direction by pressing BEND
or UNLOAD. If the bender will not move in any
direction and continues to blink “UP”, then the roller
supports must be fully retracted before the bender
will move.
Note: Bender will actively prevent user from
changing machine settings outside of -10 and
-2 degrees.
3. Load the conduit so that the bending mark is
aligned with the front edge of the hook.
4. Bend the conduit.
a. For 1-1/4", 1-1/2", and 2" EMT or IMC conduit,
use the roller engagement handle (14) to raise
the rollers from the retracted position to the
upright (engaged) position, as shown below.
Squeeze Rollers Retracted Squeeze Rollers Engaged
Press BEND while applying pressure to the roller
engagement handle until the rollers hit their stop.
Note: Lifting the tail of a long stick of conduit will
aid in engaging the rollers. The cam should hold the
rollers in the upright position, as shown below.
Chain
Guard
Cam
Note: To retract the rollers without bending once
the cam locks them in place, pump the lever below
the 2" split roller several times. If this does not
release the cam, lift the tail of the conduit while
pumping the release lever. Otherwise, advance the
shoe forward just enough for the cam to release,
and then unload.
Squeeze Roller
Release Lever
b. For all other conduit, press BEND while making
sure the bend mark stays at the front of the
hook until the conduit contacts the tail roller. If
bending 1" IMC, rotate the support roller so that
the IMC roller is up.
5. Continue to press BEND until reaching the desired
bend angle shown in the pendant display. The dis-
played angle in the pendant and on the LCD display
will be the angle of the bend after the conduit
springs back (subject to variations in conduit). Use
BEND or JOG to sneak up on an angle. JOG will
advance the shoe about 1/2°.
6. Press UNLOAD to free the conduit.
7. Twist the conduit to release it from the hook and
remove it from the shoe.
U
N
L
O
A
D
B
E
N
D
JOG
CLEAR
ANGLE
SELECT
ANGLE
SELECT
Operation (cont’d)
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
12
Manually Selecting Conduit Type and Size
The 855GX can automatically detect EMT, IMC, and
rigid conduit as well as determine 1", 1-1/4", 1-1/2",
and 2" conduit sizes. When bending with these types of
conduit, using auto mode is recommended. However, in
some cases you may want to manually set the bender
for the type of conduit being used (for example, PVC-
coated rigid conduit).
To manually set the bender, follow these steps:
1. From the home screen, press the button next to
“SET UP”.
2. From the setup screen, press the button next to
“MAN SET”.
3. Select the conduit type to be used. (Selecting
“AUTO” returns the bender to auto mode, where the
type is automatically detemined.)
4. Press NEXT to advance to the screen to select the
conduit size.
5. Select the conduit size to be used. (Selecting
“AUTO” returns the bender to auto mode, where the
size is automatically detemined.)
6. Press NEXT to go back to the setup screen, or
to go back to the home screen.
Basic Programmed Bending
You can preset an angle into the computer memory and
the bender will automatically stop at that angle.
Note: Angle will be with springback factored in.
1. Select the angle.
a. Use ANGLE SELECTp or ANGLE SELECTq
on the pendant to change the programmed
angle. A single press changes the angle by 1°.
Holding down an ANGLE SELECT key changes
the angle rapidly in 5° increments. Pressing
CLEAR resets the programmed angle back
to 0°. This angle will stay in the memory until
CLEAR is pressed, a new angle is selected, or
the power is turned off.
b. Use one of the common angles displayed in
the LCD display (4). To select an angle by this
method, press the selector button (3) next to the
desired angle shown in the display. This angle
will stay in the memory until CLEAR is pressed,
a new angle is selected, or the power is turned
off.
The programmed angle will remain in the pendant
display for about two seconds and then revert to
the current shoe position. The programmed angle
can also be viewed on the LCD home screen in the
“STOP ANGLE” box.
2. Press BEND until the bender stops. The bender
may slow down before reaching the selected
angle. This is normal. When the bender stops at
the programmed bend, the pendant display blinks
twice with the programmed angle. To continue
a bend, reset the programmed angle with the
CLEAR button, or increase the programmed angle
to be greater than the actual shoe angle with the
ANGLESELECTp button.
Operation (cont’d)
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
Operation (cont’d)
Fully Programmed Bending
The computer can also be used to help lay out bends.
1. Press the button next to “PROG BEND to start
programming a bend.
SELECT ANGLE
OR FUNCTION
Note: Press the home button
at any time to
return to the home screen shown above.
2. Press the button next to the type of conduit dis-
played in the LCD display that you will be using; or
press the button next to “LOAD FILE” to retrieve a
saved bend from a USB thumb drive. (See page 16)
Press NEXT to proceed or BACK to return to the
previous screen.
Refer to the “Load File from USB” section after
“Fully Programmed Bending” for instructions on
loading saved bends.
3. Press the button next to the size of conduit dis-
played in the LCD display that you will be using.
Press NEXT to proceed or BACK to return to the
previous screen.
Note: “1/2” and “3/4” are displayed only when
“PVCRIG” conduit type is selected in step 2.
4. Press the button next to the type of bend that you
are going to make.
a. Select “STUB/KICK” for stubs or kicks.
b. Selecting “OFFSET” and NEXT will display
a new window from which you can choose
whether you want the length to be from the end
of the conduit to the start of the rst bend or to
the end of the second bend.
c. Selecting “SADDLE” and NEXT will display
a new window from which you can choose a
three-bend or four-bend saddle.
d. Select “U-BEND” for back-to-back 90° U-bends.
5. Press NEXT to proceed or BACK to return to the
previous screen.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
14
6. Input the dimensions of the bend.
Stubs and kicks:
Press the button next to “HT” (height) if it is not
already highlighted with an asterisk. Use the buttons
next to +# and –$ to increase or decrease the height
until it is to the desired value. A single press of
the button will change the value by 1/8". Holding
the button down will rapidly change the values.
Press the button next to “A” (angle). Select the
desired angle as above. The angle changes in 1/2°
increments.
Offsets:
Press the button next to “HT” (height) if it is not
already highlighted with an asterisk. Use the buttons
next to +# and –$ to increase or decrease the height
until it is to the desired value. A single press of the
button will change the value by 1/8". Holding the
button down will rapidly change the values. Press
the button next to “L” (length). Select the desired
length as above. The length changes in 1/8" incre-
ments. Press the button next to “A” (angle). Select
the desired angle as above. The angle changes in
1/2° increments.
Saddles:
Press the button next to “HT” (height) if it is not
already highlighted with an asterisk. Use the buttons
next to +# and –$ to increase or decrease the height
until it is to the desired value. A single press of the
button will change the value by 1/8". Holding the
button down will rapidly change the values. Press
the button next to “L” (length). Select the desired
length as above. The length changes in 1/8" incre-
ments. Press the button next to “A” (angle). Select
the desired angle as above. The angle changes in
1/2° increments.
U-bends:
Press the button next to “HT” (height) if it is not
already highlighted with an asterisk. Use the buttons
next to +# and –$ to increase or decrease the height
until it is to the desired value. A single press of
the button will change the value by 1/8". Holding
the button down will rapidly change the values.
Press the button next to “L” (length). Select the
desired length as above. The length changes in 1/8"
increments.
3D bends:
A 3D bend is the same as an offset bend, except
there is an additional change of direction right and/
or left. Input the desired height by pressing the
button next to “HT” if it is not already highlighted
with an asterisk. Use the buttons next to +# and –$
to increase or decrease the height value. A single
press of the button will change the height by 1/8".
Holding the button down will rapidly change the
values. Select the rise angle by pressing the button
next to “A”. Select the angle value as above. The
angle changes in 1/2° increments.
HT
A
Select the horizontal bend angles by pressing the
button next to “H1” and adjusting the value as
above; repeat for the “H2” button. The horizontal
angles are as viewed from directly above. Refer
to the “Top Views of Bends” illustration below for
examples. Positive angles represent bends to the
right. Negative angles represent bends to the left.
Select the length by pressing the button next to “L”.
Select the value for “L” as above. All values for “L”
are to the centerline of the conduit. The length is
dened as where the sight lines of the rst and third
legs intersect each other to the end of the conduit,
as viewed from directly above. Refer to the following
illustrations for examples.
L
L
L
L
L
L
H1 = 45°
H2 = 90°
H1 = 90°
H2 = 90°
H1 = 60°
H2 = 30°
H1 = 45°
H2 = 0°
L = ∞
H1 = 30°
H2 = –60°
H1 = –45°
H2 = –60°
Top Views of Bends
Operation (cont’d)
Fully Programmed Bending (cont’d)
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15
Operation (cont’d)
Fully Programmed Bending (cont’d)
Steps 7–10 are the same for a 3D bend as for an
offset bend with the following exception: After
making the rst bend, you will be instructed to
rotate the conduit by some angle counterclockwise
or clockwise. Clockwise means pushing the bent leg
to the back of the bender while counterclockwise
means pushing the bent leg toward the front of the
bender.
Rotation
Angle
CCW CW
Note: Placing a protractor on the tail end of the
conduit before making the first bend will aid in
knowing how far to rotate the conduit.
7. Press NEXT to proceed or BACK to return to the
previous screen.
8. Place a tape measure and place marks at the dis-
played distances.
9. Press “SAVE” to save the programmed bend to the
bender’s local memory; or press “SAVE USB” to
save the programmed bend to a USB thumb drive;
or press NEXT to proceed making the programmed
bend; or press BACK to return to the previous
screen.
10. Load conduit and line up the front of the hook with
the rst mark. Press BEND until the bender stops.
The display will show both the stop angle and the
actual bend angle. Unload the conduit and reload
aligning up to the second mark. Press BEND until
the bender stops. Repeat as necessary until the
display shows “BENDING COMPLETE”.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
16
Operation (cont’d)
Load File from USB
1. Press the button next to the bend you want to
begin. The number of pages appears on the top
right. To scroll through the list of saved bends, press
the NEXT and BACK buttons.
Pressing BACK on page 1 returns you to the
previous screen.
Notes:
Straight conduits will be labeled as “CONCEN0°”.
Completed bends will be labeled as “DONE”.
2. A summary appears of all bends with up to ve
bends per page. On the bottom is the total length
of the conduit. Press the NEXT button to continue
to individual bend instructions, or press the BACK
button to return to the le select screen.
Note: A bend with the label “CONCEN 0°” indicates
there are no bends to be made. Select BACK to
return to the file select screen.
BendWorks™ Software Troubleshooting
When BendWorks™ software encounters any of the
errors in the table on the next page, it outputs an error
code to a CSV le. Each error has an Error # and Error
Code.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
Operation (cont’d)
BendWorks™ Software Troubleshooting
Process Errors
Error Code Explanation of Error
1 Bend Length Plus Head Tail
Exceeds Default Nominal
Length
ErrorCode.
BendLengthPlusHeadTailExceedsDefaultNominalLength, 1
Length of Bend + D + X + Tail
cannot be greater than default
nominal length.
2 Bend Radius Too Big ErrorCode.BendRadiusTooBig, 2 Bend radius cannot be too big.
3 Bend Spans Multiple Segments ErrorCode.BendSpansMultipleSegments, 4 A bend cannot span multiple
segments of conduit.
4 Concentric And Normal Bend ErrorCode.ConcentricAndNormalBend, 8 Cannot have concentric/segment
bend and normal bend in the same
conduit.
5 Concentric Bend Radius Too
Small
ErrorCode.ConcentricBendRadiusTooSmall, 16 The concentric bend radius cannot
be too small.
45 Conduit Length Too Small
Between Bends
ErrorCode.ConduitLengthTooSmallBetweenBends,
17592186044416
The conduit length between two
bends cannot be less than coupling
length.
6 Segment Has More Than 5
Bends
ErrorCode.SegmentHasMoreThan5Bends, 32 A segment of conduits cannot
have more than 5 bends with the
exception of concentric arcs.
7 Short Segment Length ErrorCode.ShortSegmentLength, 64 Conduit shorter than preferred
minimum length.
8 Total Segment Length Exceeds
Default Nominal Length
ErrorCode.TotalSegmentLengthExceedsDefaultNominalLength,
128
The conduit run length exceeds the
default nominal length.
Warning Errors Explanation of Error
23 Mark Prefix Used ErrorCode.MarkPrexUsed, 4194304 The mark prex has been used.
24 Total Angle Of Bends Exceed
360
ErrorCode.TotalAngleOfBendsExceed360, 8388608 Total bend angles exceed 360
degrees.
25 Total Angle Of Bends Exceeds
Max Total Angle
ErrorCode.TotalAngleOfBendsExceedsMaxTotalAngle, 16777216 Total bend angles exceed
maximum allowed bend angle.
26 Total Length Of Conduit Run
Exceeds Max
ErrorCode.TotalLengthOfConduitRunExceedsMax, 33554432 Total length of conduit run exceeds
the maximum allowed length.
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
18
BendWorks™ Software Troubleshooting (cont’d)
Preprocess Errors Explanation of Error
36 Bend Angle Too Big ErrorCode.BendAngleToolSmall, 34359738368 Bend angle cannot be bigger than
90 degrees.
37 Bend Angle Too Small ErrorCode.BendRadiusTooSmall, 68719476736 Bend angle cannot be smaller than
5 degrees.
39 Distance Too Small From
End Of Last Bend To End
Of Pipe
ErrorCode.DistanceTooSmallFromEndOfLastBendToEndOfPipe,
274877906944
The distance from the end of
the last bend to the end of the
run cannot be shorter than the
Coupling Depth.
40 Distance Too Small From
Start Of
Pipe To Start Of First Bend
ErrorCode.DistanceTooSmallFromStartOfPipeToStartOfFirstBend,
549755813888
The distance from the start of
the run to the start of the rst
bend cannot be shorter than the
Coupling Depth.
41 Loop Run ErrorCode.LoopRun, 1099511627776 The conduit run is in a loop.
42 Multiple Benders
Not Supported
ErrorCode.MultipleBendersNotSupported, 2199023255552 Multiple benders not supported.
43 Type Not Supported ErrorCode.TypeNotSupported, 4398046511104 The conduit type is not supported.
44 Back to Back Bends ErrorCode.BacktoBackBends, 8796093022208 Conduit Run cannot have back to
back bends. Distance between two
bends cannot be 0
Informational Messages Explanation of Error
55 No Valid Split From
Either Direction
ErrorCode.NoValidSplitFromEitherDirection, 18014398509482000 No valid split from either direction.
Operation (cont’d)
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
19
Operation (cont’d)
Squeeze Adjustment
Squeeze is factory set and should not normally need to
be adjusted.
When bending 1-1/4", 1-1/2", or 2" EMT or IMC, the
amount of squeeze applied to the conduit can be
adjusted to compensate for conduit variations. The
squeeze is set properly if the support shaft does not
contact the support plates while bending EMT, as
shown by the shaded parts below. The shaft should
not be more than approximately 1/4" (6 mm) above the
lower at surface.
Squeeze can be checked by loading EMT conduit
and advancing the shoe until conduit starts to bend.
If support shafts touch plates or are more than 1/4"
(6mm) from plates, unload conduit and adjust squeeze
as described.
If shaft is touching, increase squeeze.
If shaft is farther than 1/4" (6 mm), decrease squeeze.
1/4" (6 mm) max. gap between
shaft and top of side plates
To adjust the squeeze:
1. Unplug the bender.
2. Remove screw (refer to illustration below).
3. Rotate the squeeze adjuster:
If the shaft is contacting the support plates,
increase the squeeze by rotating the squeeze
adjuster clockwise.
If the shaft is too high above the support plates,
decrease the squeeze by rotating the squeeze
adjuster counterclockwise.
INCREASE
DECREASE
Squeeze Adjuster
Holding Screw
Optional PVC-Coated Conduit Bending
1. Disconnect power to the bender.
2. Position the bending head in the vertical position.
3. Remove the shoe retainer by pulling out on the
detent pin ring, and slide the retainer off the spindle.
4. Pull out and remove the shoe.
5. For 1-1/2" and 2" PVC-coated conduit:
Install shoe and begin bending. No roller changes
are required.
For 1/2" to 1-1/4" PVC-coated conduit:
Proceed to step 6 and refer to illustration below.
6. Remove the 1" roller support and lower the pivot
handle.
7. Install the PVC-coated conduit roller support by
sliding it between the existing rollers from the right
side of the bender and dropping it down so it hooks
on the bender frame roller support tubes.
8. Install 1/2" to 1-1/4" shoe and follow PVC bending
instructions.
1/2" to 1-1/4" PVC-Coated Rigid
Roller Support Installation
855GX Electric Bender
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
20
Illustrated Bending Glossary
back-to-back bend — any U-shaped bend formed by two
parallel 90° bends with a straight section of conduit or pipe
between the bends.
center-to-center distance — the distance between the
successive bends that make up an offset or a three-bend
saddle.
developed length — the actual length of pipe that will be
bent; refer to distance “d” in the illustration at left.
gain — the difference between the straight-line distance
(a + a) and the shorter radial distance, (d) where:
q = angle of bend
r = the centerline bending radius of the bending shoe
kick — single bend of less than 90°
leg length — the distance from the end of a straight section
of conduit or pipe to the bend; measured from the end to the
outside edge of the conduit or pipe.
offset bend — two opposite bends with the same degree of
bend; used to avoid an obstruction.
offset height — the distance between the two legs of
an offset bend, measured perpendicular to the two legs; also
called amount of offset and depth of offset.
rise — the distance from the end of a straight section of
conduit or pipe to the bend; measured from the end to the
center line of the conduit or pipe. Also called stub or
stub-up.
saddle — a three-bend or four-bend combination; used
to avoid an obstruction.
shrink — the amount of conduit “lost” when laying out an
offset bend working toward an obstruction.
springback — the amount, measured in degrees, that a
conduit or pipe tends to straighten after being bent.
a
a
d
r
Offset Height
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