Greenlee 855GX Intellibender Electric Bender Manual Manuel utilisateur

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

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

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

d

r

Offset Height

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