This document describes the IDEAL Bender Guide, a tool designed for bending conduit with precision and professionalism. The guide emphasizes taking the guesswork out of bending by utilizing engineered features and recommended techniques.
Function Description:
The IDEAL Bender is a tool used to bend electrical conduit into various shapes, including stubs, offsets, back-to-back bends, and saddle bends. It is designed to facilitate accurate and repeatable bends, ensuring that conduit runs fit specific job requirements. The bender can be used for both EMT (Electrical Metallic Tubing) and Rigid/IMC (Intermediate Metallic Conduit).
Important Technical Specifications:
The bender is available in two main material types:
- High strength ductile iron: Known for its durability.
- Lightweight aluminum: Offers ease of handling.
The bender features several engineered marks and scales to aid in bending:
- Arrow: Used for stub bends, offsets, and outer marks of saddle bends.
- Rim Notch: Locates the center of a saddle bend.
- Star-Point: Indicates the back of a 90° bend.
- Degree Scale: Used for offsets, saddles, and special situations, with markings for 22-1/2°, 30°, 45°, and 60°.
The manual provides specific "take-up" values for stub bends, indicating the arc of the bender shoe. For a 3/4" EMT conduit, the take-up for a stub bend is 6 inches.
For offset bends, a reference table is provided, detailing "Distance Between Bends" and "Shrink Amount" for various offset depths and bend degrees (22-1/2°, 30°, 45°, 60°). For example, a 30° bend with a 6" offset depth has a distance between bends of 12" and a shrink amount of 1-1/2".
For saddle bends, the guide provides a table for moving the center mark and making outside marks based on the obstruction height. For each inch of obstruction height, the center mark is moved ahead 3/16", and outer marks are made 2-1/2" from the center mark.
EMT Benders:
- 1/2" Conduit: Ductile Iron (74-001), Aluminum (74-031), Hickey (74-010), Handle (74-019)
- 3/4" Conduit: Ductile Iron (74-002), Aluminum (74-032), Hickey (74-011), Handle (74-019)
- 1" Conduit: Ductile Iron (74-003), Aluminum (74-033), Hickey (74-012), Handle (74-020)
- 1-1/4" Conduit: Ductile Iron (74-006), Aluminum (74-036), Hickey (74-013), Handle (74-021)
Rigid/IMC Benders:
- 1/2" Conduit: Ductile Iron (74-002), Aluminum (74-032), Hickey (74-011), Handle (74-019)
- 3/4" Conduit: Ductile Iron (74-003), Aluminum (74-033), Hickey (74-012), Handle (74-020)
- 1" Conduit: Ductile Iron (74-006), Aluminum (74-036), Hickey (74-013), Handle (74-021)
Handles:
- 3/4" IPS 38" Long Expanded Extra High Strength Handle: 74-019
- 1" IPS 44" Long Extra High Strength Handle: 74-020
- 1-1/4" IPS 54" Long Extra High Strength Handle: 74-021
Usage Features:
The guide outlines a three-step process for all bends:
- Measure your job.
- Mark your conduit using recommended tables.
- Use your bender's engineered marks.
General Bending Tips:
- Foot Pressure: When bending on the floor, pin the conduit to the floor and use heavy foot pressure to keep the EMT in the bender groove and prevent kinking.
- Body Pressure: When bending in the air, exert pressure as close to your body as possible.
- Overbending Correction: In case of overbending, use the back pusher or the expanded end of the bender handle to straighten the conduit.
- Plane Alignment: All bends must be lined up to be in the same plane.
Specific Bend Instructions:
-
Stub Bend:
- Subtract the bender's "take-up" (e.g., 6" for 3/4" EMT) from the desired stub height.
- Mark the conduit at this calculated distance from the end.
- Align the Arrow on the bender with the mark and bend to 90°.
-
Back-To-Back Bends:
- After the first 90° bend, measure to the point where the back of the second bend will be ("B").
- Mark the conduit at this distance.
- Align the Star-Point on the bender with the mark and bend to 90°.
-
Offset Bend:
- Measure the distance from the last coupling to the obstruction.
- Add the "shrink amount" (from the table) to this distance and make the first mark.
- Place the second mark at the "distance between bends" (from the table).
- Align the Arrow with the first mark and bend to the chosen angle using the Degree Scale.
- Slide down the conduit, rotate it 180°, align the Arrow, and bend again.
- Remember to ignore shrink when working away from the obstruction, but consider it when working into it.
- Shallow bends (e.g., 22-1/2°, 30°) are easier for wire pulling, while steeper bends (e.g., 45°, 60°) conserve space.
-
Saddle Bend:
- Similar to an offset, but the same plane is resumed. Often used when encountering another pipe.
- Common configurations: 45° center bend with two 22-1/2° outer bends, or 60° center bend with two 30° bends.
- Step 1 (Marking): Calculate the center mark and outer marks based on the obstruction's outside diameter using the provided formula (3/16" ahead for center mark, 2-1/2" from center mark for outer marks per inch of obstruction height).
- Step 2 (Center Bend): Align the center mark with the Rim Notch and bend to 45°.
- Step 3 (Outer Bends):
- Without removing the conduit, slide the bender to the next mark, align with the Arrow, and bend to 22-1/2°.
- Remove and reverse the conduit, locate the other remaining mark at the Arrow, and bend to 22-1/2°.
-
Hickeys:
- Hickeys are not fixed radius devices; they require several movements per bend.
- They allow for very tight radius bends.
Maintenance Features:
The document does not explicitly detail maintenance features for the bender itself. However, the emphasis on "durability" in the description of the IDEAL bender line suggests that the tools are built to withstand regular use. The guide's focus is primarily on proper usage techniques to ensure accurate and consistent bending results.
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