REPEATABLE CONDUIT BENDING - Cliffhanger Tools

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REPEATABLE CONDUITBENDINGCliffhanger ToolsCliff Howardhttp://www.cliffhangertools.com

Purpose for this Training Repeatable BendingReview theoryLearn how to gather the factsUnderstanding the Cliffhanger ToolsConduit Bending Program Practice bending conduit Talk about the art of conduit bending

The Theory of conduit bending There are a number of good conduit bendingbooks available– JATC curriculum– Cox conduit bending– Many others you can find on the web We’ll discuss Pythagorean theorem We’ll discuss Trig Functions - Sally and Oscar Formulas for circumference of a circle

The Theory of conduit bendingIf we let c be the length of the hypotenuse and a and b be the lengthsof the other two sides, the theorem can be expressed as the equation:a² b² c²or, solved for c:c a² b²If c is already given, and the length of one of the legs must be found, the following equations can beused (The following equations are simply the converse of the original equation):c² - a² b²Orc² - b² c²This equation provides a simple relation among the three sides of a right triangle so that if the lengths ofany two sides are known, the length of the third side can be found. A generalization of this theorem isthe law of cosines, which allows the computation of the length of the third side of any triangle, given thelengths of two sides and the size of the angle between them. If the angle between the sides is a rightangle it reduces to the Pythagorean theorem.

The Theory of conduit bendingThe Sine, or Sin of the angle Ø is the length of theside Opposite the angle Ø divided by the lengthof the Hypotenuse.The Cosine, or Cos of the angle Ø is the length ofthe side Adjacent to the angle Ø divided by thelength of the Hypotenuse.The Tangent, or Tan of the angle Ø is the length ofthe side Opposite the angle Ø divided by thelength of the side Adjacent to the angle Ø.The Cotangent, or Cot of the angle Ø is the length ofthe side of the triangle Adjacent to the angle Ødivided by the length of the side Opposite theangle Ø.The Secant, or Sec of the angle Ø is the length of theHypotenuse of the triangle divided by the lengthof the side Adjacent to the angle Ø.The Cosecant, or Csc of the angle Ø is the length ofthe Hypotenuse of the triangle divided by thelength of the side Opposite the angle Ø.

The Theory of conduit bending Length of circumference The ratio of a circle's circumference to its diameter is π (pi), a constant that takes thesame value (approximately 3.1416) for all circles. Thus the length of thecircumference (c) is related to the radius (r) by– c 2 ror equivalently to the diameter (d) by– c dOr to find diameter when circumference is know –d c/

Repeatable Conduit Bending Bending conduit is best done with a partner. One runs the front of shoe and thebender, the other supports the conduit and runs the CliffhangerCreate a measured length of conduit “L” (enter measurement on fact sheet)Mark conduit 2” from both ends of conduit “A” & “B”Put conduit in bender with front of shoe on mark “A”ABL Find Zero make this a personal quest– Your ability to consistently find the zero mark is the first step to being able torepeat bends– The conduit should be squeezed tight enough to require a pipe wrench to levelthe Cliffhanger, but do not start to bend the conduitFinding the Travel Mark “T”– When the conduit is in the zero position, a stationary point “Z” (behind thebending shoe) is established to determine the correct travel for the desired bend(enter measurement ZB into fact sheet)Bend a true 90 Find the Spring back Mark “T” and mark conduit– This mark “T” is determined at the maximum bend before release (93 )

Gathering the facts Place true 90 bend on bending table to check for accuracyDeduct FAMinimum stub FAGain (FC ED) – LTravel (ZB – TB) ZTBack to Back Deduct – GainDeductFC EDLengthGainPoint ZBPoint TBSide ETravelCAZTBDBottom F

Cliffhanger Tools Repeatable Conduit Bending ProgramCONDUIT3/4" IMCSeg Travel3/4" IMCOffsetMarkBend Mark6.375Degrees35Stub A15.500Cut LengthTravelDeductGainB to eesLength BShrink3/4" COB1" COBSeg TravelSeg TravelSeg TravelSeg Travel4.6465.9063/4" IMC1" IMC1 1/2" IMC2" 7.1853

Cliffhanger Tools Repeatable Conduit Bending 2RadiusFractions75.0001/160.0625dev 53/80.37507/160.437530 Bends3.9253 deg20 Bends18 Bends15 Bends5.8886.5427.8504.5 deg5 Deg6 deg10 Bends11.7759 deg

Cliffhanger Tools Repeatable Conduit Bending ProgramCONDUITCut LengthBend MarkStub ALength 4" IMC6.37515.50035.50047.5009.0009.1253.5005.6253/4" 4" 4.31335.31313.00044.43811.37511.0003.8757.1251/2" IMC1/2" Chicago1" IMC1" Chicago0.000Travel7.000Deduct7.500Gain2.875B to 14.37514.2505.3758.8751 1/2" IMC20.50035.37547.00076.50013.62514.8755.8759.0001 1/2 1 1/2 5038.00033.00063.18811.12523.7507.81315.9382 1/2"3"0.0000.0000.0003 1/2"0.0000.0000.0004"0.0000.0000.000

Input the factsCONDUIT3/4" IMCBend Mark6.375Stub A15.500Length B35.500Cut Length47.500Travel9.000Deduct9.125Gain3.500B to B5.625 Select the conduit size and type (Tan cell drop down box) in the bending program. Insert the data from fact sheet into the appropriate green column in the bendingprogram. No need to input data into the Back to Back column, the program calculates thismeasurement. You can only change or input data into a highlighted cell. All others are locked to preventchanging needed formulas and other data. Repeat the Gathering of facts for each size conduit and type as needed. You are now on your way to Repeatable Bending.

Cliffhanger Tools Repeatable Conduit Bending Program To Bend a stub 90 – Select Conduit size and type– Click on the blue box @ “Stub A” Enter the measurement for stub “A” Measurement can be a decimal number (25.5) or afractional number (25 ½)– The computer calculates the bend mark (stub) A – D (deduct) – BM (bend mark)– Place conduit in bender with the bend mark atthe front of shoe and find “zero” or “Z” mark– Place travel mark “T” (green box) on conduit– Bend conduit until the “T” mark is reached

Cliffhanger Tools Repeatable Conduit Bending Program To Bend a stub 90 with a length “B”– Select Conduit size and type– Click on the blue box @ “Stub A” Enter the measurement for stub “A”– Click on the blue box @ “length B” Enter the measurement for length “B”– The computer calculates the– bend mark (A – D BM) and the– cut length (A B) – G (gain) cut length CL– Mark conduit for “BM” and “CL” and cut and threadconduit at “CL”– Place conduit in bender and proceed to bend stub “A”– Remove from bender and check for accuracy

Cliffhanger Tools Repeatable Conduit Bending Program Bending an Offset– Enter desired offset measurement in the Blue box @ “Offset” Measurement can be a decimal number (25.5) or a fractionalnumber (25 ½)– Chose the best combination of degree and hypotenuse lengthfor desired offset– Place offset marks on conduit.– Place conduit in bender with front mark at front of shoe and find“zero”– Install Cliffhanger level in end of conduit and level– Determine “Segment Travel” (Segment travel includes springback) ST Travel 90 x degrees Enter degrees in blue box @ Degrees Mark conduit for “T” and bend conduit to “T” mark Release bender and turn conduit over 180 and find zero Rotate conduit until Cliffhanger is level Mark conduit for “T” and bend conduit to “T” mark, removeconduit to bending table and check for accuracy

Cliffhanger Tools Repeatable Conduit Bending Program Bend a 90 with a kick– Install Cliffhanger level in end of conduit and level– Bend the desired stub 90 – Remove to bending table and check– Enter the desired kick measurement into the blue box @degrees– Chose the best combination of degree and hypotenuse lengthfor desired kick– Mark conduit at the kick mark (this mark is the center of thebend)– Deduct measurement from center of bend “COB” column– Place conduit in bender with “cob” mark at front of shoe and findzero– Rotate conduit until Cliffhanger is plumb– Determine segment travel for desired degree of kick “T”– Bend conduit to “T” mark. Remove to bending table and checkfor accuracy

Cliffhanger Tools Repeatable Conduit Bending Program Shrink for kicks and offsets– Go to the shrink column on the program sheet– This figure is based on the Pythagoreantheorem c² - a² b² c – b shrink And the gain of the segment bend needs to beconsidered – formula to follow– This deduct amount is a good estimate forkicks and offset

Cliffhanger Tools Repeatable Conduit Bending Program Center of bends for saddles, offsets, andkicks– Go to the COB column in the bendingprogram– For the math to work on these bends themeasurement is made to the center of thebend or the length of the hypotenuse– This deduct amount gives you the front of theshoe for bending purposes– Other sizes and a formula to follow

Art of conduit bending Measurements and the Art of Conduit Bending– This conduit bending method will give you the ability to createany bend to specific measurements– If you have a bad measurement . The conduit will not fit– Good measurements are critical– Plumb, level and square reference points allow goodmeasurements– Good measurements fitting conduits– When you understand this bending method it allows time toapply the art of bending conduit Fewer couplings and conduit unionsFewer return trips to the bending tableFewer re-cuts and rethreading of miss-measured conduitEvenly spaced conduit racks with matching bends that anyelectrician would be proud to install No bone pile to hide Increased productivity more jobs for quality craftspeople

Art of conduit bending Cliffhanger offset42”8”24”

Trigonometric 80.4142142.6131261.0823922.41421467.51.178097

Trigonometric 98CosSinCotSecCscTanDegRad

Conduit DataCONDUIT1/2" IMC1/2" Chicago3/4" IMC3/4" PVC3/4" Chicago1" IMC1" Chicago1"PVC1 1/2" IMC1 1/2 Rigid1 1/2 PVC2"2 1/2"3"3 1/2"4"TravelDeductGainB to B

Mark conduit 2” from both ends of conduit “A” & “B” Put conduit in bender with front of shoe on mark “A” Find Zero make this a personal quest – Your ability to consistently find the zero mark is the first step to being able to repeat bends – The conduit should

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