Bend-Tech Dragon A400 Installation and operation manual

Revision 7 | English
Dragon A400
Part 1 of 3
Startup Manual
Part 1: Safety and Maintenance
©2022 Bend-Tech LLC

ii Bend-Tech Dragon A400
Startup Manual
©2022 Bend-Tech LLC
All rights reserved. The information in this manual is subject to change without notice.
Bend-Tech LLC strives to produce the most complete and accurate information regarding
its products. We are constantly working to improve and advance our products to increase
performance, user satisfaction and experience. Bend-Tech LLC assumes no responsibility for
errors or omissions regarding this manual. Bend-Tech LLC assumes no liability for damages
resulting from the use of the information contained in this publication.

iiiBend-Tech Dragon A400 Startup Manual
Dragon A400
Startup and Training Manual
Revision 7
English
Original Instructions
October 2022
Bend-Tech LLC
729 Prospect Ave.
Osceola, WI 54020 USA
[phone]
www.bend-tech.com
[email protected]

iv Bend-Tech Dragon A400
Startup Manual
Contents
Contents
Contents..........................iv
Limited Warranty ...................vi
Customer Satisfaction Commitment. . . . .vii
Customer Service. . . . . . . . . . . . . . . . . . .vii
Alerts ........................... viii
Glossary..........................x
01
Safety....................................... 13
1.1 General Safety Notes ........... 13
1.2 Safety Procedures .............. 14
1.2.1 Personal Protective Equipment
(PPE) ........................ 14
1.2.2 Machine Safety Labels ...... 14
1.3 Recommended PPE for Operating
the Dragon A400 .................. 16
1.3.1 Eye Protection ............. 16
1.3.2 Footwear ................. 16
1.3.3 Heat-Resistant Gloves....... 16
1.3.4 Hearing Protection.......... 17
1.3.5 Breather Mask or Ventilation
System ....................... 17
1.4 Operational Safety .............. 18
1.4.1 Guards................... 18
1.4.2 Machine Inspection ......... 18
1.4.3 Machine Operational
Movement..................... 18
1.4.4 Material Securing........... 19
1.5 Pinch Points ................... 19
1.6 Emergency Stops (E-Stops). . . . . . . 20
1.6.1 E-Stop Overview ........... 20
1.6.2 Control Screen E-Stop....... 21
1.6.3 Re-Home after an Emergency
Stop ......................... 21
1.7 Electrical Servicing.............. 21
1.7.1 Power Down Before Servicing. 21
1.8 Material Weight ................ 22
1.8.1 Weight Limit............... 22
1.9 Material Length ................ 22
1.9.1 Material Support Lift. . . . . . . . . 22
1.10 Modications To The Machine .... 22
1.10.1 Unauthorized Modications .. 22
1.10.2 Factory Parts Kits and
Updates ...................... 23
1.11 Other Safety Information ........ 23
1.12 More Information .............. 23
1.13 Recommended Safety Guidelines . 24
02
Maintenance............................ 25
2.1 Dragon A400 Maintenance
Overview ........................ 25
2.2 Daily Maintenance .............. 25
2.2.1 Clean the Gate. . . . . . . . . . . . . 25
2.2.2 Clean the Support Beam ..... 26
2.2.3 Clean the Rack ............ 26
2.2.4 Check the Coolant Level ..... 26
2.2.5 Clear the Part Catcher....... 26
2.2.6 Check the Air Pressure ...... 26
2.2.7 Clean the Work Area ........ 26
2.2.8 Check the Plasma System. . . . 26
2.3 Weekly or Every 40 Hours ........ 26
2.3.1 Clean Grease and Oil Buildup . 26
2.3.2 Check Electronic Connections. 27
2.3.3 Clean Chuck and Trolley ..... 27
2.3.4 Lubricate the Gear Rack ..... 27
2.3.5 Actuators and Lead Screws... 27

vBend-Tech Dragon A400 Startup Manual
Contents
2.3.6 Clean and Re-lubricate the Roller
Bearings ...................... 27
2.4 Monthly or 150 Hours............ 27
2.4.1 Check the Fasteners ........ 27
2.4.2 Clean and Fill the Material
Cooling System Reservoir ........ 27
2.4.3 Check the Eccentric Bearings . 27
2.4.4 Check the Emergency Stops .. 28
2.4.5 Clean and Lubricate the
Racks ........................ 28
2.4.6 Check Backlash............ 28
2.5 Quarterly or 500 Hours. . . . . . . . . . . 28
2.5.1 Clean Coolant Screens ...... 28
2.5.2 Grease Pillow Block Bearings . 28
2.5.3 Comprehensive Cleaning .... 28
2.6 Bi-Annually or 1000 Hours ........ 28
2.6.1 Clean the Chuck ........... 28
2.6.2 Check Level and Straightness. 28
2.7 Annually or 2000 Hours .......... 29
2.7.1 Check Rack Spacing ........ 29

vi Bend-Tech Dragon A400
Startup Manual
Contents
Limited Warranty
Covering Bend-Tech Dragon
Bend-Tech LLC provides a limited warranty on all new Dragon machines that are manufactured
directly or under license by Bend-Tech LLC, and sold by Bend-Tech LLC or its approved
distributors.
Warranty Coverage
Each Bend-Tech Dragon machine is warrantied by the manufacturer against defects in material
workmanship for 12-months. The warranty period commences upon delivery of the Dragon
machine to the customer’s facility.
Repair or Replacement Only
The Manufacturer’s sole liability, and the Customer’s exclusive remedy under this warranty
shall be limited to repairing or replacing the defective part. Repair or replacement of parts
is at the sole discretion of the manufacturer. The Customer is responsible for warranty parts
installation. Bend-Tech does not provide warranty service labor.
Limits
This warranty does not cover components subject to wear due to normal use of the machine
such as belts, lights, tooling etc. This warranty is void if Bend-Tech LLC has determined any
failure is the result of mishandling, abuse, misuse, improper installation, improper storage,
improper maintenance or unauthorized modication of the machine. The warranty does not
cover damage due to natural disasters, re, ood or other external factors. The warranty may
become void or limited in the event that hardware changes or adaptations are made to the
machine.
Software
The standard 2-year software maintenance plan is included with the purchase of a Dragon.
Before the 2-year maintenance plan has expired, the customer may purchase an extended
maintenance plan. The maintenance plan and extended maintenance plans will ensure the
customer always has the newest version of Dragon Software. The maintenance plan is critical
to keeping Dragon software updated with the newest capabilities possible, and is critical to the
servicing of the machine. Bend-Tech LLC will contact the Customer regarding updates to the
maintenance plan within 1-month of expiration. Contact Bend-Tech Support to ensure software
is up to date: [email protected].

viiBend-Tech Dragon A400 Startup Manual
Contents
Customer Satisfaction Commitment
Congratulations on your purchase of the world’s best CNC plasma tube and pipe cutting
machine, the Bend-Tech Dragon. Bend-Tech LLC places great pride in customer satisfaction
and it is our promise to o󰀨er you the best support available for your Dragon. We recognize that
our support is a key factor in your success.
Contact Us
Bend-Tech’s hours of operation are Monday - Friday, 8:00 am - 5:00 pm EST. The Bend-Tech
support team and sales team are always available during our hours of operation.
Phone: [phone]
Email: Sales team: [email protected]
Support team: [email protected]
Address: Bend-Tech, 729 Prospect Ave., Osceola, WI 54020, U.S.A..
Customer Service
Comments, questions, or concerns regarding the Dragon Machine, this manual, or the Bend-
Tech Software can be directed to Bend-Tech sales and service representatives at the above
contact information. Check out the following links for more information regarding Dragon
Machines and Bend-Tech Software.
Website, Socials, and Online Resources
• http://www.bend-tech.com
• https://www.facebook.com/2020ssi
• https://www.instagram.com/bend_tech
• https://www.youtube.com/bendtech2020
• http://www.bend-tech.com/wiki7

viii Bend-Tech Dragon A400
Startup Manual
Contents
Alerts
Bend-Tech manuals use specic callouts to highlight important information. Each style of
callout pertains to specic types of information being given. The machine operator should
familiarize themselves with the following denitions and examples of each type.
Denitions & Examples
Danger
! Danger !
Danger indicates a serious condition that could cause severe injury or death to the
operator or bystanders if the instructions are not followed.
Warning
! Warning !
A Warning indicates there is a possibility for minor injury if the instructions are not
followed correctly.
Caution
! Caution !
Caution warns the operator that minor injury or machine damage could occur if
instructions are not followed. It could also mean that not following directions could
a󰀨ect the overall procedure being performed.

ixBend-Tech Dragon A400 Startup Manual
Contents
Important Alerts
Important
Important notes give clarication or focuses on information that is critical or
unique to an operation.
Notes and Tips
Note or Tip
Notes and tips give additional helpful information for operating the Dragon machine or Dragon
software. They are meant for supplemental information and not information that is critical for
operating procedures.

xBend-Tech Dragon A400
Startup Manual
Glossary
Glossary
Axis
A xed reference line.
Beak
The front assembly that includes the
Parts Catcher and Parts Bin/Bucket.
The Material Coolant System replaces
most of the Beak when installed.
CAD
Computer Aided Design. Modeling or design
software for creating parts, components, or
whole assemblies. Used for manufacturing or
similar industries. Can be 2D or 3D design.
CAM
Computer Aided Manufacturing or Machining.
Using the computer to assist in operating
machines by converting CAD models into
G-Code that the machine recognizes.
Chuck
Secures and rotates the material. Part of
the Trolley. Also referred to as the Y-Axis.
Control Box
Contains the motor drivers and other electrical
components that allows the Dragon CAM
software to control the Dragon machines.
Deadzone
The space between the Chuck and
the Laser Light position when the
Chuck is all the way forward.
Emergency Stop
Abbreviated E-STOP. A button which shuts down
machine operations. Four are located on the
machine and one is part of Machine Control.
Gate
The adjustable mechanism that holds the
material in place at the Head of the Machine.
Head
The machine assembly that makes
up the front end of the machine.
Limit Switch
The switch that operates as an automatic
control to prevent a mechanism or process
from going beyond a prescribed limit.
Load Position
The position the machine enters after
clicking START on machine control the rst
time after starting a cutting project. This
allows the operator to more easily load the
designated material into the machine.
Mach3
The driving software behind Machine Control.
Required for the machine to operate.
Machine Control
The computer interface that controls
the machine operations. Used by the
operator when running projects.
Material Coolant System
The system that transports coolant through
the material during cutting operations.
Material Support Lift
The mechanism that supports the
material during cutting. Sometimes
referred to as the Lifter.
Parts Catcher
The Parts Catcher is placed at the front of
the machine to catch parts as they are cut.
Support Beam
Forms the backbone of the machine. Comprised
of Aluminum Beams and Steel Rails.
Tail
The machine assembly that makes
up the far end of the machine.

xiBend-Tech Dragon A400 Startup Manual
Glossary
Task Menu
The rst menu that opens upon starting
the Dragon Software or the Bend-Tech
software. From this menu various tasks
can be started, such as part designing,
importing, library access, etc.
Toolhead
The machine component that the tools
are attached too. Maneuvers the tools
into position with the A and Z axes.
Trolley
The machine component that
includes the Chuck. Travels along the
Support Beam on the X-Axis.
Beak
Control Box
Toolhead
Chuck
Material
Support Lift
Support Beam
Tail
Trolley
Gate
Head
Dragon A400
Dragon A250

xii Bend-Tech Dragon A400
Startup Manual
Glossary

13Bend-Tech Dragon A400 Startup Manual
Safety
01
01
Safety
1.1 General Safety Notes
Read all warnings, cautions, and instructions before operating the Dragon machine.
Each company has di󰀨erent procedures. Always act in accordance with Environmental Health
& Safety (EHS) standards set in place regarding the facility in which the Dragon A400 is being
operated.
Follow basic safety precautions to reduce the risk of injury or mechanical damage. CNC
metal working machines such as the Bend-Tech Dragon machines introduce hazards to the
workplace. It is the responsibility of the operator to take appropriate safety measures regarding
the potential hazards of this machine, and not the responsibility of Bend-Tech, LLC.
Maintaining a clean machine is important during normal use as well as prior to and after
servicing the machine. Cleaning procedures may require Personal Protective Equipment (PPE)
beyond the scope of daily operation procedures of the machine.
Read all parts of the Startup manual in their entirety to ensure safe and e󰀩cient operation of
the Dragon A400 machine.
This manual is a reference guide for the Dragon A400 and is not a comprehensive source of
operating or training information. A complete training course and support can be requested
from Bend-Tech, LLC, www.bend-tech.com.

14 Bend-Tech Dragon A400
Startup Manual
Safety
01
1.2 Safety Procedures
1.2.1 Personal Protective Equipment (PPE)
Metalworking and metalworking operations can be dangerous. Using the proper PPE is
important to avoid injuries that can result from sparks, heat, noise, smoke and vapor, dropped
objects, and ultraviolet light. Consult local safety codes before operating the machine. Before
working on or near the machine, it is important to read this manual and fully understand the
safe operation of the machine. Contact Bend-Tech with any questions or concerns regarding
the safe operation of the Dragon A400.
It is recommended that the operator read the plasma torch operator’s manual and become
familiar with the hazards of working with the torch before operating it in conjunction with the
Dragon.
1.2.2 Machine Safety Labels
The following Safety Labels are found on the Dragon A400.
Back Plate
! Caution !
The Dragon A400 should only be operated by authorized and trained personnel. The
operator should always act in accordance with the Dragon A400 Startup safety procedures
and machine instructions for safe operation of this machine. Failure to follow these
guidelines may pose a hazard to personnel and the machine.

15Bend-Tech Dragon A400 Startup Manual
Safety
01
Toolhead Gate
Trolley
Control Box Material Control Lifter

16 Bend-Tech Dragon A400
Startup Manual
Safety
01
1.3 Recommended PPE for Operating the Dragon A400
1.3.1 Eye Protection
Shaded safety glasses are required during cutting operations of the machine. Ensure the
shade is based on the amperage of the plasma torch being used. It is important the operator
and anyone observing the machine wear welder’s glasses or a welder’s mask. Placing a
welding curtain between the machine and other areas of the workspace is also recommended.
Refer to the Occupational Safety and Health Administration (OSHA) standards to determine
proper safety glass shading and/or welding curtain for the cutting torch amperage being used.
! Danger !
The cutting torch emits ultraviolet light. Looking directly at the plasma stream can
damage human retinas.
The minimum ANSI eye protection recommendations:
• Less than 40 amps - shade 5
• 41 to 60 amps - shade 6
• 61 to 300 amps - shade 8
For non-cutting operations, clear safety glasses are recommended.
1.3.2 Footwear
The Dragon A400 is a metal working machine and metal materials can be extremely heavy. A
piece of dropped material could cause injury to the operator or observers. Also, the Torch emits
sparks and possibly hot torch slag. It is highly recommended that the operator wear safety
shoes or boots while operating the Dragon A400.
1.3.3 Heat-Resistant Gloves
The plasma torch will introduce extreme heat into the material during the cutting process. The
operator should take caution handling newly-cut parts. Always wear heat resistant gloves when
handling parts produced by the Dragon A400.

17Bend-Tech Dragon A400 Startup Manual
Safety
01
! Warning !
Due to the extreme temperatures that result from the plasma cutting process, parts
cooled in water in the parts catcher can still be extremely hot. Always use caution
when handling newly-cut parts.
! Danger !
The plasma arc of the Torch can cause severe injury or even death. Never
approach the Torch while it is activated and operating.
1.3.4 Hearing Protection
While the Dragon A400 is relatively quiet, it is recommended that the operator wear hearing
protection as specied per the facility safety requirements.
1.3.5 Breather Mask or Ventilation System
Plasma dust and debris is toxic, and inhalation can cause respiratory di󰀩culties or other
complications. It is recommended that the operator and any observers wear a breathing mask,
or that the shop be equipped with an e󰀨ective ventilation system for safe operation of the
Dragon A400.
Important
The Dragon A400 Material Coolant System greatly reduces smoke and vapor
emitted by the machine. Bend-Tech recommends use of the Material Coolant
System whenever possible. The Coolant System is especially e󰀨ective when
working with aluminum or stainless steel.

18 Bend-Tech Dragon A400
Startup Manual
Safety
01
! Danger !
Servicing the plasma unit with power connected can result in electric shock which
can lead to severe injury or death. Disconnect power before servicing the torch or
plasma unit.
! Danger !
Do not use combustible fuel gases or oxidizing gases in the plasma cutting process.
Use of these types of gases can result in explosive conditions during cutting
operations.
1.4 Operational Safety
1.4.1 Guards
Do not operate the machine without safety guards in place.
1.4.2 Machine Inspection
Perform an inspection of the machine before each startup, making sure all electrical cords and
cables that function as part of moving assemblies are secure and fastened. Ensure all tools
are fastened securely. Ensure all E-stop switches are disengaged.
1.4.3 Machine Operational Movement
While a program is running, the Trolley and Toolhead can move rapidly at any time through its
short/long travel feed rate procedures. The operator and bystanders should stay clear of the
Trolley and Toolhead during machine operation.
! Warning !
The Trolley,Toolhead, and Gate are pinch points. Stay clear during machine
operation.

19Bend-Tech Dragon A400 Startup Manual
Safety
01
1.4.4 Material Securing
Ensure that any material loaded into the machine is securely fastened in the Chuck and is
snug in the Gate.
! Warning !
Improperly secured material may cause injury.
1.5 Pinch Points
Use caution in the area of pinch points. There are many pinch point locations identied on the
Dragon A400 including the Gate assembly, Toolhead, Trolley and Material Support Lift. It is
advised to use caution in these areas and stay clear of them during machine operation.
Toolhead
movement
Front Gate
movement
Material Support
Lift movement
Where the Trolley
contacts the Rail
Chuck
movement
Where the Trolley contacts
the rear bumper

20 Bend-Tech Dragon A400
Startup Manual
Safety
01
1.6 Emergency Stops (E-Stops)
1.6.1 E-Stop Overview
There are four external emergency stop (E-Stop) buttons located on the Dragon A400
machine. There is one E-Stop on the Tail of the machine, one on the Trolley cover, and one on
each side of the Gate. These four emergency stops completely shut power o󰀨 to all motors and
outputs. To re-enable the machine after pressing an E-Stop, the E-Stop must be disengaged
and power to the motors must be initialized by pressing the green light on the Control Box. If
the green light doesn’t initialize, this is an indicator that an E-Stop is still engaged. The green
light indicates the motors have power.
E-Stop
Locations