Bend-Tech Dragon A400 Installation guide

Revision 4 | English
A400
Part 4 of 4
Start-Up and Training Manual
Part 4: Side Offsets, Angle & Channel, and Calibration
©2020 Bend-Tech LLC

ii Bend-Tech Dragon A400
Start-Up and Training Manual
©2020 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 Start-Up and Training Manual
Dragon A400
Start-Up and Training Manual
Revision 4
English
Original Instructions
July 2020
Bend-Tech LLC
729 Prospect Ave.
Osceola, WI 54020 USA
[phone]
www.bend-tech.com
[email protected]

iv Bend-Tech Dragon A400
Start-Up and Training Manual
Contents
Contents
Contents...................................iv
01
Dragon CAM Side O󰀨sets
Calibration................................ 7
1.1 Side O󰀨sets Calibration for Square
and Rectangle Tube.................7
1.1.1 Open Bend-Tech 7X .........7
1.1.2 Chuck Grip Settings..........7
1.1.3 Corner Rotation Extension. . . . . 7
1.1.4 Add Square Or Rectangle
Material .......................8
1.1.5 Disable Feature .............9
1.1.6 Power On The Machine.......9
1.1.7 Homing Procedure...........9
1.1.8 Load The Material .......... 10
1.1.9 Torch Distance ............. 10
1.1.10 Run Test Cuts .............11
1.1.11 Measure Test Cuts ..........11
1.1.12 Save Calibration .......... 12
02
Angle and Channel Material
Setup ....................................... 13
2.1 Angle and Channel Material
Overview ........................ 13
2.2 Adding Angle and Channel
Material ......................... 13
2.3 Angle and Channel Material
Machine Settings .................. 13
2.3.1 Corner Radius ............. 14
2.3.2 Y-Axis (Chuck) Acceleration. . . 14
2.3.3 Corner Rotation Extension. . . . 15
2.3.4 Edge Cut O󰀨set ............ 15
2.3.5 Lead In/Out Settings ........ 16
2.4 Side O󰀨sets Calibration .......... 16
2.4.1 Open Bend-Tech 7X ........ 16
2.4.2 Begin The Calibration
Process....................... 16
2.3.3 Disable Feature ............ 17
2.4.4 Power On The Machine...... 17
2.4.5 Homing Procedure.......... 17
2.4.6 Load The Material .......... 17
2.4.7 Angle Material Spacers ...... 18
2.4.8 Channel Material Spacers .... 18
2.4.9 Torch Distance ............. 19
2.4.10 Run Test Cuts ............ 19
2.4.11 Measure Test Cuts ......... 19
2.4.12 Save Calibration .......... 20
03
Calibrating .............................. 21
3.1 Calibration Overview ............ 21
3.1.1 Calibration Points. . . . . . . . . . . 21
3.2 Wizard ....................... 22
3.3 Dragon Calibration Wizard........ 22

vBend-Tech Dragon A400 Start-Up and Training Manual
Contents
3.3.1 Introduction ............... 22
3.3.2 Computer Setup. . . . . . . . . . . . 22
3.4 Calibration Wizard and Computer
Interface Conrmation .............. 23
3.4.1 Jog Trolley - X Axis ......... 23
3.4.2 Jog Chuck - Y Axis.......... 23
3.4.3 Jog Toolhead - Z Axis ....... 23
3.4.4 Jog Toolhead - A Axis........ 24
3.4.5 Jog Material Lift Support - B
Axis.......................... 24
3.4.6 Jog The Powered Gate -
C Axis ........................ 24
3.5 Homing Switches ............... 25
3.6 Ready the Trolley ............... 25
3.7 Begin Homing Process. . . . . . . . . . . 26
3.7.1 Toolhead ................. 26
3.7.2 Chuck. . . . . . . . . . . . . . . . . . . . 26
3.7.3 Powered Gate ............. 27
3.7.4 Lifter Station Switch......... 27
3.7.5 Lifter Station. . . . . . . . . . . . . . . 27
3.8 Maximum Chuck Travel (X Axis) ... 28
3.8.1 Dead Zone Length.......... 28
3.9 Toolhead Calibration ............ 28
3.9.1 Type of Material ............ 28
3.9.2 Load Material.............. 29
3.9.3 Material Dimensions ........ 29
3.9.4 Load Material Into Machine ... 29
3.9.5 Laser Calibration ........... 30
3.9.6 Calibrating The Marker ...... 31
3.9.7 Calibrating the Engraver ..... 31
3.9.8 Calibrating the Torch ........ 31
3.10 Pierce Hole. . . . . . . . . . . . . . . . . . . 32
4.10.1 Pierce Hole Verication ..... 32
3.11 Lifter Station Material Gap ....... 33

vi Bend-Tech Dragon A400
Start-Up and Training Manual
Contents

7Bend-Tech Dragon A400 Start-Up and Training Manual
Dragon CAM Side O󰀨sets Calibration
01
01
Dragon CAM Side O󰀨sets
Calibration
1.1 Side O󰀨sets Calibration for Square and Rectangle Tube
Square and Rectangle Tubing has measurable sides which makes the procedure for setting
up these materials in the Dragon A400 di󰀨erent than setting up round tubing. The following
process will walk the Operator through the procedure to set up a piece of square tubing, but
rectangular tubing will be similar.
1.1.1 Open Bend-Tech 7X
To begin the Side O󰀨set Calibration process, open Bend-Tech 7X. Click Dragon CAM near the
center of the interface.
1.1.2 Chuck Grip Settings
Before proceeding with Side O󰀨sets Calibration it is important to ensure the Chuck Grip setting
in the Bend-Tech Dragon software matches how the material is chucked into the machine.
In the Tube / Pipe Library, under the Machine tab, locate the Chuck Grip dropdown menu
within the Basic Settings box. To reference which Chuck Grip to choose, click the question
mark icon next to the Chuck Grip dropdown. Set Chuck Grip appropriately.
1.1.3 Corner Rotation Extension
Corner Rotation Extension is the distance set before the tool reaches the edge of a given
material prior to the machine beginning rotation of the material. If the Corner Rotation
Extension is not set correctly it can lead to Torch collision or the Torch cutting vertically into the
wall of the material. It can also cause Torch failure.

8Bend-Tech Dragon A400
Start-Up and Training Manual
Dragon CAM Side O󰀨sets Calibration
01
In the Tube / Pipe Library, in the Machine interface, locate the Corner Rotation Extension box
in the bottom center of the interface. Use the formula to calculate the value to enter in the
Distance text box.
(wall thickness + kerf) - radius = Corner Rotation Extension
Example:
(.120 + .06) - .15 = .03
If the Corner Rotation Extension value is negative, leave it set to 0 in the software. For this
material the CRE would be set to 0.
1.1.4 Add Square Or Rectangle Material
On the Bend-Tech Dragon Home Interface click Tube Library then click Add New below
the Material List in the bottom left of the interface.
Select the shape of the material that will be used in the Select Shape
box on the right hand side of the interface. Enter the dimensions of the
material in the appropriate text boxes. Enter a name for the material.
Click Save.
Bend-Tech recommends using a corner radius gauge to determine material corner
radius. If a corner radius gauge is not available the Operator can multiply material
thickness by 2 and enter that value as an estimated corner radius.
Ensure Machine Control is open before clicking the Calibrate icon.
The material will appear in the Material List on the left hand side of the interface. Click
on the material. In the menu bar at the top of the same interface click Advanced.
In the middle of the interface in the Side O󰀨sets box, click Calibrate.

9Bend-Tech Dragon A400 Start-Up and Training Manual
Dragon CAM Side O󰀨sets Calibration
01
1.1.5 Disable Feature
The next interface will give the Operator the option to Disable the Side O󰀨set Calibration
feature and use the machine’s default measurements.
Bend-Tech requires performing the Side O󰀨set Calibration to achieve more precise results
when cutting square or rectangular material.
Click Next.
1.1.6 Power On The Machine
Select the machine, click Next, then assure the machine is powered on. The interface will
prompt the Operator to Start Mach by clicking the icon on the interface.
Click Start Mach.
1.1.7 Homing Procedure
The Operator will be asked to perform the machine’s
Homing process. To begin the Homing process click
the image in the interface.
During the homing process, the software will display a message in green text. Upon
homing, the green text will disappear.
After the Homing process is complete, click Next.

10 Bend-Tech Dragon A400
Start-Up and Training Manual
Dragon CAM Side O󰀨sets Calibration
01
1.1.8 Load The Material
The machine will ask the Operator to enter the length of the material. The Side O󰀨sets
Calibration should use a piece of material between 3 ft. and 6 ft. in length. This will move the
Trolley into place so the Operator can load the material into the machine.
Turn the Gate Lead Screws clockwise until the Gate rollers are snug to the material. The
material should move freely in the Gate with no play. Ensure the Gate Lead Screws are in the
12 o’clock and 3 o’clock positions.
Feed the material into the Chuck, making sure the Chuck is adjusted so it will accept the
material. Using a torpedo level on the material, secure it in the Chuck making sure it is as level
side-to-side as possible. If the machine is equipped with a Powered Gate the Operator will not
need to position the Gate Lead Screws or use a Torpedo Level on the material.
When the material is loaded into the machine click Next.
1.1.9 Torch Distance
The program will ask the Operator to record the gap
distance between the Torch and the material for each
side of the material. This can be accomplished using
a set of feeler gauges and Vernier calipers. Before
beginning, verify the Gate Lead Screws are in the 12
o’clock and 3 o’clock positions.
To begin, click Move Torch. Measure the distance between the Torch and the
material by stacking the appropriate number of feeler gauges. Measure the
thickness with a caliper. This is the gap distance.
Type the gap distance into the text box and click Next. The machine will
automatically move to the next side of the material. Perform this for all four
sides.

11Bend-Tech Dragon A400 Start-Up and Training Manual
Dragon CAM Side O󰀨sets Calibration
01
1.1.10 Run Test Cuts
The machine will now perform a test cut procedure based on the Torch height values entered
by the Operator.
Click Run to begin this process.
When the process is complete, click Next.
1.1.11 Measure Test Cuts
The program will ask the Operator to measure
the distance of the left hand and right hand side
of the hole to the edge of the material.
Use the images on the interface as a reference
regarding which sides to measure. Enter the
appropriate values in the text boxes.
After performing this for sides A, B C and D, click Next.
An interface will open showing the
Side O󰀨set values for the material. The
program will use the material size and
the values entered in the Side O󰀨set
Calibration to center the holes on each
side.
To assure the calculations are correct, click verify and the machine will perform
the test cut process again. If the holes are not centered after the second test
cut click Go Back to repeat the calibration process.
If the holes are centered click Finish.

12 Bend-Tech Dragon A400
Start-Up and Training Manual
Dragon CAM Side O󰀨sets Calibration
01
1.1.12 Save Calibration
Once the calibration is nished, the program will bring the Operator back to the Tube and Pipe
Library interface. The Side O󰀨sets box will show the calibration values determined during the
Side O󰀨set Calibration process.
Click Save to record the calibration values to go along with the material. Whenever the
material is run the machine will pull the calibration values saved in this process.
Material only needs to be calibrated when it is rst entered into the Tube and Pipe
Library.

13Bend-Tech Dragon A400 Start-Up and Training Manual
Angle and Channel Material Setup
02
02
Angle and Channel
Material Setup
2.1 Angle and Channel Material Overview
In addition to round, square and rectangle tubing, the Dragon A400 is also capable of
processing angle and channel material. Bend-Tech software allows the user to design parts
and assemblies using angle and channel material. Angle and channel material designs cannot
be imported to Dragon software, angle and channel material parts can only be designed in
Dragon CAM.
2.2 Adding Angle and Channel Material
Before processing angle or channel material, the Operator will need to add the material to the
Tube and Pipe Library. After creating and saving angle or channel material, the Operator will
be directed to the Lead In/Out tab in the material settings.
2.3 Angle and Channel Material Machine Settings
Angle and channel material brings unique challenges to the Operator when trying to process
that material in the Dragon A400. The Operator must take into consideration the sharp radius
on the outside corner, as well as the di󰀨ering thicknesses of the material. It is important to
follow the steps outlined in this chapter for proper processing of angle and channel material.

14 Bend-Tech Dragon A400
Start-Up and Training Manual
Angle and Channel Material Setup
02
2.3.1 Corner Radius
It is advised that the Operator enter .015 as the corner
radius in the material dimensions when processing angle
material.
Using a value less than .015 will cause rounding issues.
Using a value greater than .015 will move the Torch closer
to the material and possibly result in the Torch contacting
the material.
2.3.2 Y-Axis (Chuck) Acceleration
It is advised the Operator set the Y Axis acceleration value to .030 to ensure the angle or
channel material is moved properly and stays secure and in position during machine operation.
Another method the Operator can use to gure Y Axis acceleration is:
Radius x 2 = Y acceleration
To set Y-Axis acceleration, on
the Bend-Tech Dragon home
interface, under Library, click Tube
Library, then click the Machine
icon. In the bottom right, in the
Machine Acceleration box, change
the Rotation (Y) value to .030 in.

15Bend-Tech Dragon A400 Start-Up and Training Manual
Angle and Channel Material Setup
02
2.3.3 Corner Rotation Extension
When processing angle and
channel material, or any material
with a sharp radius, it is necessary
to slow the Torch and give it a
larger radius as it passes over the
corner. Bend-Tech has calculated
a formula for this:
Material Thickness + Kerf Width
For example, if the Kerf Width is 0.060 in. and the material thickness is 0.25 in. the corner
rotation extension would calculate to 0.31 in.
2.3.4 Edge Cut O󰀨set
Under the Machine tab, in the Basic Settings box, set Edge Cut O󰀨set to .0625.
Edge Cut O󰀨set is the distance beyond the edge of the material the Lead In/Out
is allowed to extend when performing edge cuts. Bend-Tech has found .0625 to
be the optimal setting when processing angle or channel material.
Incorrect corner rotation extension (too close to the material or too far) could result in
loss of Torch arc.
Using a value greater than .0625 for Edge Cut Oset may cause
the Torch to lose arc. A value smaller than .0625 will result in
inconsistent cut quality.

16 Bend-Tech Dragon A400
Start-Up and Training Manual
Angle and Channel Material Setup
02
2.3.5 Lead In/Out Settings
In the Lead In/Out settings, under Edge Cuts,
set the Lead-In Type to Angle From Edge, the
Length/Distance to 0.2 in. and the Angle/Sweep to
45-degrees.
Set the Lead Out Type to Path From Edge and the
Length/Distance to 0.030 in.
Set all other values in Edge Cuts to 0 or leave at the
default value. Internal cuts can be run with typical
settings.
2.4 Side O󰀨sets Calibration
As with square or rectangular tubing, the Operator must perform a Side O󰀨sets calibration prior
to processing angle and channel material.
2.4.1 Open Bend-Tech 7X
To begin the Side O󰀨sets Calibration process, open Bend-Tech 7X. Click Dragon CAM.
2.4.2 Begin The Calibration Process
On the Bend-Tech Dragon Home Interface click Tube Library then choose the angle or channel
material to be calibrated from the Material List.
In the menu bar at the top of the same interface click Advanced.
In the middle of the interface in the Side O󰀨sets box, click Calibrate.

17Bend-Tech Dragon A400 Start-Up and Training Manual
Angle and Channel Material Setup
02
2.3.3 Disable Feature
The next interface will give the Operator the option to Disable the Side O󰀨sets Calibration
feature and use the machine’s default measurements. Bend-Tech requires performing the Side
O󰀨sets Calibration to achieve more precise results when cutting square, rectangular, angle or
channel material.
Click Next.
2.4.4 Power On The Machine
Select the machine, click Next, then assure the machine is powered on. The interface will
prompt the Operator to Start Mach by clicking the icon on the interface.
Click Start Mach.
2.4.5 Homing Procedure
The Operator will be asked to perform the machine’s Homing process. To begin the homing
process click the image in the interface.
After the homing process is complete, click Next.
2.4.6 Load The Material
The machine will ask the Operator to enter the length of the material. This will move the Trolley
into place so the Operator can load the material into the machine. Always load angle material
with one at down and one at on the left (Marker side) of the machine. If one at is larger than
another, ensure the larger at is down.
For channel material, load with the largest side down. Turn the Gate Lead Screws clockwise
until the Gate rollers are snug to the material. The material should move freely in the Gate with
no play. Ensure the Gate Lead Screws are in the 12 o’clock and 3 o’clock positions. Feed the
material into the Chuck, making sure the Chuck is adjusted so it will accept the material.
When the material is loaded into the machine click Next.

18 Bend-Tech Dragon A400
Start-Up and Training Manual
Angle and Channel Material Setup
02
2.4.7 Angle Material Spacers
When loading angle material, the Operator will need
to use a spacer to ensure the material is securely
clamped in the Chuck. This may require fabricating
a piece that ts the material. The spacer should be
the size of the material minus the thickness of the
material. The spacer should t the angle material so
it essentially creates a square.
2.4.8 Channel Material Spacers
When loading channel material, the Operator will
need to use a spacer to ensure the material is
securely clamped in the Chuck. This may require
fabricating a piece that ts the material. Channel
material will have a spacer above and below the
material.
Formula
Size of material - material thickness
For example, if the material is 2 in. angle, and is .25 thick, the spacer
would measure 1.75 in. x 1.75 in. -- [2.0 - .25 = 1.75]
Formulas
Bottom Spacer: ((Width - Height) / 2)
Top Spacer: (Bottom Spacer + (Height - Material Thickness))
For example, if the material is 3 in. x 2 in. channel, and is .25 thick, the top
spacer would measure 2.25 in. and the bottom spacer would measure .5
in. -- [(3 - 2) / 2 = .5] and [.5 + (2 - .25) = 2.25]
Width
Height
Top Spacer
Material Thickness
Bottom Spacer
Spacer
Width
Height
Material Thickness

19Bend-Tech Dragon A400 Start-Up and Training Manual
Angle and Channel Material Setup
02
2.4.9 Torch Distance
The program will ask the Operator to record
the gap distance between the Torch and the
material for each side of the material. This
can be accomplished using a set of feeler
gauges and calipers as outlined in section
1.1.7.
To begin, click Move Torch. Measure the
distance between the Torch and the material,
this is the gap distance.
Type the gap distance into the text box and click Next. The machine will
automatically move to the next side of the material. Perform this for all
sides.
2.4.10 Run Test Cuts
The machine will now perform a test cut procedure based on the Torch height values entered
by the Operator. Click Run to begin this process.
When the process is complete, click Next.
2.4.11 Measure Test Cuts
The program will ask the Operator to measure the distance
of the left hand and right hand side of the hole to the edge of
the material. Use the images on the interface as a reference
regarding which sides to measure.
After performing this for each side of the material, click Next.
An interface will open showing the Side O󰀨sets values for the material. The program will use
the material size and the values entered in the Side O󰀨sets Calibration to center the holes on
each side.

20 Bend-Tech Dragon A400
Start-Up and Training Manual
Angle and Channel Material Setup
02
To assure the calculations are correct, click verify and the machine will
perform the test cut process again. If the holes are not centered after the
second test cut click Go Back to repeat the calibration process.
If the holes are centered click Finish.
2.4.12 Save Calibration
Once the calibration is nished, the program will bring the Operator back to the Tube and Pipe
Library interface. The Side O󰀨sets box will show the calibration values determined during the
Side O󰀨sets Calibration process.
Click Save to record the calibration values to go along with the material. Whenever the
saved material is run the machine will pull the calibration values saved in this process.
Material only needs to be calibrated when it is rst entered into the Tube and Pipe
Library.