Bend-Tech Dragon A400 Installation guide

Revision 6 | English
A400
Part 1 of 3
Startup and Training Manual
Part 1: Safety and Maintenance
©2021 Bend-Tech LLC

ii Bend-Tech Dragon A400
Startup and Training Manual
©2021 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 and Training Manual
Dragon A400
Startup and Training Manual
Revision 6
English
Original Instructions
January 2021
Bend-Tech LLC
729 Prospect Ave.
Osceola, WI 54020 USA
[phone]
www.bend-tech.com
[email protected]

iv Bend-Tech Dragon A400
Startup and Training Manual
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
Dragon software is covered by a 2-year maintenance plan from the purchase date of the
Dragon machine. After the 2-year maintenance plan is expired, the Customer can purchase
a maintenance plan. A maintenance plan 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: support@
bend-tech.com.
Limited Warranty

vBend-Tech Dragon A400 Startup and Training Manual
Any questions or concerns regarding this manual can be directed to Bend-Tech, LLC
representatives via the Dragon website, www.bend-tech.com. Click Contact in the menu bar for
communication options and send your comments to the Dragon Customer Service department.
Online Resources
• https://www.youtube.com/user/bendtech2020
• http://www.bend-tech.com/wiki7
• http://www.bend-tech.com
• https://www.facebook.com/2020ssi
• https://www.instagram.com/bend_tech
Customer Service
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 - 5:00 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 Satisfaction Commitment

vi Bend-Tech Dragon A400
Startup and Training Manual
This manual contains important statements that are called out from the regular text with an
associated signal word: “Danger,” “Warning,” “Caution,” or “Note.” Each of these signal words
is accompanied by its own icon. These signal words and icons indicate the severity of the
condition and the warning. The machine operator should familiarize themselves with these
warnings and read the statements before operating the machine.
Denitions & Examples
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
A Warning indicates there is a possibility for minor injury if the instructions are not followed
correctly.
! Danger !
Exceeding the material weight limit of the Dragon A400 can result in serious injury
to the operator and/or bystanders.
! 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.
Warnings
Example
Example

viiBend-Tech Dragon A400 Startup and Training Manual
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.
Note
A Note gives clarication or focuses on information that is critical or unique to an operation.
! Caution !
Exceeding the material weight limit can a󰀨ect performance and possibly damage
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.
Example
Example

viii Bend-Tech Dragon A400
Startup and Training Manual
Glossary
Glossary
Axis
A xed reference line used by the Dragon.
Bend-Tech 7x
Machine design software - CAD.
BOB
Breakout Board.
Material Support Lift
The Material Support Lift supports
material to reduce sag.
Chuck
Located on the Trolley, the Chuck
holds the material so it can be moved
forward, backward and rotated.
Control Box
Connects Dragon Software Suite to the Dragon.
Coolant Tray
Cools cut parts as they are produced.
E-Stop
Emergency stop.
ESS
Ethernet Smooth Stepper (Control Board).
Ethernet
System for connecting multiple
computers via a Local Area Network.
Gate
The Gate supports the material at the
front of the machine. It consists of two
sets of self-centering roller jaws.
Gate Lead Screw
Controls operation and adjustment of the Gate.
Interface
Any particular screen display generated
by Bend-Tech software.
Mach3
Machine driver software.
Parts Catcher
The parts catcher is placed at the front of
the machine to catch parts as they are cut.
Rack & Pinion
The rack and pinion gear assembly is
the method that drives the horizontal
movement of the Trolley.
Rail & Beam
The Beam is the main structure of the
Dragon A400, the rails are attached to
the beam and guides the Trolley.
Tail
The Tail is located at the opposite end of the
Head of the machine. The Tail arrives pre-
assembled. The X-Axis homing sensor, rear
E-Stop are located at the Tail of the machine.
Toolhead
Operates the Marker, Engraver and Torch.
Trolley
The Trolley rides on the Rail, and carries
the Chuck forward and backward along
the length of the Rail Support Beam.

ixBend-Tech Dragon A400 Startup and Training Manual
Contents
Contents
Limited Warranty .....................iv
Customer Service.................... v
Customer Satisfaction
Commitment............................. v
Warnings ..................................vi
Glossary ..................................viii
Contents...................................ix
01
Safety....................................... 11
1.1 General Safety Notes ............11
1.2 Safety Procedures .............. 12
1.2.1 Personal Protective Equipment
(PPE) ........................ 12
1.3 Recommended PPE for Operating
the Dragon A400 .................. 12
1.3.1 Ultraviolet Eye Protection .... 12
1.3.2 Footwear ................. 13
1.3.3 Heat-Resistant Gloves....... 13
1.3.4 General Eye Protection ...... 13
1.3.5 Hearing Protection.......... 13
1.3.6 Breather Mask or Ventilation
System ....................... 13
1.4 Operational Safety .............. 14
1.4.1 Guards................... 14
1.4.2 Machine Walkthrough ....... 14
1.4.3 Machine Operational
Movement..................... 14
1.4.4 Material Securing........... 14
1.5 Pinch Points ................... 15
1.6 Emergency Stops (E-Stops). . . . . . . 16
1.6.1 E-Stop Overview ........... 16
1.6.2 Control Screen E-Stop....... 17
1.6.3 Re-Home after an Emergency
Stop ......................... 17
17 Electrical Servicing .............. 17
1.7.1 Power Down Before Servicing. 17
1.8 Material Weight ................ 18
1.8.1 Weight Limit............... 18
1.9 Material Length ................ 18
1.9.1 Material Support Lift. . . . . . . . . 18
1.10 Plasma Torch ................. 19
1.10.1 Torch Overview ........... 19
1.10.2 Ultraviolet Light ........... 19
1.10.3 Heat .................... 19
1.10.4 Gloves .................. 19
1.10.5 Fumes .................. 20
1.11 Modications To The Machine .... 20
1.11.1 Unauthorized Modications .. 20
1.11.2 Factory Parts Kits and
Updates ...................... 20
1.12 Other Safety Information ........ 21

xBend-Tech Dragon A400
Startup and Training Manual
Contents
1.13 More Information .............. 21
1.14 Recommended Safety Guidelines . 21
02
Maintenance............................ 23
2.1 Dragon A400 Maintenance
Overview ........................ 23
2.2 Daily Maintenance .............. 23
2.2.1 Clean the Gate. . . . . . . . . . . . . 23
2.2.2 Clean the Rail ............. 24
2.2.3 Clean the Rack ............ 24
2.2.4 Check the Coolant Level ..... 24
2.2.5 Clear the Part Catcher....... 24
2.2.6 Check the Air Pressure ...... 24
2.2.7 Clean the Work Area ........ 24
2.2.8 Check the Plasma System. . . . 24
2.3 Weekly or Every 40 Hours ........ 24
2.3.1 Clean Grease and Oil Buildup . 24
2.3.2 Check Electronic Connections. 25
2.3.3 Clean Chuck and Trolley ..... 25
2.3.4 Lubricate the Gear Rack ..... 25
2.4 Monthly or 150 Hours............ 25
2.4.1 Check the Fasteners ........ 25
2.4.2 Clean and Fill the Material
Cooling System Reservoir ........ 25
2.4.3 Check the Eccentric Bearings . 25
2.4.4 Check the Emergency Stops .. 25
2.4.5 Clean and Lubricate the Racks 25
2.4.6 Check Backlash............ 25
2.5 Quarterly or 500 Hours. . . . . . . . . . . 26
2.5.1 Clean Coolant Screens ...... 26
2.5.2 Grease Pillow Block Bearings . 26
2.5.3 Comprehensive Cleaning .... 26
2.5.4 Actuators and Lead Screws... 26
2.6 Bi-Annually or 1000 Hours ........ 26
2.6.1 Clean the Chuck ........... 26
2.6.2 Check Level and Straightness. 26
2.7 Annually or 2000 Hours .......... 27
2.7.1 Check Rack Spacing ........ 27

11Bend-Tech Dragon A400 Startup and Training 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 the Startup and Training manual in its 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.

12 Bend-Tech Dragon A400
Startup and Training 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.
1.3 Recommended PPE for Operating the Dragon A400
1.3.1 Ultraviolet Eye Protection
Safety glasses with the proper shade based on the amperage of the Torch are required for
operation of the machine. It is important the operator and anyone observing the machine wear
welder’s glasses or a welder’s mask, or the machine be surrounded by a welding curtain.
Refer to Occupational Safety and Health Administration (OSHA) standards to determine proper
safety glass shading and/or welding curtain for the cutting torch amperage being used.
! 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 and Training
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.
! Danger !
The cutting torch emits ultraviolet light. Looking directly at the plasma stream can
damage human retinas.

13Bend-Tech Dragon A400 Startup and Training Manual
Safety
01
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
Parts produced by the Dragon will be extremely hot and could cause severe burns if not
handled properly. It is recommended that the operator wear heat-resistant gloves when
handling parts produced by the Dragon A400.
1.3.4 General Eye Protection
The Dragon A400 will emit sparks, plasma dust and slag during operation. Anyone operating or
observing the machine should wear the appropriate eye protection.
1.3.5 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.
1.3.6 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.
! 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.
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.

14 Bend-Tech Dragon A400
Startup and Training Manual
Safety
01
1.4 Operational Safety
1.4.1 Guards
Do not operate the machine without safety guards in place.
1.4.2 Machine Walkthrough
Perform an inspection walkthrough 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.
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 !
The Trolley,Toolhead, and Gate are pinch points. Stay clear during machine
operation.
! Warning !
Improperly secured material may cause injury.

15Bend-Tech Dragon A400 Startup and Training Manual
Safety
01
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

16 Bend-Tech Dragon A400
Startup and Training 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

17Bend-Tech Dragon A400 Startup and Training Manual
Safety
01
1.6.2 Control Screen E-Stop
There is an additional emergency stop located on the machine control screen. This E-Stop
does not cut power to any motors or outputs, but will temporarily disable any software that
is being used. This will stop any project that is being run, without disconnecting power to the
motors.
1.6.3 Re-Home after an Emergency Stop
When an E-Stop is engaged, the machine will need to be re-homed after the E-Stop is cleared
and disengaged.
17 Electrical Servicing
1.7.1 Power Down Before Servicing
Completely power o󰀨 the Control Box before handling any electrical components. Electrical
components include all motor connections, motor cables, sensors, sensor cables, emergency
stops, laser cable, and Torch cable.
! Danger !
Do not touch 120VAC components inside the Control Box without rst disconnecting
the machine from its power source.
! Warning !
Never disconnect a Motor Cable with power applied.

18 Bend-Tech Dragon A400
Startup and Training Manual
Safety
01
1.8 Material Weight
1.8.1 Weight Limit
Material weight limit for the Dragon A400 should not exceed 400 lbs. This is the maximum
weight of material the Trolley can support while still operating safely.
1.9 Material Length
1.9.1 Material Support Lift
Some non-rigid materials, or excessively long materials, can sag and cause material to raise
at the Toolhead. This introduces the danger of material contacting the Torch or damaging
the Engraver. Material longer than 10 ft. or thinner material may need to be supported by the
Material Support Lift in order to avoid contacting the Torch or damaging the Engraver.
! Danger !
Exceeding the material weight limit of the Dragon A400 can result in serious injury
to the Operator and/or bystanders.
! Caution !
Exceeding the material weight limit can a󰀨ect performance and possibly damage
the Dragon A400.

19Bend-Tech Dragon A400 Startup and Training Manual
Safety
01
1.10 Plasma Torch
1.10.1 Torch Overview
The Torch and plasma cutting device is a high-voltage system that requires extreme caution
when operating. It is recommended that the operator read the Hypertherm manual and become
familiar with the hazards of working with the machine before operating it in conjunction with the
Dragon.
1.10.2 Ultraviolet Light
The Torch emits extreme ultraviolet light which can damage human retinas. Never look directly
at the torch arc without the appropriate eye protection.
1.10.3 Heat
The 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 after cutting.
1.10.4 Gloves
Always wear insulated gloves when handling Torch consumables. Consumables get extremely
hot during Torch operation. Touching Torch consumables can result in electric shock if the
Torch is not disabled before handling.
! Danger !
The plasma arc of the Torch can cause severe injury or even death. Never
approach the Torch while it is activated and operating.
The minimum ANSI eye protection recommendations:
• Less than 40 amps - shade 5
• 41 to 60 amps - shade 6
• 61 to 300 amps - shade 8

20 Bend-Tech Dragon A400
Startup and Training Manual
Safety
01
1.10.5 Fumes
Some metals, including stainless steel, can emit toxic fumes when cut. Bend-Tech
recommends using a ventilation system with the Dragon A400 or ensure the facility has
adequate ventilation to ensure air quality meets standards and regulations.
1.11 Modications To The Machine
1.11.1 Unauthorized Modications
Performing unauthorized modications to the Dragon A400 is not recommended. Bend-Tech,
LLC is not responsible for damage resulting from modications to the Dragon A400.
Unauthorized modications include modications to the machine’s G-code that alter the factory
settings and adversely a󰀨ect the operation of the machine.
1.11.2 Factory Parts Kits and Updates
Some parts kits and update packages are manufactured and sold by Bend-Tech, LLC.
Customers may choose to install these kits and updates themselves. However, the Customer
should have a thorough understanding of the machine and the service actions being
performed. If a Customer has any doubts regarding their ability to install parts kits or update
packages contact Bend-Tech for assistance.
! 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.