Dragon Wholesaling A400 User manual

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Dragon - A400 Operator's Manual
Available in 12 foot or 24 foot models.
Bend-Tech Dragon Support Team
Bend-Tech LL .
Phone: [phone]
Address: 729 Prospect Ave. Osceola, WI, 54020
E-Mail: [email protected]
[email protected]
Website: http://www.bendtechdragon.com

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Table Of Contents: Pg. #
Introduct on and Warranty 1
•Included n th s Manual 1
Safety Procedures 2-5
•Personal Protect on Equ pment (PPE) 2-3
•P nch Po nts 3
•Emergency Stop Buttons 4
•General Safety Gu del nes 4-5
Mach ne Capac t es 6
Cutt ng Speed Recommendat ons 6
•Torch Manual Charts 6-7
•H gh Speed Vs Low Speed Dross 7
•Consumable L fe 7
Cut Charts 8-11
Mach ne Components 12
Mach ne Uncrat ng and Installat on 13-14
•Safety And Inspect on 13
•Heavy L ft ng 13
•Placement n the Shop 13
•Level ng and Anchor ng 14
•Vent lat on 14
•Hum d ty and Temperature 14
•A r Requ rements 14
W r ng D agrams and Paths 15-17
•Mach ne Control Box 15
•Torch Cable Plug 16
•Ground W r ng Path 17
•A r Hose Connect ons 18
General Mach ne Operat ons 19-25

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Table Of Contents: Pg. #
•Power ng On/Power ng Off Sequence 19
•Hom ng the Mach ne: When? 19
•Us ng the Mach ne Controller 20-23
•L brary Setup 20-24
•Gate Operat ons 25
FAQ 26-27
DRAGON Preventat ve Ma ntenance Gu de 28-30
Thank you and Contact Informat on 31

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Introduct on:
•Bend-Tech LLC. greatly appreciates your new purchase of the Dragon – A400 1 ' or
4' machine. We stand behind our promise to you in offering our best support in
helping you along with getting to know your machine and producing quality parts
efficiently and in a timely manner.
•With that in mind, there are certain procedures that we must first set in place in order to
get your machine up and running smoothly., so we appreciate your patience during this
period. We've taken measures at our shop location to ensure that your machine is
capable of operations at your shop and have calibrated it as much as possible to
provide you a seamless setup experience.
Included n th s manual:
•Safety Procedures
•Installation Information
•Diagram of Machine Components
•Machine Dimensions and Capacities
•Wiring Diagrams and Paths
•Setup and Operating Procedures
•Scheduled Maintenance Procedures
•Technical Support Information
Warranty:
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•Your Dragon machine has a 6 month electronics and hardware limited warranty.
Defective or faulty parts identified on your machine within this time period after
purchase will be replaced at no charge and shipped to your location.
•After the 6 month warranty period, replacement parts can be purchased through
Bend-Tech C. and shipped to your location at your discretion.
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•Your Dragon software is always improving to ensure the best capabilities for
your company and others. Your maintenance plan for software updates and
service is good for 2 years from the Dragon purchase date.
•After this 2 years, an annual software maintenance plan is available to purchase.
This will ensure consistent updates to your software product and keep you in
the newest capabilities possible. Your Bend-Tech C. sales personnel will
contact you 1 month to 2 weeks before your maintenance plan expires to ask if
you'd like to re-apply for an annual subscription.
•YOUR WARRANTY MAY BECOME VOID OR IMITED IN THE EVENT THAT YOU
MAKE SIGNIFICANT HARDWARE CHANGES TO THE MACHINE.

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Safety Procedures:
IMPORTANT: P EASE READ THIS OPERATOR'S MANUA IN ITS
ENTIRETY TO ENSURE YOUR SAFE AND EFFICIENT OPERATION OF
YOUR DRAGON A400 MACHINE.
Personal Protect ve Equ pment (PPE):
•Metal working can be dangerous if safe and proper operating procedures are not
followed strictly. As with all machinery, there are certain hazards involved with the
operation of the product. Using the machine with respect and caution will considerably
lessen the possibility of personal injury. However, if normal safety precautions are
overlooked or ignored, personal injury to the operator may result.
•Safety equipment such as welder's masks, dust masks, heat resistant gloves, steel
toe boots and hearing protection can reduce your potential for injury. But even the
best guard won’t make up for poor judgment, carelessness or inattention.
A WAYS use common sense and exercise caution in the workshop. If a
procedure feels dangerous, don’t try it. REMEMBER: Your personal safety is
your responsibility.
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1. DO NOT look directly into the plasma stream emitting from your plasma
torch. A WAYS use protective eye wear when running the torch on your
Dragon machine. There are also sparks, plasma dust and debris that
could cause damage to your retinas. Failure to adhere to this simple
precaution could cause temporary or permanent eye damage.
. DO NOT use your bare hands to pick up tube or pipe newly cut from the
torch! The material will be incredibly hot, even after it has been doused in
water. A WAYS use heat resistant gloves, or thick enough gloves that will
prevent your hands from the dangers of scolding hot material. It would
not be uncommon to incur second or even third degree burns from hot
materials.
3. Plasma dust and debris contain toxic fumes, so we strongly suggest
either a ventilation system in your shop or the use of breathable face
masks for anyone operating the Dragon machine. Failure to do so when
in close proximity to the machine can result in respiratory illness or
other complications.

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4. Hearing protection is recommended around loud machinery. Although
this machine isn't particularly noisy, ear protection may be necessary for
some operators with pre-existing hearing problems.
5. A WAYS wear protective footwear while loading and unloading materials
into the Dragon machine. We recommend steel toe boots to minimize the
chance of personal injury or dismemberment.
KEEP YOUR HANDS AND OTHER APPENDAGES AWAY FROM THE P ASMA
TORCH WHI E THE MACHINE IS POWERED ON. P ASMA EMITTING ONTO THE
SKIN CAN CAUSE SERIOUS INJURY, DISMEMBERMENT OR EVEN DEATH.
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P nch Po nts:
•Working with machinery in general, keep in mind that there is no
possible way to prevent every chance to incur an injury. That being said,
we do stress the use of COMMON SENSE once again.
•Pinch points on this machine are evident as there are many moving parts and the
operator is encouraged to use caution during operation. Certain locations that we
consider pinch points are located in the following diagram.

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Emergency Stop Buttons:
•It is because of pinch points and the possibility of serious bodily
injury that each Dragon machine comes equipped with 4 E-Stop
buttons located on different sections for your safety and
convenience.
•2 are located on each side of the head, 1 is located on the top side
of the chuck cover and 1 is located on the tail of the machine as
well.
•We strongly advise you to become familiar with the locations of these emergency stops
and what they will do when pressed.
Pressing an Emergency Stop button WI :
1. Stop every axis of the machine from moving by locking up the motors.
. Force the operator to disengage the emergency stop button afterward by
twisting it.
3. Force the operator to home the Dragon machine before next use.
Pressing an Emergency Stop button WI NOT:
1. Cause the torch to stop firing. It WI complete its currently assigned action.
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General Safety Gu del nes:
1. DO NOT jog any axis at full speed beyond its limit. You will experience a crash.
. Keep children and unqualified persons away from the machine.
3. Keep your workstation around the machine clear of debris, cables, tools, etc.
4. Keep body parts away from the working parts of the machine during operations.
5. Keep body parts away from the engraver and plasma torch during operations.
6. DO NOT operate this machine under the influence of alcohol or other illicit substances.
7. Wear your PPE at all times during the operation of this machine.

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8. Use COMMON SENSE.
9. Keep flammable liquids and other hazardous materials away from the machine
and plasma torch.
10.Beware of the risk of electric shock. DO NOT touch loose wires with your bare
hands. BE SURE to always power off the machine and disconnect it from the main
power source before working with or accessing the electronic components on the
machine. Although many of the wiring components only output 5v of electricity, others
inside the control box can output up to 1 0v.
-Refer to your plasma torch manual for electrical safety precautions for your torch system.-
11. DO NOT OVER OAD your machine's capacities. Your Dragon machine can rotate the chuck
at an excess of 00 inches per minute (IPM), but not assuming an extreme material weight . It
is important to refer to the capacities list (located on pg. 6) to ensure that you do not exceed
speeds and weights designated for your machine.
1 .DO NOT wear loose fitting clothing or dangling jewelry that may get caught in moving
parts on the machine.
13.BE AWARE of sharp edges on your material. The plasma torch on your machine can create
sharp and jagged edges so always use gloves when handling material and be sure to deburr or
chamfer sharp edges if necessary.
14.DO NOT make adjustments or alterations to your machine if you don't now what you're
doing. Consult a Bend-Tech Representative before ma ing changes that will affect the way your
machine operates. Not only could you cause your machine to crash, or increase the ris of
personal injury, but you may void your machine warranty and incur limited support from Bend-
Tech LLC. as a result.
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Mach ne Capac t es:
Descr pt on 24 Foot Mach ne 12 Foot Mach ne
•Machine Travel Length: 94" (unlimited when using pass
through chuck)
144” (unlimited when using pass
through chuck)
•Tube Size (Outer
Diameter):
-Round: 0.5" to 6.0" diameter
-Square: 0.5" to 4.0" width
-Rectangle: 0.5” to 4.0” width X
0.5” to 4.0” height
-Round: 0.5" to 6.0" diameter
-Square: 0.5" to 4.0" width
-Rectangle: 0.5” to 4.0” width X
0.5” to 4.0” height
•Tube Weight: 400 lb maximum 400 lb maximum
•Machine Weight: Approx. 1300 lb Approx 1000 lb
•Footprint: 37 "L x 30"W x 7 "H 8”L x 30”W x 7 ”H
•Speeds: 1,500" per minute rapid travel 1,500" per minute rapid travel
•Cutting Speeds: Varies by material and cutting
amperage – See chart below.
Varies by material and cutting
amperage – See chart below.
•Material Center
Support:
Approx. 4.0” roller for up to 4.0”
square or 6.0” round tube
Not Included
•Machine Power 110V, Single Phase, 10A 110V, Single Phase, 10A
Cutt ng Speed Recommendat ons:
•The charts (located on pages 8-11) are meant as an option for you to log your
personal values for feed rates and amperage based on the knowledge that
changes will vary depending on material type, wall thickness, shape of material
and other factors.
•Differences in consumables, torch capacities and shop environment can change
your inputted settings from their originals.
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Torch Manual Charts:
•Regardless of your manufacturer of plasma torch, there will be cutting charts
located in your torch manual. We suggest using these cutting charts for entering
your speed information into our software, but with a few things in mind.
1. When entering speed values, you must consider the rotational axis of your new
machine and decrease the speed and amperage settings on your torch in the case that
your cut quality is less than desired. The Dragon machine can cut round material at
higher speeds because it can rotate the tubing in a single fluid motion.

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. Square material must be cut at a slower speed. This is because the rotational
axis must rotate in increments of 90 degrees and so it is forced to slow down even
more around the corners of the material.
3. Speeds and amperage settings should be entered on the low end of the spectrum for
optimal quality when operating this machine. (Ex. Your torch suggests 280 ipm and
65A you should divide these values by half to increase cut quality).
H gh Speed Vs Low Speed Dross:
An example is provided below showing how speeds can affect the level of dross on your cuts.
Credit: Hypertherm Inc. 2017; https://www.hypertherm.com/en-US/customer-support/getting-the-most-from-your-
products/cut-quality/too-much-dross/?region=NART
Please refer to your torch manual for further explanation and instruction.
Consumable L fe:
•Although your torch consumables are not always the culprit for badly executed cuts,
they serve you the best when they are new and not worn out. The more often they are
used, the more widened the hole for the plasma stream becomes which will decrease
your cut quality overall. Because of this, we suggest changing them as needed.
•Increase your torch life along with the life of your consumables by installing an air filter
and an air dryer onto your torch power source. (More is mentioned about this on Pg.
14 of this manual.)
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Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
**FOR YOUR PERSONAL USE**

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Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
Round Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
**FOR YOUR PERSONAL USE**

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Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Qual ty)
**FOR YOUR PERSONAL USE**

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Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
Square Mater al
(Th ckness/Type)
Amps
(30/45/65)
Notes Feed Rate Range
(For Speed)
**FOR YOUR PERSONAL USE**

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Mach ne Components:
A-Axis Drive -Controls the vertical movement of the toolhead.
Z-Axis Drive -Controls the horizontal movement of the toolhead.
X-Axis Drive -Controls the front and back movement of the chuck trolley.
Y-Axis Drive -Controls the rotational axis of the chuck.
Beak -Supports the part catcher. Extends 5' past the machine head.
Part Catcher -Catches the parts cut off by the machine.
Slug Shoot -Catches drop sections of the nesting project along with small parts.
Water Tray -Catches and cools drop sections and small parts.
Front Gate -Secures the material at the machine head.
Sparks Shield -Shields operator and other tools from plasma sparks and debris.
Toolhead -Moves tools vertically and horizontally during operations.
Chuck -Clamps and rotates material.
Chuck Trolley -Feeds material to the machine head.
Control Box -Holds the inner electronic components for the machine.
Lifter Station -Supports material from its position halfway along the rail.

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Mach ne Uncrat ng and Installat on:
Safety and Inspect on:
•WARNING: SUFFOCATION HAZARD! Immediately discard any plastic bags,
wrapping and packing materials to eliminate choking and suffocation hazards to
children and animals.
•Inspecting your machine is an important and necessary measure to ensure that you
have received your machine with all of its components. Be sure to contact a Bend-Tech
LLC. Representative in the case that you are missing anything, or your machine has
incurred damages during shipping.
•If any parts are missing, DO NOT plug in the power cable, or turn the power switch on
until the missing parts are obtained and installed correctly.
•Installation of your machine raises a few questions: Can I lift these heavier machine
sections? Where will I put the machine? Is my shop floor level enough? Etc.
Here are some answers from our specialists.
Heavy L ft ng:
•Certain sections of the machine are going to be heavier than others and will require
the use of another set of hands or a hand truck/dolly to maneuver off of the shipping
crate. We have a recommended method of moving these parts illustrated in our
Assembly Manual (sent separately as a link in the Setup Checklist).
•CAUTION: Always be sure to lift with your legs and not your back. Be sure to use
common sense and recognize when sections of the machine are too heavy to lift
without another person or without the use of a forklift. DO NOT attempt to uncrate
this machine on your own.
•CAUTION: The machine legs and other components may have SHARP EDGES.
Wear protective gloves and steel toe boots to protect your hands from cuts and your
feet in the event that you drop a machine section on your foot.
•BE AWARE of TOP HEAVY sections of the machine. It is recommended to have one
person strictly dedicated to maintaining the balance of machine sections during the
uncrating process.
Placement n the Shop:
•The best location to place your machine is going to be completely up to you, but be
sure to consider the machine dimensions (on pg. 6 of this manual) and keep in mind
the length of tubing/parts that will be ran on the machine.
•It should also be noted that electrical interference can be caused due to a close
proximity to other machinery, so distance from other shop equipment is
recommended.

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Level ng and Anchor ng:
•This product comes equipped with leveling feet to ensure that your machine sections
make up for the different heights and slopes of your shop floor and anchoring
brackets so that you can anchor your machine once the machine is leveled. It is highly
recommended to level the machine during the assembly process and anchor it to the
floor afterwards to maintain stability.
(See the Assembly Manual for illustrations).
•Once the machine is positioned and leveled, anchor it to
the floor, as shown in the diagram, using bolts and
expansion plugs or sunken tie rods that connect through
holes in the base of the stand.
Vent lat on:
•WARNING: Toxic fumes and plasma dust are dangerous to inhale and requires some
form of ventilation, especially in close quarters. In many cases, you can simply keep
your shop door open near the machine, but we highly recommend a ventilation fan or
shaft above the machine head to expel the fumes that are emitted.
Hum d ty and Temperature:
•Locations where humidity levels and temperatures are high, we recommend an air
filter and an air dryer to increase the life of your torch and consumables as well as to
increase the quality of your cuts.
•In extreme cases, the plasma torch will not even fire without an air filter and dryer.
A r Requ rements:
•It is important when connecting air hoses that the proper PSI is being fed to our to your
machine. All plasma manufacturers include minimum air flow and pressure
requirements in the owner’s manual.
•The suggested air pressure should be anywhere between 100-120 PSI as it's being fed
to the Control Box of the machine.
•There are air regulators for the pressure to the engraver which are preset. If they are
ever changed for any reason, the defaults are shown in the image below. The left
regulator reading typically between 70-80 and the right reading typically between
5-7.
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W r ng D agrams and Paths:
WARNING: DO NOT attempt to remove any wires from this
control box while the machine is plugged in and powered
on. You risk causing permanent damage to the cables and
their plugs.
Mach ne Control Box:

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Torch Cable Plug:
•This is for your reference only. These illustrations will not always be necessary, but if
they are, consult your Bend-Tech LLC. Representative for assistance. DO NOT attempt
wiring or re-wiring of these components unless you are a licensed electrician or have a
general knowledge of electrical processes.
*Wire #4 would then be located in Pin 1 .
**Contact your Bend-Tech LLC. Representative to obtain further wiring schematics if needed.

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Ground W r ng Path:
•The grounding path for this machine should not be altered or otherwise changed in any
way unless by an licensed electrician or by someone who has an expert level
knowledge of electrical processes.
•This grounding wiring must be setup in the manner expressed below to ensure the
proper grounding of your plasma torch current. If this wiring is compromised in any
way, your plasma torch may not fire, or may attempt to ground the current to a different
location potentially causing damage to your machine, personnel or surrounding
objects/machinery.
•The grounding cable end located inside the chuck housing will be routed to the rear
pillow block to ground to its bearing filled with dielectric grease. See our Preventative
Maintenance Schedule at the end of this operator's manual for maintenance.