Dragon A400 Assembly Manual

Size: px

Start display at page:

Download "Dragon A400 Assembly Manual"

Elwin Gaines
6 years ago
Views:

1 Dragon A400 Assembly Manual Crate Size: 120 L x 65 W x 80 H Machine Size (After Assembly): 372 L x 30 W x 72 H The Dragon A400 will arrive in its crate and will need to be opened with a minimum of

1 1 Dragon A400 Assembly Manual Crate Size: 120 L x 65 W x 80 H Machine Size (After Assembly): 372 L x 30 W x 72 H The Dragon A400 will arrive in its crate and will need to be opened with a minimum of two people with pry bars and/or claw hammers. The top of the crate should be removed first, followed by at least one large face of the crate as shown here. It is highly recommended to remove all four walls of the crate for easy access to the machine's parts.

Upon revealing your new Dragon A400 machine you'll notice that it's packaged into several different pieces, all of which are bolted to the base of the crate with 1/2 bolts.

2 Upon revealing your new Dragon A400 machine you'll notice that it's packaged into several different pieces, all of which are bolted to the base of the crate with 1/2 bolts. These pieces are also shrink-wrapped to prevent damage due to swaying during shipping. 2 Boxes include the Hypertherm Box (if ordered), the Chuck Housing box, the Miscellaneous Parts box, and a box containing the Chuck Head. The miscellaneous box contains the leveling feet, wrench, magnet tool, airline regulator, rail connector bolts, ethernet cable, power cord, torch barrel connector plug and cable, zip ties, and miscellaneous wires. Any zip ties attached to parts of the machine which have their tails in place indicate that those parts will be moved to a new location. Any zip ties without tails must remain in their current position. Plotting out all pieces before assembly is the best course of action.

The Unpacking And Assembly Process 3 DO NOT REMOVE THE SHRINK WRAP AND RATCHET STRAP SECURING THE CHUCK AND CABLING CONNECTED TO THE HEAD OF THE MACHINE. 1.

3 The Unpacking And Assembly Process 3 DO NOT REMOVE THE SHRINK WRAP AND RATCHET STRAP SECURING THE CHUCK AND CABLING CONNECTED TO THE HEAD OF THE MACHINE. 1.) Remove the shrink wrap and 1/2 bolts securing the rear rail section (green) and the two corresponding leg sections (pink and yellow). The head of the Dragon (red) will be removed last. Keep in mind that each location where rail sections meet will be labeled with a number to match them up easier. Those numbers are shown here, but best illustrated on the diagram on page 4 which shows the machine fully assembled. REFER BACK TO THIS IMAGE/PAGE ON AN AS NEEDED BASIS.

4 4 The image below shows the machine fully assembled with each of the numbered sections lining up with each other. They are color coded, so pay close attention to the following instructions that refer to any section with a corresponding color after the part description. Green: The machine tail. Set up with both legs already attached. Blue: A rail section meeting up with the tail #5 (green) and leg #4 (yellow). Yellow: An independent leg section supporting the blue and orange rail sections. Orange: A rail section meeting up with leg #4 (yellow) and the head #3 (red). Red: The head of the machine including lifter station meeting up with rail section (orange) and the part catcher/beak #0 (purple). Purple: The part catcher and beak meeting up with the head of the machine (red) and an independent leg section #0 (pink). Brown: An independent cable track guide section attached to rail section (blue). Gray: An independent cable track guide section attached to rail section (orange).

5 2.) Using a tin snips or similar tool, cut the banding straps off of the rails that are secured to the base of the crate (blue and orange). Next, remove all of the unsecured parts from the crate and begin to line them up where the tail of the machine will be located in your shop. 5 NOTE: The cable/belt track guide sections that are stacked onto each other on the tail section (green) of the machine can be set aside until step 13 of this manual. These are also numbered for matching up with the rail sections they belong to. The tail is the piece of rail on two legs (green). The independent rail (blue) will attach to the first independent leg (yellow). It is important to have the leg (yellow) in place before any rail section becomes attached to it.

) It s very important to attach the leveling feet (located in the parts box) before assembling each part of the machine.

6 6 3.) On the front end of the tail (green #5), start by removing the four 1/8 allen head screws from the top face of the rail as shown here: 4.) It s very important to attach the leveling feet (located in the parts box) before assembling each part of the machine. Attach the leveling feet to each leg of the machine and ensure that all of the lower nuts on the feet are positioned as low as possible, assuming that your floor in your shop is level. These leveling feet will be adjusted later to ensure a level machine.

7 5.) Slide the independent rail section (blue) into the tail (green) making sure to line up the sticker numbers with each other

Then, retrieve the bag of screws and mounts from the parts box. 6.

them through the bolt holes provided. 7.

7 7 5.) Slide the independent rail section (blue) into the tail (green) making sure to line up the sticker numbers with each other (5:5). Have another person hold the support leg (yellow) into position as this happens. Then, retrieve the bag of screws and mounts from the parts box. 6.) Using the magnet tool provided, guide the T-nut mounts into the sides of the rail and screw the 3/16 allen head screws into them through the bolt holes provided. 7.) Before connecting the independent support leg (yellow) to rail (blue), make sure to loosen up the 3/16 allen head screws on at least one side of each support leg on the tail to provide an easier fit. Do not completely remove the screws. Then, maneuver the support leg into position so that it completely supports the rail.

8.) At the front end of the independent rail (blue), loosely affix the rail to the independent support leg (yellow) using the magnet tool and allen head screws as in the previous step.

8 8.) At the front end of the independent rail (blue), loosely affix the rail to the independent support leg (yellow) using the magnet tool and allen head screws as in the previous step. Make sure that the support leg is level before tightening down any screws. You may need to tap the rail into position using a rubber mallet on the opposite end. 8 The following step is useful if you don't have access to a forklift. 9.) With the help of at least 2 other people and a 2x6 or 2x4 length of wood, prop up the heaviest end of the head of the machine (red) and a third person at the lighter end, and lift it off of the base of the crate and onto your shop floor. Make sure to move slow as the machine is top heavy. It is suggested to have a fourth person at the head of the machine to make sure it doesn't topple or tip over. NOTE: Remember to attach the leveling feet.

10.) Line up the head of the machine (red) a rail s length away from the independent support leg (yellow) and slide the head towards the rail to close the gap on the second independent rail section

9 10.) Line up the head of the machine (red) a rail s length away from the independent support leg (yellow) and slide the head towards the rail to close the gap on the second independent rail section (orange). Using the magnet tool, connect the rail section as before. Make sure all support legs are level before tightening the screws completely ) This step may require backing off the head of the machine (red) in order to fit the rail section in between the legs, so re-positioning slowly and accurately is going to be important. 12.) Once the head (red) is attached to the rest of the machine, you are free to remove the shrink wrap, ratchet strap, and the bubble wrap from the cable track, chuck trolley along with the rest of the machine and discard them.

using the 5/32 allen head screws already in their threaded slots located on the legs.

10 10 13.) Connect the cable/belt track guide sections (brown and gray) to the legs of the machine using the 5/32 allen head screws already in their threaded slots located on the legs. NOTE: The section with the large hole and grommet located on it must be placed nearest the front of the machine above the middle leg (yellow). Use the numbered stickers on the parts as a guide.

11 14.) Affix the part catcher and beak (purple) to the head of the machine using the 9/16 bolts (x4) located in the machine underneath the tool head. 11

12 15.) Retrieve the support leg for the beak (pink) and connect the leveling feet first. Then, unscrew the 3/16 allen head screws and set them aside before maneuvering the support leg (pink) into position under the beak (purple). 12

) Using a bubble or digital level, make adjustments to each of the section's leveling feet to ensure

13 13 16.) Connect the beak to the support leg using the 3/16 allen head screws and spacers provided. Make sure to level the feet before tightening all bolts and screws down. 17.) Using a bubble or digital level, make adjustments to each of the section's leveling feet to ensure that the machine is lined up correctly. This will ensure that the efficacy of your Dragon machine will be in pristine order during operations.

) Slide the clamp block into the bolt and pins at the rear of the machine.

14 18.) Remove the shrink wrap on the white X-drive belt and unroll it to the end of the machine. Make sure the belt doesn't twist and that it rides properly on top of the X-drive pulley ) Slide the clamp block into the bolt and pins at the rear of the machine. Tighten the entire drive belt by turning the rear 3/4 nut so that the distance from the belt clamp to the rear aluminum plate is exactly the distance specified on the sticker provided.

into the grommet halfway down the rail as shown here. 21.

15 15 20.) Remove the zip ties and unwrap the cable track. Roll the end of the track under itself and run the end of the cables into the grommet halfway down the rail as shown here. 21.) Affix the end of the cable track to the track guide using the 3/16 allen head screws and 7/16 nuts provided.

leading the cabling toward the control box near the front of the machine (red). 23.

16 16 22.) Using the ties in the parts box, zip tie the cabling underneath the track guide at each tie location leading the cabling toward the control box near the front of the machine (red). 23.) Connect the wiring to the control box ports according to their assigned placement. Also retrieve the air pressure regulator from the parts box and install it onto the control box along with a split airline to the lifter station at this time.

17 17 24.) Connect the power cable and ethernet cable to the ports provided in the control box. 25.) Retrieve the chuck cover from it's shipping box along with the 1/8 inch bolts (x36) for use in assembling it together.

) Locate the emergency stop button from the chuck trolley and

18 26.) Attach the front plate to the chuck housing with 10 of the bolts, then attach the grommet to the top of the housing base ) Locate the emergency stop button from the chuck trolley and disassemble is as shown. This will be re-assembled on top of the chuck housing base.

There are 16 bolts for the base in total. 19 29.

19 28.) Place the half-completed chuck housing onto the chuck trolley and affix a few 1/8 bolts to the base to keep it steady. There are 16 bolts for the base in total ) Reach into the back of the chuck housing to place the e-stop switch into it's assigned hole and re-assemble it.

20 20 30.) Finally affix the rear plate to the chuck housing and use the remainder of the 1/8 bolts to assemble it to the rest of the chuck trolley 31.) Remove any zip ties around the machine that might inhibit its movement. Zip ties with a tail are considered shipping ties and should be removed. Those without a tail are intended to secure certain elements/cables on the machine.

Also make sure to connect your air hose to the power supply and ensure that you have at least

21 32.) Install your Hypertherm torch and connect the torch barrel plug to the torch power supply, and to the control box (labeled Torch). Also make sure to connect your air hose to the power supply and ensure that you have at least PSI feeding to it. This value may change depending on your torch specifications. See your Hypertherm torch manual for additional help. 21

22 33.) Install the torch sparks shield on the head of the machine using the 3/16 allen head screws provided. NOTE: You will not have a sparks shield on machines after serial number ) Place water tray (or slug shoot) in the holder below the tool head attached to the beak.

) Lastly, The mounting brackets available for the machine can be used to

23 35.) Ensure that your plasma torch power source alligator clamp is connected to the grounding wire from the Dragon machine ) Lastly, The mounting brackets available for the machine can be used to mount the machine to the shop floor as an option. They will be used in accordance with the following picture.

Step 2: Set aside the remote on/off pendant as we will be using the Dragon software to control the machine.

24 Modifying and Installing your Hypertherm Torch For Hypertherm: 45 Amp If your Hypertherm 45 torch is brand new or unaltered, there are a few adjustments that must be made to the torch itself in order to install it onto the Dragon machine's tool head. Step 1: Remove the brass teeth from the torch itself by using a phillips head screwdriver. There are 2 screws that must be removed in this step. Step 2: Set aside the remote on/off pendant as we will be using the Dragon software to control the machine. 24 Step 3: Install the torch head into the adjustable mounting brackets on the face of the tool head plate. Note: The height of the torch tip should lie within the stroke of the engraver tip next to it. This is to ensure that the torch will not crash into large diameter tubing while the engraver is in use. The mounting brackets will then be tightened with a 3/16 inch hex wrench.

For Hypertherm: 65 Amp Installing and modifying your 65 amp torch

Follow the steps below in order to install the 65 amp torch onto

Step 1: Remove the red rubber cap at the head (if attached) and use

unscrewing the clasp attached to the air hose. (As seen in picture.

25 For Hypertherm: 65 Amp Installing and modifying your 65 amp torch is slightly different than with the 45 amp. Follow the steps below in order to install the 65 amp torch onto your Dragon machine. Step 1: Remove the red rubber cap at the head (if attached) and use a phillips head screwdriver to remove the 3 screws accessible from the head of the torch. 25 Step 2: Now, loosen the connection at the rear of the torch by unscrewing the clasp attached to the air hose. (As seen in picture.) Step 3: Then, loosen the section of the ceramic torch nearest the head, remove it and set it aside. Note: The bulk of the torch will turn; not the section nearest the head. Step 4: Finally, loosen the next ceramic section all the way and maneuver it to one side in order to slide the brass teeth out from its slot on the torch.

26 Step 5: Reassemble the torch in the order it was taken apart (minus the brass teeth), and make sure to line up the pin inside of the

Step 6: Tighten up all of the parts by screwing on the rear clasp last, then return the 3 phillips head screws to their original positions

Step 8: Install the torch head into the adjustable mounting brackets on the face of the tool head plate.

26 26 Step 5: Reassemble the torch in the order it was taken apart (minus the brass teeth), and make sure to line up the pin inside of the torch with the first ceramic section that was removed. Step 6: Tighten up all of the parts by screwing on the rear clasp last, then return the 3 phillips head screws to their original positions at the head of the torch. Step 7: Set aside the remote on/off pendant as we will be using the Dragon software to control the machine. Step 8: Install the torch head into the adjustable mounting brackets on the face of the tool head plate. Note: The height of the torch tip should lie within the stroke of the engraver tip next to it. This is to ensure that the torch will not crash into large diameter tubing while the engraver is in use. The mounting brackets will then be tightened with a 3/16 inch hex wrench.

27 27 Thank you for following this assembly guide. The next step is to contact your Bend-Tech service representative and set up your Bend-Tech Dragon software and follow through our Calibration wizard (torch only). Support Concerns or Questions: Support Team Bend-Tech LLC. Contact Info Phone: Website: Address: 729 Prospect Ave, Osceola, WI, **************************************************************************** The information transmitted is intended solely for the individual or entity to which it is addressed and may contain confidential and/or privileged material. Any review, retransmission, dissemination or other use of or taking action in reliance upon this information by persons or entities other than the intended recipient is prohibited. If you have received this in error please contact the sender by reply and destroy all copies of the original message. ****************************************************************************

Bend-Tech Dragon Assembly Manual

p.1 Bend-Tech Dragon Assembly Manual IMPORTANT: Please read before unpacking. Place shipping container in a wide open area where you will have room to work and assemble this product. Shipping The Dragon