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Bend-Tech Dragon A150

Troubleshooting Guide

Operator Control Panel

The Operator Control Panel allows the Operator to control the Dragon A150 machine. The

Operator Control Panel contains the ESS board and Breakout Board. The Operator Control

Panel gathers information from Bend-Tech software and sends it to the Dragon A150 machine

to perform its CNC operations. Knowing the functions of the ESS board and Operator Control

Panel can assist the Operator in diagnosing issues that may arise regarding the Dragon A150.

Reading ESS LED Status Codes

The port where the Ethernet cable

connects to the Ethernet Smooth Stepper

board inside the Operator Control Box

has colored status lights. Knowing the

meaning of the behavior of these status

lights can help the Operator diagnose

connection problems between Mach3 and

the DragonA400.

Summary of Contents for DRAGON A150

Page 1: ...A150 Part 1 of 1 Maintenance Troubleshooting Revision 1 English 2020 Bend Tech LLC...

Page 2: ...e 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 ass...

Page 3: ...0 Troubleshooting Guide Dragon A150 Maintenance Troubleshooting Revision 1 English Original Instructions September 2020 Bend Tech LLC 729 Prospect Ave Osceola WI 54020 USA 651 257 8715 www bend tech c...

Page 4: ...tenance 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...

Page 5: ...tps www instagram com bend_tech Customer Service Congratulations on your purchase of the world s best CNC plasma tube and pipe cutting machine the Dragon A150 Bend Tech LLC places great pride in custo...

Page 6: ...e machine Definitions 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...

Page 7: ...uld affect the overall procedure being performed Note A Note gives clarification or focuses on information that is critical or unique to an operation Caution Exceeding the material weight limit can af...

Page 8: ...ail E Stop Emergency stop ESS Ethernet Smooth Stepper Control Board Ethernet System for connecting multiple computers via a Local Area Network Front Gate The Gate supports the material at the front of...

Page 9: ...hain Maintenance 17 Reversing Cut Direction 20 Editing Polyline Resolution 21 Adjusting Torch Position 22 03 Toolhead 23 Toolhead 23 Adjusting the Toolhead Trolley 24 Remove the Toolhead 24 Toolhead R...

Page 10: ...rection 53 Additional Trolley Set Screws 54 Chuck Alignment 54 Aligning the Chuck 54 12 Center Support Lift 57 Center Support Lift 57 Center Support Lift Air Cylinder 58 Center Support Lift Air Pressu...

Page 11: ...icate Homing Switch is Triggered 68 X and A Axis Limit Switch Failure 69 Replacing The A Axis Limit Switch 69 Replacing the X Limit Switch 70 16 Mach3 71 Mach3 Machine Driver Software 71 Installing Wa...

Page 12: ...xii Bend Tech Dragon A150 Troubleshooting Guide Contents...

Page 13: ...ope of this guide please contact Bend Tech service support bend tech com or 651 257 8715 Dragon A150 Manufacturing Differences The Bend Tech Dragon A150 is continuously being updated and refined Becau...

Page 14: ...n have a solution ready before we even pick up the phone 1 If there is a problem with a specific part design or nesting project open the project before sending a Support Session then keep the project...

Page 15: ...e Action Copes cuts not on same rotation Incorrect backlash Check set screws on X and Y axis perform backlash correction in Dragon software X axis chain and or drive gear set screws Check X chain tens...

Page 16: ...d chains are tight and adjusted and Backlash Correction is performed in Bend Tech Dragon software will maintain cut rotation accuracy Tools Required 3mm Allen wrench 3 32 in Allen wrench 5 16 in Allen...

Page 17: ...Use a 5 16 in Allen wrench to remove the Trolley cover 2 Using a 5 16 in Allen wrench remove the X Chain Cable Cover by removing the two screws 3 Using a 5 32 in Allen wrench on the large sprocket an...

Page 18: ...e the Operator will be required to re tension the chain Using a in wrench loosen the Y motor mount bolts on the bottom of the Trolley just enough to slide the motor and mount to the outside tensioning...

Page 19: ...ench on the nut inside the Rail and using a second in wrench tighten the bolt one full turn Reinstall the X chain cable cover 8 Ensure tension is set correctly on the X chain and cable combination Loc...

Page 20: ...rection throughout the job process eliminates any backlash that can occur in the chain drive system since the machine is always keeping tension in the system 1 In Bend Tech Dragon software under Creat...

Page 21: ...ate material chosen in the Material List click the Advanced icon in the menu bar at the top of the interface 2 Default Polyline Resolution settings will read as follows Max Length 0 1 Max Angle 5 Max...

Page 22: ...ieving more accurate cuts 1 Ensure Torch is centered on the material 2 Move the A axis left or right 050 in 3 Run a test cut from this new start position and assess cut rotation If the cuts are more a...

Page 23: ...Jagged Cuts Toolhead trolley out of adjustment Adjust the Toolhead trolley so the Toolhead rides smoothly along the rail with no play A axis mount bearings out of spec Check Toolhead play on A axis m...

Page 24: ...ll be resting on the Engraver tensioning spring mount at the top of the Toolhead Place a in wrench on the nut on the backside of the Engraver tensioning spring Holding the nut secure with the in wrenc...

Page 25: ...Reassemble the Toolhead by reversing the order of disassembly Toolhead Rail Leveling The Toolhead Rail For most accurate cutting the Operator should ensure the Toolhead rail is level Leveling the Tool...

Page 26: ...pically the Operator can adjust the bearings to bring them back into spec This can be achieved in one of two ways Method 1 After removing the Toolhead loosen the bearing stanchions and insert a small...

Page 27: ...s drive chain Slide the gear off the shaft 3 Clean the A axis drive motor shaft and the A axis drive gear with Loctite Cleaner Degreaser or similar cleaner such as acetone 4 Apply Loctite 609 Retainin...

Page 28: ...28 Bend Tech Dragon A150 Troubleshooting Guide Toolhead 03...

Page 29: ...herm unit Customers who choose to use a plasma machine other than Hypertherm will not receive the same level of technical support Please refer to the Bend Tech Dragon A150 Plasma Cutting Guide for mai...

Page 30: ...Torch lead clear of the Ethernet cable The Torch lead can cause connectivity issues if routed close to the Ethernet cable Some models of the Dragon A150 are equipped with cable loops pre installed for...

Page 31: ...Tech can provide a mounting tab for the Torch ground cable or the Operator can fabricate a ground cable mount using 3 16 in steel 4 Place the mounting tab over the pillow block bearing mounting hole...

Page 32: ...ssible the Torch relay can fail In the case of a failed Torch relay the Torch will fail to ignite If the Torch is not functioning it will be necessary for the Operator to check the Torch relay inside...

Page 33: ...e Torch 04 6 With the Torch wires secure in the relay reassemble the Control Box Reattach the Control Box cover plate If the Torch still does not fire it is possible the relay has failed Contact a Ben...

Page 34: ...34 Bend Tech Dragon A150 Troubleshooting Guide Torch 04...

Page 35: ...broken Symptom Cause Corrective Action Engraver air cylinder not extending all the way Air pressure too low Increase air pressure to air cylinder Too much friction in actuation cylinder Lubricate the...

Page 36: ...36 Bend Tech Dragon A150 Troubleshooting Guide Engraver 05...

Page 37: ...f in order to fit in the Marker holder Bend Tech recommends wrapping a piece of duct tape or similar tape around the marker to help hold it in the Marker holder Ensure the Marker holder is clean Keep...

Page 38: ...38 Bend Tech Dragon A150 Troubleshooting Guide Marker 06...

Page 39: ...the Laser wire to come loose from its connection to the 4 Relay Module To check the Laser connection access the Control Box as outlined in the Control Box section In the 4 Relay Module in the D2 Modu...

Page 40: ...screw that secures the Laser to the Torch mounting collar Depending on the age of the machine this may require a 3 32 in Allen wrench or 5 16 in wrench 2 Remove the Laser remove the Laser cord from t...

Page 41: ...y loosening the thumb screws and turning the outer ring by hand The inner rollers are adjustable to fit the diameter of the given material loaded into the machine Ensuring the inner rollers are adjust...

Page 42: ...f its proximity to the Torch the Gate is subject to a high level of slag debris and plasma cutting dust and fumes It is important to keep the Gate clean to ensure it is operating as designed Clean the...

Page 43: ...socket and ratchet to remove the nut from the mounting bolt Repeat for the second bolt 4 Use a 3 16 in Allen wrench to remove the Allen head cap screws at the top of the Gate assembly On some Gate des...

Page 44: ...44 Bend Tech Dragon A150 Troubleshooting Guide Gate 08...

Page 45: ...properly the Trolley should move along the Rail smoothly with no play or bind anywhere along its travel If there is play in the Trolley the Operator will be required to adjust the Trolley assembly Tr...

Page 46: ...y s roller system 3 With one hand push up on the lower half of the Trolley roller system Using the other hand tighten the four socket cap screws while holding steady upward pressure on the lower half...

Page 47: ...it or X Home when calibrating the machine The Operator can test the X limit switch by depressing it manually if the limit lights up in Mach3 Diagnostics the X limit switch is operating properly Replac...

Page 48: ...48 Bend Tech Dragon A150 Troubleshooting Guide Trolley 09...

Page 49: ...g Chuck Jaws The Chuck jaws can be removed without removing the Chuck from the shaft 1 Use the Chuck key to open the Chuck jaws as far as possible When the Chuck jaws stop moving the Operator should b...

Page 50: ...g the location of each jaw so it can be reinstalled in its original location 3 Clean the Chuck with brake cleaner spraying the inner mechanism as much as possible If the Operator has access to a parts...

Page 51: ...atter Cause X chain drive gear Install revised X chain drive gear check X drive chain tension ensure anti chatter kit is installed Y motor not holding torque Y drive chain tension too tight Adjust Y c...

Page 52: ...he Trolley cover 2 Using a 5 16 in Allen wrench remove the X Chain Cable Cover by removing the two screws 3 Using a 5 32 in Allen wrench on the large sprocket and 3 32 in Allen wrench on the small spr...

Page 53: ...y by first tightening the nut and bolt combination by hand Hold the nut inside the rail with one hand while turning the bolt head with the other With the bolt and nut combination finger tight place a...

Page 54: ...t will be necessary for the Operator to bring the Chuck back into alignment Aligning the Chuck 1 Jog the Chuck to front of machine approximately 1 ft behind the Gate 2 Using a 5 16 in Allen wrench rem...

Page 55: ...ad in through the bottom of the Trolley plate Ensure the material remains in the centered position 11 Using two in wrenches tighten Pillow block mounting bolts then tighten another turn 12 Pull the Y...

Page 56: ...56 Bend Tech Dragon A150 Troubleshooting Guide X and Y Axis Maintenance 11...

Page 57: ...and Gate and assists in preventing potential Torch collision The Center Support Lift is operated via compressed air It uses a mechanical push pull switch to engage and disengage from the material Sym...

Page 58: ...pport Lift on the material the Operator is required to pull the switch out manually As the Trolley moves forward along the Rail during its job process it will contact the switch depressing the switch...

Page 59: ...rator will be required to remove the Cover Plate to access the Control Box Accessing The Control Box Using a in deep well socket or wrench remove the four nuts that secure the Control Box Cover Plate...

Page 60: ...e and resolve problems associated with the unit Reading the LED lights and knowing the meaning of them as well as being able to identify other issues associated with the unit are key to initiating suc...

Page 61: ...tion If the motors on the machine are not operating properly Bend Tech recommends adjusting the screws to the 8 o clock position Tools Required 3 8 in wrench Phillips screwdriver small 1 Power off the...

Page 62: ...the aluminum plate holding the orange wiring connectors Ensure no wires come loose from their respective connectors 3 Remove the four Phillips head screws at each corner of the Gecko drive Hold the nu...

Page 63: ...tware and sends it to the Dragon A150 machine to perform its CNC operations Knowing the functions of the ESS board and Operator Control Panel can assist the Operator in diagnosing issues that may aris...

Page 64: ...mmunication N A Green Right Two quick blinks Waiting for communication with Mach3 This could be a normal delay in communication or it could be an issue with connectivity One second on one second off B...

Page 65: ...board The Ribbon Cable serves as the output from the ESS to the Gecko Drive If it is not making a complete connection it can cause the machine to operate sporadically or fail to operate ESS Failure T...

Page 66: ...s are running on the computer Right click on the Task Bar at the bottom of the screen click Task Manager click More Details at the bottom of the Task Manager window Scroll through the Task Manager to...

Page 67: ...d so when a switch is triggered it breaks the loop Symptom Cause Corrective Action A limit switch broken The machine lost power and the Toolhead crashed against the A axis limit switch Replace the A l...

Page 68: ...of that switch to shorten the loop Refer to the diagram for reference The Operator can also use a multimeter to test each loop for continuity If a particular loop shows no continuity it is likely the...

Page 69: ...it in yellow in Mach3 X and A Axis Limit Switch Failure The X and A axes on the Dragon A150 use micro switch style limit switches The limit switches are triggered when the Toolhead assembly makes phys...

Page 70: ...olhead will be resting on the Engraver tensioning spring mount at the top of the Toolhead Place a in wrench on the nut on the backside of the Engraver tensioning spring Holding the nut secure with the...

Page 71: ...il When the switch contacts the head of the button head cap screw it signals the X limit or X Home when calibrating the machine 1 Remove the outer plastic cover from the X axis limit switch 2 Note the...

Page 72: ...72 Bend Tech Dragon A150 Troubleshooting Guide Limit Switch Operation 15...

Page 73: ...e Ethernet port on the computer needs to be configured for use Typically the software will display a wakeup error message that reads The ESS did not respond to the wakeup message If this is a new prof...

Page 74: ...l also read If you unplugged the USB cable while Mach was still running then that is likely the cause Symptom Cause Corrective Action Mach3 Lost Communications Bad Ethernet Cable Replace Ethernet cabl...

Page 75: ...If power is good it is likely a bad ESS board Symptom Cause Corrective Action Homing switch active in Mach Homing switch triggered homing switch failed Check homing switches re route homing switch wi...

Page 76: ...re E stops are active Machine not plugged in not getting power Ensure machine is plugged in and has power Axis resting on a homing switch Ensure no homing switches are triggered Breakout Board has los...

Page 77: ......

Page 78: ...Bend Tech LLC 729 Prospect Ave Osceola WI 54020 1 651 257 8715 sales bend tech com www bend tech com...

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