BACA SYSTEMS BOSS User manual

BOSS Saw User Manual V1.0
5/9/2019
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BOSS Saw User Manual
Version 1.0

BOSS Saw User Manual V1.0
5/9/2019
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BOSS Saw User Manual V1.0
5/9/2019
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Table of Contents
Overview .................................................................................................................................................................................5
Description..............................................................................................................................................................................5
SAFETY.....................................................................................................................................................................................6
BOSS Saw Safety..................................................................................................................................................................7
Saw Motor Safety................................................................................................................................................................ 9
Human-Machine-Interface (HMI) .........................................................................................................................................10
Controls Tab......................................................................................................................................................................11
Menu Items...................................................................................................................................................................11
Absolute Home .................................................................................................................................................................11
Functionality .....................................................................................................................................................................13
Single Cut ......................................................................................................................................................................13
Multiple Cuts.................................................................................................................................................................13
Cross Cuts......................................................................................................................................................................14
Square ...........................................................................................................................................................................15
Add Pieces.....................................................................................................................................................................16
Separate Pieces.............................................................................................................................................................18
Cut Pieces......................................................................................................................................................................20
Extend Cuts ...................................................................................................................................................................23
Machining .........................................................................................................................................................................23
ISO.................................................................................................................................................................................24
Antivirus Software.............................................................................................................................................................24
BOSS Saw Calibration and Tool Calibration ..........................................................................................................................25
Automated Saw Diameter.................................................................................................................................................25
Master Blade Program ......................................................................................................................................................25
Base Frame Calibration.....................................................................................................................................................26
Table Origin Definition..................................................................................................................................................26
Establish Table Level and Height...................................................................................................................................26
Calculating the Table Level ...........................................................................................................................................26

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Tool Frame Compensation................................................................................................................................................26
Saw Plumb.....................................................................................................................................................................26
Saw Trim........................................................................................................................................................................26
Saw Kerf ........................................................................................................................................................................26
Saw Y Value: Opposing Line Test ..................................................................................................................................26
Saw Y Value: Measured Square ....................................................................................................................................26
Troubleshooting Calibration Issues...............................................................................................................................26
Arming and Operating BOSS Saw..........................................................................................................................................27
Starting BOSS Saw.............................................................................................................................................................27
Tilt Table............................................................................................................................................................................28
Manual moves...................................................................................................................................................................29
Using the Wireless Pendant..............................................................................................................................................30
Performing Maintenance Safely on the BOSS Saw ...............................................................................................................31
Cautions and Warnings.....................................................................................................................................................32
Smart Compensation: Saw Wear Detector Feature..............................................................................................................33
Smart Probe ..........................................................................................................................................................................33
Troubleshooting Guide .........................................................................................................................................................34
Support..................................................................................................................................................................................34
BACA Systems Technical Support .....................................................................................................................................34
Minimum Spare Parts List.....................................................................................................................................................35
Preventative Maintenance....................................................................................................................................................36

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Overview
The purpose of this manual is to describe the operations and functions of the TouchDrive software interface to the BOSS
saw machine.
This manual is intended for the BOSS Saw operator, the BOSS Saw maintenance personnel, and the BOSS Saw
supervisor.
Anyone who interacts with this machine should first read and fully understand the instructions in this manual before
proceeding.
There are many warnings and cautions to be aware of before operating this machine.
Description
The BOSS Saw is a 5-axis saw machine used to dimensionally cut slab or sheet products such as granite, quartz, marble,
and the like. The physical machine is coupled with TouchDrive and VeinMatch software applications to accomplish this
task.
Work positioning onto a slab can be accomplished with calibrated images from Digital Cameras and/or the use of Hard
Stops.
The machine is set to be a single cutting table configuration.

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SAFETY
This section contains safety instructions that must be followed to ensure safe operation, loading/unload, and
maintenance of the equipment. Everyone operating the equipment must read and understand these precautions before
operating the equipment. OSHA and state safety agency rules must be complied with in addition to those given in the
safety section and elsewhere in this manual. Applicable plant general safety practices must also be followed.
BACA Systems designed your BOSS Saw with safety in mind. Throughout this manual, safety precautions and warnings
are highlighted for specific operations. Safety precautions are also posted on the equipment. Operator and service
personnel shall pay attention to these cautions at all times.
On-site safety and engineering personnel should develop and maintain proper work instructions for this machine which
incorporate general and specific safety instructions as found in this manual.
On-site safety and engineering personnel should develop and maintain proper lockout/tagout procedures for this
equipment following applicable local requirements. If unsure of these requirements you should contact your state or
federal OSHA representatives.
Make a routine daily inspection of the entire machine before operating it. Visually check all parts of the machine for
abnormal condition. If any issue is noted report it immediately to your supervisor for immediate correction.

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BOSS Saw Safety
Never attempt to perform any maintenance functions or clean around the equipment while the system is in operation.
Safety procedures and precautions must always be observed while working on the BOSS Saw, or any part of the
installation. Service should only be done by qualified personnel.
Personnel must take extra precautions when working on electrical systems in a damp or wet area.
Use proper tools. Make sure tools are well insulated for the job.
Never bypass or alter protective interlocks or devices unless specifically instructed to do so and unless all precautions
are followed.
Make sure that all tools, parts, rags, etc., are cleared from any moving parts after servicing the equipment.
Control panel doors and junction boxes covers must be closed after servicing.
Do NOT use jumper wires across breakers or terminals. Repair any electrical issue properly before placing the
equipment back into service.
Operators must wear protective equipment when working around the BOSS Saw. Operators must wear goggles or
safety glasses to guard against spray and flying debris. Operators and others exposed to noise levels above 90dBa for
more than 1 hour must wear suitable hearing protection. Operators must protect themselves from Dust Inhalation
hazards that may exist near the machine.
BACA Systems recommends that plant/work-site safety personnel approve all safety equipment and/or requirements for
everyone working on or around the BOSS Saw.
Various warnings are displayed throughout this manual which indicate a potentially hazardous situation to be highly
aware of. Based on the geographical location where the BOSS Saw is installed and commissioned, BACA Systems will
provide all warning labels and stickers in the local language, in addition to English.

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Do not operate this equipment with personnel inside the perimeter guarding. Doing so can result in
great bodily harm including death. Make sure the machine is clear before executing a cycle!
The machine cutting table is intended for materials ONLY! Personnel should not climb, stand or
otherwise be on the cutting table. Doing so can result in great bodily harm including death. Make
sure the machine is clear before executing a cycle!
The BOSS Saw system must never be operated without the saw guard in place. Doing so can result
in materials being ejected from the saw blade which could result in injury or death.
Proper LOCKOUT/TAGOUT procedures must always be followed when servicing and/or maintaining
the BOSS Saw system. Be aware that live electrical circuits are present in the control cabinet
whenever the master disconnect is ON, regardless whether the E-Stop button is pressed or released.

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Saw Motor Safety
The saw motor is a 220V 3 phase 20hp air cooled, asynchronous electric motor. Service to this electrical motor must be
carried out ONLY by a qualified technician.
All electrical power must be LOCKED OUT/TAGGED OUT before service is to be performed.
The saw motor must NEVER be operated without the saw guard present. Doing so can result in great bodily harm or
even death.
The Saw blade should be inspected daily for cracks or damage and should be replaced immediately if any abnormal
conditions are present.
Make sure that the saw blade is attached to the saw arbor correctly and tightened properly.

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Human-Machine-Interface (HMI)
Slab Edge - This should be done before almost every type of cut function. Mostly to minimize errors.
1. START PROGRAM
2. AUTO
3. CAMERA COVER
4. Open Pylon Viewer
5. Double click on the camera name (I.e. BACA (22965708)
6. Select Auto Adjust
7. Select Continuous Shot
8. Once the picture has stabilized, Press Stop
9. Save
10. Minimize Pylon Viewer
11. Open TouchDrive
12. Close CAMERA COVER
13. Menu
14. Slab
15. TAKE PHOTO
16. Input Material Thickness
17. Delete Slab- YES
18. Confirm
19. Select the last picture taken
20. OK
21. Wait up to 30 seconds
a. The image should now be displayed
22. Now you must define the edge of the slab
a. Two Points
b. Left click just outside the bottom left corner of the slab
c. Select First
d. Left click just the outside of the top right corner of the slab
e. Select Second
i. A yellow border should now be around the edges of the slab
ii. Be sure that it is mostly outside the slab
23. MENU

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Controls Tab
Projects –Select projects from main menu
Open = opens a saved project
Save As = Saves current project
Delete Cuts = Deletes cuts and machining only
Delete Pieces = Deletes pieces only
Delete All = Deletes everything. Including the picture
Menu Items
Parameters –Primary screen that controls tooling
1. Select Parameters
2. Tables
3. Tools
4. From here, you can modify, delete, or add tools
**Must start with a COMPLETEY blank project for tooling changes to take affect**
Absolute Home

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Functionality
Single Cut
1. Select Single Cut
2. You must position the head exactly where and how you want it to start cutting
3. There are 3 ways to set the cutting limits
a. 2 point (precise)
i. Start
ii. Move the head where you want the cut to end
iii. End
b. Length
i. Length
ii. Type desired length in Length box
iii. Press Enter
c. Through
i. If slab is defined, it will apply the cut all the way through the slab
4. In either case, a cut should appear. If you get any kind of alarm, something is not satisfied.
5. Menu
6. See SEND PROGRAM for further instructions
Multiple Cuts
1. Select Multiple Cuts
2. You must position the head exactly where and how you want it to start cutting
3. There are 3 ways to set the cutting limits
a. 2 point (precise)
i. Start
ii. Move the head where you want the cut to end
iii. End
b. Length
i. Length
ii. Type desired length in Length box
iii. Press Enter
c. Through
i. If slab is defined, it will apply the cut all the way through the slab
4. In either case, a cut should appear. If you get any kind of alarm, something is not satisfied.
5. Pieces number= Number of pieces you want at that size
6. Piece Width= How wide do you want that piece
a. the cuts should update as you change the information

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7. First Cut= Yes
8. If you want additional cuts at different widths
a. ADD
b. Input new piece number and piece width
c. Repeat as needed
9. Menu
10. See Send Program for further instructions
Cross Cuts
1. Select Cross Cut
2. You must position the head exactly where you want it to start cutting
a. The blade edge and blade center must be inside the define box and/or material
b. You do not have to change the orientation of the head
i. But the blade must point in the direction you want the first type of cuts
3. There are 3 ways to set the cutting limits
a. 2 point (precise)
i. Start
ii. Move the head where you want the cut to end
iii. End
b. Length
i. Length
ii. Type desired length in Length box
iii. Press Enter
c. Through
i. If slab is defined, it will apply the cut all the way through the slab
4. In either case, a cut should appear. If you get any kind of alarm, something is not satisfied.
5. Pieces number= Number of pieces you want at that size
6. Piece Width= How wide do you want that piece
a. the cuts should update as you change the information
7. First Cut= Yes
8. If you want additional cuts at different widths
a. ADD
b. Input new piece number and piece width
c. Repeat as needed
9. Switch
a. Now you can apply cuts from a perpendicular direction
10. Steps 3-8 work the same way here
11. Menu

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Square
1. Select Square
This screen will have different options depending on if you have defined the slab or not
1. Slab Defined
The head does not need to be positioned
a. ADD
b. Piece Width= Width of pieces
c. Piece Length= Length of pieces
d. Piece Angle= affects vertical cuts only
e. Piece Number= is filled in automatically by how many it can cut
f. X Position= adjustment left or right
g. Y Position= adjustment up or down
h. Cut Angle= changes the rotation of all the pieces
2. Slab NOT defined
The head MUST be positioned exactly when you want the first left to right cut to start. And the center of the blade to
be center over where you want the first back to front cut to start.
a. ADD
b. Piece Width= Width of pieces
c. Piece Length= Length of pieces
d. Piece Angle= affects vertical cuts only
e. Number of parts 1st series= number of columns
f. Number of parts 2nd series= number of rows
a. You will have to do the math and figure out how many pieces in each type of row
g. X Position= adjustment left or right
h. Y Position= adjustment up or down
i. Cut Angle= changes the rotation of all the pieces
3. Menu
4. See SEND PROGRAM for further instructions

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Add Pieces
From the main Menu
1. Select ADD PIECES
a. Parametric
i. This menu has many different types of shapes. It is up to you to decide what and how you use
specific shapes.
ii. Rectangle will be the most common used. And the one that will be used to explain the
procedure of use.
iii. Rectangle is also at the bottom when in Parametric
iv. Click on the RED number on the left side of the piece. Input the width you desire.
v. Click on the RED number one the bottom side of the piece. Input the length you want.
vi. Preview
vii. ADD ALL
viii. See PIECE movement below.
b. File
i. USB
1. DXF files brought over on a flash drive
ii. Path 1
1. DXF files saved to- C:\Users\Public\Documents\Wintag Taglio 34\Touch\Draw
a. Cannot be changed
iii. Path 2
1. This can be changed to other folders on C:
If there are more files than what can be displayed, left click and hold near the right side of the screen. And drag to the
left. This will scroll the screen over.
iv. Click on the DXF you desire.
v. If you want everything in the file
1. ADD ALL
2. Pick INCHES
vi. If you only want certain parts, shapes, or pieces
1. MANUAL SELECT
2. Pick INCHES
3. Click on the shapes that you want
a. You must pick everything individually. If a piece has cutout and or holes, you
must also pick that shapes that are inside of it that you want to process.
4. MAKE PARTS

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2. Piece Movement
a. Select a piece
b. It will be one of 2 colors
i. Green= on slab
ii. Yellow= Not on slab
1. These colors only work if the slab has previously been defined
c. On the bottom left corner of the piece/ box containing the pieces, is a crosshair. Click and hold. Now you
can drag it around
d. On the bottom right corner of the piece/ box containing the pieces, is a radius with arrows. Click and
hold. Now you can manually rotate the piece
e. In the top left corner of the screen is the coordinate system. It will display the pieces current position.
i. Selecting either X or Y will allow you to input the specific location you want. This is a distance
from 0,0.
f. In the bottom left side of the screen is the incremental move functions.
i. The big arrows WITHOUT perpendicular lines, is the only one to use.
ii. Click the center of it to change its style
g. In the bottom right side of the screen is the incremental rotation functions.
i. The 90’s rotate 90 degrees from its current angle
ii. The arrows are for rotation in increments.
h. In the top right corner of the screen is the parameter page for the increments.
i. Press the down arrow to see the menu
ii. Change the numbers to increments you want to use.
i. Click anywhere on the piece to deselect it, once you are done moving it
i. If you don’t do this, and select another piece, you will be moving/ rotating both pieces.
j. Repeat as needed
3. FLOOD - is a visual aid.
a. Active- pieces that are not selected are more visible.
b. Deactivated- pieces that are not selected, will become invisible. So that you can see the slab
underneath.

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Separate Pieces
The slab MUST be defined to use this function
1. Select SEPARATE PIECES
2. Left click on the piece or area you want to move
3. It will find the nearest line segment, extend it to the edges of the slab, and show you the direction it will move
(with a green arrow)
a. If the blue or green arrows do not point in the correct direction, or if they are on the wrong side of the
piece. Click close to the side of the line you want to use. This will select that line and point to where you
clicked.
4. In the top right-hand corner will display the movement step. Be sure that the number on the top is larger than
the number below.
Clicked near here

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5. Press PLAY
6. The piece and yellow box should now be moved
a. Notice. The picture will not move with the piece. This is showing you where it will be AFTER the Cut,
Pickup, Move, and Drop
b. This is a protected process. It and anything programmed prior can NOT be SORTED or have anything
moved in the ISO LIST before it. So be sure to do this when you want it to happen in the ISO.
If you delete cuts, either from the ISO LIST or from PROJECTS, the slab will remain defined exactly how it was before the
deletion. If you need the defined slab to be whole again;
1. Menu
2. Slab
3. Restore
4. The slab will revert to its original shape.

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Cut Pieces
1. CUT PIECES
2. Saw Parameters
3. Check to be sure you are happy with the parameters in this page.
a. Any changes made here will NOT affect any cuts that have already been added. So, it is best to make
changes to this screen BEFORE adding any cuts!!!
4.