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

BOSS Saw User Manual V1.0
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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