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TCT WebSaw Manual

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TCT WebSaw

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Summary of Contents for TCT WebSaw

  • Page 1 TCT WebSaw...
  • Page 2 Websaw Disconect Websaw Disconect Disconnect Disconnect Switch on the main power disconnect (make sure both switches are turned on). Wait for computer to boot up and open the Websaw software (located on desktop called “Websaw”). Page 1 Starting the Websaw...

  • Page 3: Emergency Stop

    Operating the Websaw Confirm that the power Confirm that the power light comes on in Websaw light comes on in Websaw Emergency Stop Emergency Stop Power Power Conveyor Conveyor Check that the “Emergency Stop”button is not engaged. Turn the power on by pressing the green “Power” button.
  • Page 4 Prox Prox If the saw carriage is up the top proximity sensor is tripped and the Websaw software will show this on the front screen as “Saw Carriage Up”. Conversely if the saw carriage is down the proximity switch will be trigged causing Websaw software to indicate “Saw Carriage Down”. The only other position the Websaw software will read is “Saw Carriage Middle”...
  • Page 5 Motion Control The TCT Websaw has two computers used for controlling the saw. One computer is a standard PC running Microsoft Windows 98. In addition to this a second computer called a “PMAC” controller is located inside the PC. PMAC is a 16bit computer running a real time OS for all motion control.
  • Page 6 Printer The Websaw uses a Matthews Jet A Mark © printer for printing on each board. The printer consists of a three parts. The pump, control unit, and print head. Text Button Text Button Printer control unit Printer control unit...
  • Page 7 Websaw Software The Websaw software is a Windows application that provides an interface for the operator of the Websaw. When upgrading the Websaw software both the PMAC microcode and Websaw software must be kept up to latest versions (see software upgrade for additional details).
  • Page 8 + or - 90 first cut first cut From within the “Cycle Status” screen all the software settings for the Websaw are easily calibrated. See “Calibrating the Websaw” for additional details. For additional details on the Websaw software see “Websaw software”.
  • Page 9 Feed Rollers The Websaw feed rollers must be at least cleaned daily to allow for reliable traction on lumber. We recommend using a steel brush with denatured alcohol for best results. Clean with soft brush daily...
  • Page 10 Oil Flow Oil Flow Control Control Pneumatics Keep oil reservoir supplied with approved pneumatic oil. Adjust pneumatic oil flow to last between 2-3 weeks. Adjust as Adjust as 1-1/4” 1-1/4” necessary necessary Roller Conveyor Maintain 1-1/4 inch parallel adjustment between the feed rollers and the conveyor. This is an average figure and may need to differ depending on your wood thickness.
  • Page 11 Worm Gear Worm Gear 1/16” 1/16” (check for oil leaks) (check for oil leaks) Overtravel Overtravel (check and lube) (check and lube) Pivot Head Check for oil leakage on worm gear. Check prox switches for tightness and maintain 1/16” gap. Using a light silicon lube mechanical overtravel switch. Grease Nipples Grease Nipples Pillow Blocks...
  • Page 12 (used to open door with no power) (used to open door with no power) Keep Clean Keep Clean Door Lock Clean door lock daily by blowing off any saw dust buildup. Keep door lock clean and lubricate with a light dry silicon. If the door lock sticks you can remove the side cover and lightly lubricate the plunger and all moving parts.
  • Page 13 Most common cause of needing adjustment is when a board is placed into the websaw and the websaw does not see the board or when the websaw keeps cutting air even when no wood is in the saw. Note the eye will not see black and may have trouble seeing dark colors.
  • Page 14 Printer The Websaw uses a Matthews Jet A Mark © printer for printing on each board. The printer consists of a three parts. The pump, control unit, and print head. Text Button Text Button Printer control unit Printer control unit...

  • Page 15: Lcd Readout

    FA=01 FC=H1 Holding down the “Flush” button use the “Text” button to change the printer settings as needed. 2. From the computer desktop open “Printer1” icon. Note make sure Websaw is not running while configuring the printer. Hyper Terminal Settings Hyper Terminal Settings Confirm your Hyper Terminal settings as in photos above.
  • Page 16 Allows you to print same thing on each board same thing on each board 4. From within Websaw chose the printing options that you would like to have printed on the board by turning the desired switch. Printer Preview Printer Preview Note from the main screen in Websaw you can preview what will be printed.
  • Page 17 Cleaning the Print Head Open the Websaw door and remove the print head. Using a soft brush dip the brush in the Matthews cleaning solution and gently wipe away the built up grime. Keep washing away the dirt until the head once again looks shiny.
  • Page 18 Websaw Websaw is a 32bit Windows application designed to give the Websaw operator an easy to use intuitive interface. Input / Output screen provides realtime sensor readings. Page 17 Websaw Software...
  • Page 19 Sends 24VDC to infeed pneumatic switch (clamp) Sends 24VDC to infeed pneumatic switch (unclamp) Sends 24VDC to infeed pneumatic switch (unclamp) Sends 24VDC to pneumatic switch to drop blade Sends 24VDC to pneumatic switch to drop blade Page 18 Websaw Software...
  • Page 20 PLCs are extremely fast running mini programs of code that run on the PMAC motion controller. They control anything time critical and start and stop the servo motion on the Websaw. Most of the time you won’t be able to see any PLCs running except 3, 5, 6, 7, 8, and 9. The other PLCs do turn on and off as required however most of the time they run to fast to actually see.
  • Page 21 Overtravel occures when the blade goes outside its safe operational range (15 to 165 degrees). When this occurs one of the three over travel switches will trip causing the Websaw to stop for safety reasons. See “First Steps Incase of Saw Malfunction” page 36 for detailed instructions on recovering from overtravel.
  • Page 22 Cycle Status screen is the location for all the behind the scenes settings within Websaw. Most of these settings are calibration settings and you should use the calibration guide for adjusting these settings. See “Websaw Calibration” page 29 for more details.
  • Page 23 Manual cut allows you to quickly design a web. By dialing in a few options within seconds you can lay out your web and then close back out to Websaw and load the file “manual cut.txt” which contains your new custom web.
  • Page 24 Settings from logon users screen Settings from logon users screen Settings from logon users screen You can manually change any value in the Websaw.ini file however you may need to restart Websaw for the settings to take affect. Page 23 Websaw Software...
  • Page 25 PMAC using Pewin32. Although this is not necessary for the operation of the Websaw it can be handy for troubleshooting. At any stage you can open Pewin32 and type in a variable to view its current value.
  • Page 26 Updating Websaw Software Updating the TCT Websaw software to the latest version requires that you have two files. One file is a Windows EXE file (Websaw.exe) and the other is a Pmac CFG file (12.5.cfg). Make sure you have both files before attempting to upgrade unless otherwise stated by a TCT representative. Note the Pmac file name will change based on the version you are attempting to update to.
  • Page 27 “Total Errors:” both are 0. If you have an error you may have a bad PMac file. Type “I5=1” and press enter key. Then type “save” and press enter key. You should now see the above message once the save command is completed. Page 26 Websaw Software...
  • Page 28 Type “enable plc 0” and press enter key. Congratulations you have now updated the PMac software and may close out of the Pewin32 Executive program. Install new Websaw.exe software. Open my computer and browse to “C:\Program Files\Websaw” as above. Rename “Websaw.exe” to “Websaw.exe.old”. Page 27 Websaw Software...
  • Page 29 Copy your new “Websaw.exe” to “C:\program Files\Websaw” as above. Congratulations you are now ready to run your TCT Websaw. First time settings: The first time you run the saw with the new software you will need to set a few settings. Follow “calibration guide to your 90 degree angle, check centerline, and board length etc.
  • Page 30 Websaw Calibration Jog wood through to determine if fence angle is correct Pick a straight board, which is the longest board that you are likely to cut with the TCT Websaw. Normally this would be a 20 foot board. Correctly riding...
  • Page 31 Select a board to cut that has a 90 degree front cut. Place the board into the saw and allow the Websaw to cut the front end of the board off. Once the front cut is made back the board out.
  • Page 32 “Angle” number using the “New Angle” selection box. Apply your settings by hitting “Save”. Exit to the main Websaw screen and Home the Blade. Note the angle settings are not set until you home the blade after making the angle change.
  • Page 33 Set Kurf Pick a board length as long as you are going to cut in the Websaw. For our example we will say 20 feet. Set the stretch/shrink factor on 0. Same Length 15/165 15/165 Cut one board 90 on the front end and 90 on the backend at say 19-10-0. Then cut a board with 15,165 degree angles on both ends of the board with the same length 19-10-0.
  • Page 34 When first setup the Websaw needs to be calibrated to cut boards the correct length. Once the calibration is set you can adjust minor length differences daily by adjusting the stretch/shrink factor on the main Websaw screen. Start by picking the longest board you would cut and select a straight board with few blemishes.

  • Page 35: Top View

    Websaw 30-150 Testing Guide The 30-150 test is a set of cuts designed to test that the TCT Websaw is cutting accurately and calibrated correctly. The test requires the saw to be perfectly calibrated for the set of boards to cut correctly.
  • Page 36 Pieces 1 and 6 are long and 2 and 5 are short. Resolution: Fence is off center towards the front of the Websaw. Adjust fence by cutting a double 45 and adjust as necessary. See “Websaw Calibration” page 31for detailed fence adjustment.
  • Page 37 Resolution: This is a combination of the fence being to far back and the blade being towards the motor. Adjust fence, check 90 degree, and then repeat 30-150 test (See “Websaw Calibration” page 31guide for detailed fence adjustment). Once you have repeated the 30-150 test you should clearly see what direction the blade needs to move.
  • Page 38 First Steps Incase of Saw Malfunction Restart the Websaw Exit the Websaw application and shutdown Windows 98. Once the screen has gone blank turn off both power disconnects and wait 30 seconds (waiting 30 seconds allows the power to drain out of the system).
  • Page 39 New Style Breakers New Style Breakers Approx 120-240 Approx 120-240 Volts AC Volts AC Volts DC Volts DC Old Style Fuses Old Style Fuses 1AMP Approx 120-240 Approx 120-240 24 Volts DC Volts DC Volts AC Volts AC Check Fuses and Breakers ( Warning use Extreme Caution by Qualified Personnel Only Check that you have power on the bottom side of each fuse and breaker and that the current is correct based on the diagram above.
  • Page 40 Make Sure E-Stop is Disengaged Make Sure E-Stop is Disengaged (turn clockwise to disengage) (turn clockwise to disengage) Check E-Stop Button Check that the E-Stop button has not been accidently pressed. Check E-Stop Check E-Stop Check for E-Stop Condition (E-Stop can be caused by 1 of 3things) 1.
  • Page 41 Check for Board Jam If wood feeds into the Websaw and then suddenly stops check and see if the wood is jamming. Go into “Motor Data” screen and check each motor axis for a “Fatal Following Error”. If a following error is found visually check that nothing is out of the normal causing the board to jam.
  • Page 42 AC - Tech Configuration ( Warning use Extreme Caution by Qualified Personnel Only Turn power on Turn power on With the cabinet door open With the cabinet door open it is necessary to use a wrench it is necessary to use a wrench to turn the power disconnect to turn the power disconnect to the on position.
  • Page 43 Change Settings Once the password is entered you will see the first setting (P01) appear on the screen. Press “mode” again to view the setting for P01. If a setting change is needed use the scroll arrows to change as needed.
  • Page 44 AC-Tech Error Codes Description & Possible Causes Fault High Temperature Fault: Ambient temperature is too high; Cooling fan has failed (if equipped). Control Fault: A blank EPM , or an EPM with corrupted data has been installed. Performa a factory reset using Parameter 48 - PROGRAM SELECTION. Incompatibility Fault: An EPM with a different parameter version has been installed.
  • Page 45 Pneumatic Ceram Valve Pneumatic valves are used to control the clamps and carriage cylinders. They require that the air have minimum water for long term operation. If maintenance is required the pilot override can be used to test the valve by bypassing the computer system (when the saw is shutdown). Make sure you are consuming oil as described on page 9 of “Maintenance”.

  • Page 46: Input Modules

    Relay The Websaw uses 4 24VDC form C relays for the ESR, MCR, SAR, and ATR relays. The diagram below indicates the open and closed state of the relay. Relay On Relay Off 24VDC Relay Sensors The Websaw has 3 differently wired proximity switches. Each proximity switch is an type NPN with an operational range of 10-30VDC.
  • Page 47 Proximity Sensor Wiring Homing Prox Overtravel Prox Top Prox (Carriage) +24VDC Off Condition Signal Common Bottom Prox (Carriage) +24VDC Off Condition Signal Common Photo Sensor (Eye) +12VDC Off Condition Signal Common Page 46 Proximity Sensor Wiring...
  • Page 48 ESR Relay The ESR relay should come on when the machine is first started. When the relay is on you should see a green light indicating it is on. If the relay is not on check that your PC is running and follow the wiring diagram below to troubleshoot.
  • Page 49 MCR Relay The MCR relay should come on when the power button is pressed. If the MCR relay does not come on follow the below diagram for troubleshooting. Common bar TB3-5 Keeps relay on once power is 24VDC pressed PS 2 Power 3AMP Overtravel Switch...
  • Page 50 SAR Relay The SAR relay turns on when the power button is pressed because it is a slave to the MCR relay. If the SAR relay does not come on follow the below diagram for troubleshooting. Common bar TB3-5 24VDC PS 2 Power 3AMP...
  • Page 51 ATR Relay The ATR relay should come on when the “blade start” button is pressed. It is the only relay that will turn off when the “blade stop” button is pressed. Note the blade will not turn without the ATR on. If the ATR relay does not come on follow the below diagram for troubleshooting.
  • Page 52 Pneumatic Valve Wiring Outfeed Infeed Unclamp Unclamp Shielding TB1-2 Wires TB3-1 Outfeed Carriage Infeed Clamp Drop Clamp I/O Modules Page 51 Pneumatic Valve Wiring...
  • Page 53 AC-Tech Wiring Diagram AC Tech Mode 25AMP AB Contactor To saw motor I/O Modules Page 52 AC-Tech Wiring Diagram...