ALhp User Manual

ALhp CNC User Manual
For
Whitney 647

CNC User Manual

Version 2.0 (23 Jan 2007) Page i

Information in this documentation is subject to change without notice. Reproduction or transmission of any part of this
documentation in any form or by any means without the express written permission of Altronics Service, LLC is strictly prohibited.

Altronics Service has taken best efforts to ensure the accuracy and integrity of the information contained in this documentation.
Altronics Service makes no representation of guarantee, express or implied, with regard to the completeness or accuracy of the
information contained in this documentation, and cannot accept any legal responsibility or liability for any errors or omissions that
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2008 Altronics Service, LLC. All rights reserved.

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All other product names are either registered trademarks or trademarks of their respective owners.

Intellectual Property. All Intellectual Property, as defined below, and relating to the AL or ALhp, including but not limited to,
accessories, parts, hardware, and software (the System), is proprietary to Altronics Service, LLC. or its suppliers under federal
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to) modify, prepare derivative works of, reverse engineer, decompile, disassemble, or otherwise attempt to create source code from
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includes, but is not limited to, inventions (patentable or unpatentable), patents, trade secrets, copyrights, software, computer
programs, and related documentation and other works of authorship.

The furnishing or distribution of this documentation does not grant any license to these patents, trademarks, copyrights, and/or other
intellectual property rights.
CNC User Manual
Table of Contents
1. SAFETY ............................................................................................................................................. 1
2. SECURITY LEVELS.......................................................................................................................... 2
3. NAVIGATION..................................................................................................................................... 3
3.1 TOUCH SCREEN................................................................................................................................3
3.2 FUNCTION KEYS ...............................................................................................................................3
3.3 CONTROLLER BUTTONS ....................................................................................................................4
3.4 CONTROLLER BUTTONS DESCRIPTIONS .............................................................................................5
4. MAIN SCREEN.................................................................................................................................. 8
5. F1 MACH ........................................................................................................................................... 9
6. F2 PROG.......................................................................................................................................... 11
7. F3 PRGCHK..................................................................................................................................... 17
8. F4 GRAPH....................................................................................................................................... 19
9. F5 EDIT............................................................................................................................................ 21
10. F6 VIEW........................................................................................................................................... 22
11. F7 OFFSET...................................................................................................................................... 23
12. F8 PARAM....................................................................................................................................... 28
13. F9 MAINT......................................................................................................................................... 29
14. F10 MSG.......................................................................................................................................... 41
15. PROGRAMMING OVERVIEW......................................................................................................... 42
15.1 G CODES BY GROUPS. ................................................................................................................42
15.1.1 Movement Group................................................................................................................... 42
15.1.2 Dwell Group........................................................................................................................... 42
15.1.3 Cutter Compensation Group ................................................................................................. 42
15.1.4 Work Coordinates Group....................................................................................................... 43
15.1.5 Canned Cycle Group............................................................................................................. 43
15.1.6 Inch/Metric Group.................................................................................................................. 43
15.1.7 Absolute/Incremental Group.................................................................................................. 43
15.1.8 Preset Group ......................................................................................................................... 43
15.2 M CODES BY GROUP ...................................................................................................................43
15.2.1 Tool Change.......................................................................................................................... 43
15.2.2 Safe Zone.............................................................................................................................. 43
15.2.3 Torch Control Group.............................................................................................................. 44
15.2.4 Attachment Control Group..................................................................................................... 44
15.2.5 End Program Group .............................................................................................................. 44
15.2.6 RAM Control Group............................................................................................................... 44
15.2.7 Reposition Group .................................................................................................................. 44
15.2.8 Punch Control Group............................................................................................................. 44
15.2.9 Material Control Group.......................................................................................................... 44
15.2.10 Sub-Program Group .......................................................................................................... 44
15.3 MISCELLANEOUS CODES .............................................................................................................44
16. OPERATING PROCEDURES ......................................................................................................... 46
16.1 POWER ON PROCEDURE .............................................................................................................47
16.2 POWER OFF PROCEDURE............................................................................................................47
16.3 SECURITY SETTINGS ...................................................................................................................48
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CNC User Manual
16.3.1 Change to Different Security Level........................................................................................ 48
16.3.2 Change Security Settings...................................................................................................... 48
16.4 MANUAL J OGGING.......................................................................................................................48
16.4.1 Continuous Jog...................................................................................................................... 48
16.4.2 Incremental Jog..................................................................................................................... 48
16.5 STARTING/REFERENCING THE MACHINE .......................................................................................49
16.6 SET ZERO PROCEDURE ...............................................................................................................49
16.7 EXECUTING A PART PROGRAM.....................................................................................................50
16.8 PAUSING AND RESTARTING THE PROGRAM...................................................................................50
16.9 RECOVERY FOLLOWING A FAULT DURING PROGRAM EXECUTION ..................................................51
16.10 STARTING PROGRAM EXECUTION FROM A SPECIFIED BLOCK.........................................................52
16.11 MDI MODE..................................................................................................................................52
17. MAP OF FUNCTION KEYS.................................................................................................................. 54
17. APPENDIX A: LEVEL 1 ACCESS .................................................................................................. 55
18. APPENDIX B: LEVEL 2 ACCESS .................................................................................................. 56
19. APPENDIX C: LEVEL 3 ACCESS .................................................................................................. 57
20. APPENDIX D: LEVEL 4 ACCESS .................................................................................................. 58
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CNC User Manual

List of Figures
Figure 3-1: Controller Buttons.......................................................................................................................4
Figure 4-1: Main Screen................................................................................................................................8
Figure 5-1: Machine Position Screen............................................................................................................9
Figure 6-1: Program....................................................................................................................................11
Figure 6-2: Copy Screen.............................................................................................................................14
Figure 7-1: Program Check Screen............................................................................................................17
Figure 8-1: Graph........................................................................................................................................19
Figure 9-1: CncPad.....................................................................................................................................21
Figure 10-1: View Screen............................................................................................................................22
Figure 11-1: Active Offsets/Data Screen....................................................................................................23
Figure 11-2: Radius Offset (Inch) Screen...................................................................................................24
Figure 11-3: Tool Data Screen....................................................................................................................27
Figure 13-1: Maintenance Screen...............................................................................................................29
Figure 13-2: Sample Password Setup Screen............................................................................................30
Figure 13-3: Machine Data Screen.............................................................................................................31
Figure 13-4: Clamp Graphic........................................................................................................................34
Figure 16-1: Overview of Operation Process..............................................................................................46
Figure 16-2: Main Screen Field Descriptions..............................................................................................50
Figure 17-1: Map of Function Keys.............................................................................................................54

List of Tables
Table 1: Main Screen Function Keys............................................................................................................3
Table 2: Mode Select Controller Buttons ......................................................................................................5
Table 3: J og Select Controller Buttons .........................................................................................................6
Table 4: J og Speed Controller Buttons.........................................................................................................7
Table 5: Miscellaneous Controller Buttons ...................................................................................................7
Table 6: Machine Timer Table Descriptions ...............................................................................................33
Table 7: Safe Zone Dimension Table .........................................................................................................35
Table 8: Cycle Start Inhibit..........................................................................................................................38
Table 9: Punch Inhib...................................................................................................................................38
Table 10: Feed Hold....................................................................................................................................38
Table 11: Punch Wait Table........................................................................................................................38
Table 12: Prelude........................................................................................................................................39
Table 13: Postludes ....................................................................................................................................39
Table 14: E-stop Requests..........................................................................................................................39
Version 2.0 (23 Jan 2007) Page iv

1. SAFETY
Safety is a primary concern when working on or near any CNC or related equipment. The ultimate
responsibility of safety rests with the user who is ultimately responsible for the safety of all personnel and
equipment. The user is also responsible for ensuring that any personnel who install, operate, program, or
maintain/repair the CNC are trained on the safety issues related to the CNC and their job task.
Altronics Service, LLC. does not consider itself a safety expert, so if further guidance is required, consult
the appropriate safety system experts to ensure a safe working environment that complies with all
industry and local requirements.
Note some of the safety features Altronics Service has incorporated into the ALhp:
The default system setting is that the CNC powers up in an E-stop and unreferenced state. The
operator must reference the axes after initial power up, but not after E-stops.
Can jog without referencing the machine, but cannot program or execute a program while in an
unref (unreferenced) state. There are four over travel limit switches on the CNC.

WARNING: When in an unref state, software end of travel
limits are not enforced. The hardware end of travel limit
switches are always enforced.

Password protected user accounts permit restricting functionality and access to certain user groups.
The active level of security will not change in the event of a power outage. The only way to change
the assigned security level is to login using an alternate password.
Version 2.0 (23 Jan 2007) Page 1

2. SECURITY LEVELS
Four levels of hierarchical security are built into the system. Levels 1 through 4 can be assigned as
needed. Level 1 is the lowest security and has the least amount of privileges. Level 4 has the highest
security and has full access to the system. The currently assigned level of security is not displayed on
screen.

Important: The currently assigned level of security will not
change if the power is interrupted or turned off. The only way
to change the assigned security level is to login on the
Maintenance screen.


3. NAVIGATION
The CNC uses a combination of function keys, a touch screen monitor, and push buttons located on the
Machine Front Panel to navigate the system.
Function keys are used to move through the screens. Each screen has function keys F1 through F10
listed on the bottom of each page. F1 is generally used to go back to the previous screen. F10 generally
contains system messages. The rest of the function keys change on each screen. For a single page map
of the function keys, see Section 17: Map of Function Keys.
The Machine Front Panel contains a variety of push buttons used to set the mode of operation, to
determine jog type, and to set the jog speed. The Operator Panel also has an E-stop button which is used
in an emergency to immediately stop the program and disable the axis drives.
3.1 TOUCH SCREEN
The CNC is equipped with a touch screen monitor. Throughout this manual, step-by-step instructions will
include references to tap or double-tap which is similar to clicking or double-clicking with a mouse. The
user also has the ability to touch & drag which is similar to clicking & dragging with a mouse.
3.2 FUNCTION KEYS
The function keys are used to navigate throughout the system. Each screen contains different function
keys which are explained in greater detail throughout this document.
Key Function Name Description
F1 Mach Displays current machine position.
F2 Prog
Selects the program to run. The operator can also create new directories,
copy, and delete programs.
F3 PrgChk Performs a syntax check on the program.
F4 Graph
Displays a graphical image of the real time tool path. Graph images can
be zoomed in to view greater detail of small areas.
F5 Edit Opens current program in Notepad for editing.
F6 View Displays the current program in read-only mode.
F7 Offset
Offsets are considered the machine data types of information such as
tool offsets, safe zones, zone avoidance, clamps, and acceleration.
F8 Param Parametric programming is not available for this release of AL.
F9 Maint
The maintenance area is used to setup clamps and safe zones, to access
I/O slots, to check circuits and lights, to set passwords, to change security
settings, and to view shared memory.
F10 Msg Displays current messages. Viewable from most screens.
Table 1: Main Screen Function Keys
CNC User Manual
an 2007) Page 4

3.3 CONTROLLER BUTTONS
Below is a representation of the buttons and controls found on the Machine Front Panel. The grey buttons are blank and not used in this version of
AL. Specific information about the buttons found within the Mode Select, J og Select, and J og Speed/Inc sections can be found in the next section.

Important: The orange axis buttons blink until referenced. The
grey buttons are blank and are not used in this version of AL.
Figure 3-1: Controller Buttons
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CNC User Manual
3.4 CONTROLLER BUTTONS DESCRIPTIONS
Buttons located in the Mode Select section are used to set the operation to automatic, manual, or Manual
Data Input (MDI). This section is also used to set the way the program is run whether one block at a time,
skipping a block, performing a dry run, or setting a new zero reference. The Set Zero button is not the
same as referencing the axes or pressing RTH/REFN.

Mode Select
Key Description
Auto Automatic mode. Used for execution of part programs. See section 16.7.
MDI Manual Data Input. See section 16.11.
MAN Manual mode. Used for jogging of machine and referencing of axes. See section 16.4.
Single Block
Advances one block of program at a time when in Auto mode. Pressing Cycle Start will
execute the next block and then execution will stop again.
Option Stop
The Option Stop button is used in conjunction with the M01 code. If the M01 code is
used in the current block and the Option Stop button is pressed on the Machine Front
Panel, then the program will stop once the M01 code is reached. If the Option Stop
button is not highlighted, the M01 code will be ignored and the block executed normally.
Block Delete
The Block Delete button is used in conjunction with the / at the start of a block. If the
Block Delete is highlighted and the block begins with a /, then the block is skipped. If
the Block Delete is not pressed and the block begins with a /, then the block is
executed normally.
Dry Run
Runs the program with both the torch and punch inhibited. It is produces the same
effect as pressing both Torch Inhib and Ram Inhib combined, but cannot be turned off
while executing a program.
Read Only Performs a syntax check on the program. See section 7.
Torch Ignite
This is used to test the plasma torch. You must be in Manual Mode and the control
power ON. Press and hold Torch Ignite while depressing the MAN button will ignite the
torch. Release the push buttons to drop the torch ignite signal. Caution should be used
when test firing the torch.
Set Zero
This function is available only in the manual mode and will allow for the presetting of the
current axes position to be that of program zero. See procedure section 16.6.
Initial Goto
Used to start the selected program at any specified block or to recover following a fault
during program execution. See procedure sections 16.9 and 16.10.
Table 2: Mode Select Controller Buttons

The buttons located in the J og Select section are used to specify the type of manual jog and are also
used to home (or reference) the machine. The orange axis buttons will blink until the machine is
referenced.


CNC User Manual
Jog Select
Key Description
INC Incremental jog mode. See section 16.4.
CONT Continuous jog mode. See section 16.4.
HOME Homes the machine. See section 16.5, Starting/Referencing the Machine.
Y+ Moves the Y axis in the positive direction.
X+ Moves the X axis in the positive direction.
RTH/REFN
If any axis is unreferenced, this button will automatically reference the X axis first and
then the Y axis. If both axes are referenced, this button will automatically return the X
axis to the X home position at high jog speed, and then return the Y axis to the Y axis
home position.
X- Moves the X axis in the negative direction.
Y- Moves the Y axis in the negative direction.
Table 3: Jog Select Controller Buttons

Several of the buttons located in the J og Speed section have dual functions depending on the jog mode
selected. This section is also used to inhibit the ram or torch and to move the ram up or down as needed.

Jog Speed/Inc
Key Description
Low
x1
This is a dual function button. The top refers to the continuous jog speed. In this case,
the speed is set to low. The bottom refers to the incremental jog distance. In this case,
the x1 means the axis is moved .001 inch each time the button is pushed.
MedLo
x10
This is a dual function button. The top button refers to the continuous jog speed. In this
case, the speed is set to Medium low. The bottom refers to the incremental jog
distance. In this case, the x10 means the axis is moved .01 inch each time the button
is pushed.
Med
x100
the speed is set to Medium. The bottom refers to the incremental jog distance. In this
case, the x100 means the axis is moved .1 inch each time the button is pushed.
High
x1000
the speed is set to High. The bottom refers to the incremental jog distance. In this case,
the x1000 means the axis is moved 1 inch each time the button is pushed.
Ram Up
The Ram Up button is only active in Manual mode. Pressing the Ram Up button allows
the Operator to manually raise the ram to the tool change position.
Hyd On/Off
Turns the hydraulics on and off. Note, the hydraulics must be on for any program to be
executed in automatic mode. Manual jogging and homing is permitted with the
hydraulics off, however the ram must stay in the up position to allow motion.
Ram Inhib
The ram will not operate while the Ram Inhibit is active. When active the button is
illuminated. This feature is used when the Operator wants to execute a part program
and verify table movement without any punches.

CNC User Manual
Jog Speed/Inc
Key Description
Ram Down
The Ram Down button is only active in the Manual mode. Pressing the Ram Down
button allows the Operator to manually lower to ram to the ram down position.
Torch Inhib
The torch will not operate while the Torch Inhibit is active. When active the button is
illuminated. This feature is used when the Operator wants to execute a part program
and verify table movement without any cutting.
Zone Inhib
When active (highlighted) the clamp safe zones are disabled. This may be used to allow
manual jogging of the CNC out of a safe zone.
Table 4: Jog Speed Controller Buttons

The Miscellaneous Controller buttons are used frequently while operating the CNC. These buttons are
mainly used to start and stop motion.

Miscellaneous Buttons
Key Description
Feed Hold The FEED HOLD button pauses all motion and turns off the torch or punch.
Clear
Pressing Clear will rewind the program and reset all machine functions to the default
status. Note: Pressing Clear while in Auto mode with a program running will result in an
error message.
Cycle Start Used to start execution of the selected part program.
Feed Override
Provides a runtime manual override for the feedrate of interpolated moves, eg G01,
G02 & G03. The dial units are percentage of the current feedrate value (F). Eg if the
programmed feedrate is 200/min and the dial is set to 50 then the actual cut feedrate in
affect will be 100/min,
Control On
Used to bring the controller out of an E-stop condition, if no fault messages are
displayed on screen.
Rapid
Override
Provides a runtime manual override of the traverse rate for G00 moves. The dial units
are percentage of full speed.
E-stop
The emergency stop button is used to put the machine into an E-stop condition and
inhibit the axis drives, hydraulics and any plasma start signal.
Table 5: Miscellaneous Controller Buttons


CNC User Manual
4. MAIN SCREEN
CNC operation is controlled by using the function keys, touch screen and various Machine Front Panel
controls. This user manual will devote a separate section to each of the function keys options shown
below in Figure 4-1: Main Screen.

Esc | F1 | F2 | F3 | F4 | F5 | F6 | F7 | F8 | F9 | F10 | F11 | F12 | Ent

Figure 4-1: Main Screen


CNC User Manual
5. F1 MACH
The Machine Position screen displays the actual machine tool location of the X and Y axis on the table.
The name of the currently selected program is displayed in the Name field. The Block field displays the
current block of the program. The Mode field is used to display the selected option of either incremental
or absolute. Units are measured in either inches or millimeters and are displayed in the Units field. The
letter code fields (G, M, S, T, F, and D) display the active value(s) for each letter code.


Figure 5-1: Machine Position Screen
(F1)
File Path: Main Screen F1 Mach F1
Return to Main screen.
MACH (F2)
File Path: Main Screen F1 Mach F2 Mach
The Machine Position screen is displayed. This screen provides the actual machine tool location
on the table.
COMM (F3)
File Path: Main Screen F1 Mach F3 Comm
The Command Position screen is displayed. This contains the programmed end point for the
current block being executed.

CNC User Manual
DTG (F4)
File Path: Main Screen F1 Mach F4 DTG
The Distance to Go screen displays the distance remaining before the next program block is
activated. The Distance to Go value is the difference between the Machine (actual) position and
the Commanded position.
ERROR (F5)
File Path: Main Screen F1 Mach F5 Error
The Following Error screen is displayed. This contains the current difference between the actual
machine position, as seen by the motor feedback, and the theoretical desired position, as
calculated by the control system. If the following error on either axis exceeds 2then the machine
is stopped and a fault is given.
The AL controller uses a loop gain of 1 for the motion control, which in practice will give a
following error approximately 1/1000
th
of the federate, eg when moving at 400 /sec the following
error should be approximately 0.4.
FEED (F6)
File Path: Main Screen F1 Mach F6 Feed
The Feed screen displays the current federate of each axis.


CNC User Manual
6. F2 PROG
The Part Program File Utilities screen is displayed. Use the F2 TAB button to move between the windows,
or simply touch them on the screen. Use the arrow soft-keys or the touch screen to navigate folders and
select program files. Note, pressing down and holding the soft-key arrows will cause the cursor to move at
a faster rate up/down the window.

WARNING: This system enables anyone with the rights to
select a program, the ability to browse throughout the network.
Therefore, Altronics recommends that the Administrator
blocks access to sensitive files and information on the network
accordingly.


Figure 6-1: Program
TAB (F2)
File Path: Main Screen F2 Prog F2 Tab
To scroll between windows on screen, press F2 TAB.
TOP (F3)
File Path: Main Screen F2 Prog F3 Top
To move the cursor to the first line of the active window, press F3 TOP.

CNC User Manual
BOTTOM (F4)
File Path: Main Screen F2 Prog F4 Bottom
To move the cursor to the last line of the active window, press F4 BOTTOM.
EXECUTE (F5)
File Path: Main Screen F2 Prog F5 Execute
To select the currently highlighted program, press F5 EXECUTE. The Main screen is displayed with
selected program name displayed in the Name field and the first six lines of code viewable on
screen.
Steps:
Complete the following steps to open a program for execution:
1. On the Main screen, press F2 PROG.
2. Select the desired file from the list.
3. Press F5 EXECUTE. The Main screen is displayed showing the first lines of code.
EDIT (F6)
File Path: Main Screen F2 Prog F6 Edit
To edit a selected program, press F6 Edit. The selected program is opened in the CncPad editing
application (see section 9).
Steps:
Complete the following steps to edit a new or existing file:
2. Browse to select the desired file.
3. Once the desired file has been selected or a new file created, the file can be edited by
pressing F6 EDIT.
4. The selected file is opened in CncPad for editing. User makes any necessary changes, then
closes the program file and then closes CncPad.
5. The Part Program File Utilities screen is displayed again.
VIEW (F7)
File Path: Main Screen F2 Prog F7 View
The View function is used to display the selected program as a read-only file.
Steps:
To view a file, complete the following steps:
2. Browse to select the desired file.
3. Press F7 VIEW to view the file in a read-only state.
4. Press F7 UTIL to go back to the Part Program File Utility screen, or
5. Press the F1 button to return to the Main screen.


CNC User Manual
NEW (F8)
File Path: Main Screen F2 Prog F8 New
The New function is used to create a new program.

Important: A new file cannot be named the same name as an
existing file.

Steps:
Complete the following steps to create a new program:
2. Press F8 NEW to create a new program. The New Program pop-up is displayed.
3. Enter the name of the new program and press ENTER.
4. Use the arrow buttons to select the file from the list. Press F6 EDIT. The selected file opens in
CncPad. Note that all new files are blank until edited.
5. Write the program in CncPad, then save and close the file and close CncPad.
6. The Part Program File Utilities screen is displayed again.
RENAME (F9)
File Path: Main Screen F2 Prog F9 Rename
The Rename function enables the name of a file to be changed.
Steps:
Complete the following steps to rename an existing file:
2. Select the desired file from the list.
3. Press F9 RENAME. The Rename Program pop-up is displayed.
4. Change the name of the program and press ENTER. Another Rename Program pop-up is
displayed to confirm your action.
5. To rename the file, select YES.
6. To leave the file name unchanged, select NO.
7. The newly named file is displayed in the File list.
(F10)
File Path: Main Screen F2 Prog F10
The function key displays the Copy File(s) From window that is used copy files between
folders or from an external drive such as a USB flash drive.

CNC User Manual


Figure 6-2: Copy Screen
TAB (F2)
The F2 TAB button is used to scroll between the Drive, Directory,
File, and Copy List windows on screen.
TOP (F3)
The F3 TOP function moves the cursor to the first line of the
active window list.
BOTTOM (F4)
The F4 BOTTOM function moves the cursor to the last line of the
active window list.
ALL (F5)
The F5 ALL function highlights all files in the active window list.
SELECT (F6)
The F6 SELECT function moves the highlighted files from the File
list to the Copy List.

CNC User Manual
COPY (F7)
The F7 COPY function is used to copy one file or multiple files to
a different directory.
Steps:
Complete the following steps to copy and paste a file to a
different directory:
1. On the Main screen, press F2 PROG. The Part Program
File Utilities screen is displayed.
2. Press F10 . The Copy Files From screen is displayed.
3. Navigate to the required drive and folder and use the
arrow keys to highlight the desired file from the list.
4. Press F6 SELECT to move one file at a time to the Copy
List. Or press F5 ALL to move all listed files to the Copy
List. Note, files can be removed from the Copy List by
highlighting and pressing F9 DELETE.
5. In the Dir list, select the directory to which the selected
file should be copied.
6. Highlight the Copy List window again.
7. Press F7 COPY. The Copy File(s) To pop-up is displayed
to verify the action.
8. Press YES to start the copy.
9. Press F1 to return to the Part Program File Utilities
screen.
MAKEDIR (F8)
The F8 MakeDir feature allows the user to create new
subdirectories within existing master directories. The MakeDir
function is only available after an existing directory is selected.
When a new subdirectory is created, the directory is empty. Files
can be copied into the new directory, or new programs can be
created and saved to the new directory.
Steps:
Complete the following steps to create a new subdirectory:
1. On the Main screen, press F2 PROG. The Program Part
File Utilities screen is displayed.
2. Press F10 . The Copy File(s) From screen is
displayed.
3. Select the desired master directory from the Dir field.
The F8 MAKEDIR button is now available.
4. Press F8 MAKEDIR. A New SubDirectory pop-up window
is displayed.
5. Enter the name of the new subdirectory and press
ENTER.
6. The new subdirectory is now listed in the Dir field.

CNC User Manual
DEL (F9)
The F9 Delete function can be used to delete a single file, files in
the Copy List field, or an entire directory including all attached
files and subdirectories.
Steps:
Complete the following steps to delete a file from the File list:
3. Browse to select the file to be deleted.
4. Ensure that the selected file is the correct file. Once
deleted, the file cannot be recovered.
5. Press F9 DELETE. The Delete Files pop-up is displayed.
6. Select YES and press ENTER to delete the file.
7. Select No and press ENTER to cancel the deletion.
Complete the following steps to delete an entire directory:
3. Browse to select the file to be deleted.
4. Select the directory to be deleted from the Dir field.
5. Ensure that all files and sub directories contained within
the selected master directory are safe to delete. Once
deleted, these files and sub directories cannot be
recovered.
6. Press F9 DELETE. Delete Subdirectory pop-up is
displayed.
7. Select YES and press ENTER to delete the selected
directory and all files and sub directories contained
within that directory.
8. Select NO and press ENTER to cancel the deletion.


CNC User Manual
7. F3 PRGCHK
This is a read-only feature that checks the program for over travels and syntax errors. The CNC table
does not move and the punch and torch are inhibited while the Program Check is being completed. If an
error is found, a message is displayed on the Main screen and in the Messages screen. To fix the error,
see section 16.7: Editing an Existing Program.


Figure 7-1: Program Check Screen
Steps:
To initiate a program check, complete the following steps:
1. From the Main screen, the F3 PRGCHK button is not active.
2. Complete the necessary steps to select the desired program.
3. Press F5 EXECUTE.
4. Press the READ ONLY button on the Machine Front Panel. The F3 PRGCHK mode
is now active.
5. Press F3 PRGCHK.
6. Press F2 PLOT if you wish to see a graphical representation of the program.
7. Clear any faults and press CONTROL ON on the Machine Front Panel.
8. Press CYCLE START on the Machine Front Panel to run through the program. The
CNC table will not move. The Punch and Torch are inhibited during a program
check.
9. Press F8 SLOW to plot the image at a lower speed. Or, press F9 FAST to quickly
plot the image.

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10. Once complete and the syntax check is OK then press the READ ONLY button
again to deactivate the read only mode.

Important: On the graph, a green line represents the torch
cutting path and the white line represents the traverse G00
moves between punches and cuts.

Slow Check (F8)
File Path: Main Screen F3 PrgChk F8 Slow Check
The Slow Check function is used to slowly perform a syntax check of a program.

Fast Check (F9)
File Path: Main Screen F3 PrgChk F9 Fast Check
The Fast Check function is used to rapidly perform a syntax check of a program.

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8. F4 GRAPH
The Graph feature is a real time tool path plot feature. The graph function key remains ghosted when
using read-only mode.
The Graph feature produces a graphical representation of the tool path while in normal running mode.
The purpose of the Graph tool is to complete an actual part for inspection and graphical representation of
the programmed part for comparison. In the event that something is not correct on the part, the user can
zoom in and inspect the graph in greater detail. If the graph is not correct and the part is not correct,
check the program for errors. If the graph is correct, but the part is wrong, then a mechanical error on the
CNC caused the problems. Perform troubleshooting on the CNC to determine the cause of the errors.

Important: F3 PrgChk and F4 Graph are mutually exclusive. If
operating in read-only mode, the F3 PrgChk function is available and
the F4 Graph function remains ghosted. When using the F4 Graph
function, the axis will move during execution of the part program.


Figure 8-1: Graph

On the graph displayed in Figure 8-1, the red dots represent where a punch occurs, dashed white lines
indicate rapid moves (eg G00), yellow lines represent interpolated moves (eg G01/G02/G03) And green
lines indicate cutter compensated moves (eg G01 with a G41 offset applied).


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Important: When a program is being plotted, if the user exits
the Graph screen all data on the graph will be lost.
Zoom (F2)
File Path: Main Screen F4 Graph F2 Zoom
The Zoom function enables the user to view sections of the graph in greater detail. The
measurement scale automatically adjusts when the zoom feature is used. Use the arrow keys on
the keyboard to move the purple zoom box to the desired location.
When the zoom feature is used the Cancel, Decrease, and Increase function keys are
operational.
Steps:
To zoom in on a section of the graph, complete the following steps:
1. Press F2 ZOOM. A purple box is displayed on the graph. (The CANCEL, INCREASE and
DECREASE buttons are now available for use.)
2. Use the touch screen arrow keys to move the purple zoom box:
a. Press F3 CANCEL to remove the zoom box.
b. Press F4 DECR to decrease the size of the zoom box.
c. Press F5 INCR to increase the size of the zoom box.
3. Press F2 ZOOM when the desired region has been selected.
Cancel (F3)
File Path: Main Screen F4 Graph F3 Cancel
The Cancel function is only available as part of the zoom function. The F3 CANCEL function is
used to cancel the current zoom and return to the previous graph view.
Decr (F4)
File Path: Main Screen F4 Graph F4 Decr
The Decrease function is only available as part of the zoom function. This button is used to
decrease the size of the zoom box.
Incr (F5)
File Path: Main Screen F4 Graph F5 Incr
The Increase function is only available as part of the zoom function. This button is used to
increase the size of the zoom box.
Trav (F6)
File Path: Main Screen F4 Graph F6 Trav
The Traverse function is used to hide/show traverse (white) move paths during the plot.
Clear (F7)
File Path: Main Screen F4 Graph F7 Clear
The Clear function cancels the current plot and removes all plotted data from the screen.

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9. F5 EDIT
A separate text editing application called CncPad is used to edit CNC programs. A screenshot of this is
application is shown below in Figure 9-1.

Figure 9-1: CncPad

There are two ways to launch CncPad to edit a particular program. If a program is already open within the
Main screen:
- press F5 EDIT
- click Yes to the warning pop-up window
Otherwise:
- press F6 PROG and then highlight the desired program.
- press F5 EDIT
- click Yes to the warning pop-up window

The icons at the top of the CncPad application provide the ability to:
- Create a new program file
- Open an existing program file
- Save the current program file
- Find a text string, eg a known block number search such as N050.
- Exit the application

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10. F6 VIEW
The View function is read-only. This function is used to view the selected program code in detail. If
changes are needed, use the Edit feature.


Figure 10-1: View Screen
(F1)
File Path: Main Screen F6 View F1
Returns to the Main screen.
Top (F3)
File Path: Main Screen F6 View F3 Top
The Top function is used to move the cursor to the first block of the program.
Bottom (F4)
File Path: Main Screen F6 View F4 Bottom
The Bottom function is used to move the cursor to the last block of the program.
Msg (F10)
File Path: Main Screen F6 View F10 Msg
The Message function displays a list of active messages.

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11. F7 OFFSET
Various offsets can be applied during the execution of a part program to act as programming aids.
Typical examples of these are the G92 Preset Position command and the Cutter Compensation offset.
The Offset screen gives a read only view of the below offsets and settings that are currently in effect:
G92 offset (Preset Position)
G54 offset (reference ram tool)
Cutter compensation offset (Dxxx)
Tool number, size (S/M/L) and number of hits since last reset
The Offset screen also has sub-screen options for the setup of some of the offset features. These are
described in turn in the following sections.


Figure 11-1: Active Offsets/Data Screen
(F1)
File Path: Main Screen F7 Offset F1


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Work (F2)
File Path: Main Screen F7 Offset F2 Work

Figure 11-2: Radius Offset (Inch) Screen

When F2 WORK is pressed, the Work Coordinate Offsets (Inch) screen is displayed with G54
through G59 offsets viewable. This screen is used to modify the G54 through G59 offsets. In the
standard format the G54 offset is 0,0 and is used to reference the punch, where the G55 offset
contains a 12 value and is used to reference the torch.
TAB (F2)
The TAB button is used to move between the tables displayed on
screen.
+0.001 (F5)
The +0.001 button is used to increase the offset amount.
-0.001 (F6)
The -0.001 button is used to decrease the offset amount.

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CLEAR (F8)
The CLEAR button is used to return the offset values to zero. A
pop-up window is displayed to verify the change before resetting
the values to zero.
INCH/MM (F9)
The INCH/MM button is used to switch the values between inches
and millimeters.
MSG (F10)
Displays messages.
Radius (F3)
File Path: Main Screen F7 Offset F3 Radius
When the F3 RADIUS button is pressed, the Radius Offset (Inch) screen is displayed. This screen
provides a look up table for setting up the cutter compensation D-variable values. Up to 30
different cutter compensation values can be assigned and then used within the CNC programs
with the G41/G42 commands. For example, using the below settings a block containing G41D01
would offset the torch path by 1/8
th
of an inch.
There are several variables that combine to produce different radius of the plasma cutter kerf:
Thickness and type of material
Torch current and speed
Type of torch consumables and gas used


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(F1)
TOP (F3)
Moves the cursor to the top of the table.
BOTTOM (F4)
Moves the cursor to the bottom of the table.
+0.001 (F5)
The +0.001 button is used to increase the radius amount. Press
and hold to increase at a faster rate.
-0.001 (F6)
The +0.001 button is used to increase the radius amount. Press
and hold to decrease at a faster rate.
CLEAR (F8)
Returns all values to zero.
INCH/MM (F9)
Toggles between units of inches and millimeters.
MSG (F10)
Displays all current messages.
Tool (F4)
File Path: Main Screen F7 Offset F4 Tool
When the TOOL button is pressed, the Tool Data screen is displayed. This screen is used to
define the safe zone size (S, M or L) used for each tool. When a tool number is used in a
program, eg M06T3, then the controller will look in this table to see what size clamp safe zone is
required. The actual dimensions of the three different clamp safe zone sizes are set in the CLAMP
menu (Main Screen F9 Maint F7 Offset F6 Clamp, see section 13.6). The required clamp
safe zones will be centered on the clamp locations, as defined by the CL1=and CL2=
commands. A sample of the Tool Data screen is shown in Figure 11-3 below.
The Act. (Actual) Hits column displays the total number of hits by each tool. The Actual Hits
information can be used to automatically generate a message that the tool tip may be dull and
may need replacement. When the actual hits reach the max hits count a message is given.
Double clicking on either the max hits or actual hits values allows editing.


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Tool Number Tool Size (S, M, L) Max. Hits Act. Hits
T01 Small 3000 587
T02 Small 9999 (Default) 0
T03 Med 9999 (Default) 0
Figure 11-3: Tool Data Screen

To activate the clamp safe zones the M10 code must be used along
with the applicable clamp definitions, CL1=xx.xxx and CL2=xx.xxx.

The MFP button ZONE INHIB can be used to temporarily deactivate
the safe zones. This might be required to manually jog the CNC out of
a safe zone, or to run a program that the operator knows from
experience is safe to run, even though the clamp safe zone is violated.

During setup and testing of the various clamp safe zones it can be
useful to view the Status screen (Main Screen F9 Maintenance
F8 Status) to see the current size and location of the safe zones.

Further information on the clamp safe zones can be found in the ALhp
Software Reference Manual Section 4.3, M10/M11.

(F1)
Returns to Main screen.
TOP (F3)
Moves the cursor to the first row of the table.
BOTTOM (F4)
Moves the cursor to the last row of the table.
CLEAR (F8)
Resets all values to default value.
MSG (F10)
Displays current messages.

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12. F8 PARAM

This section is currently not used and is for future development of parametric programming.


CNC User Manual
13. F9 MAINT
The Maintenance screen is used for diagnostic and entering the various machine setup parameters. Each
of the sub-menu screens are detailed in the following sections.


Figure 13-1: Maintenance Screen
13.1 I/O (F2)
File Path: Main Screen F9 Maintenance F2 I/O
The F2 I/O button displays the status of the various machine inputs and outputs. The first page
shows the status of the AC outputs, DC outputs and the first rack of DC inputs. Pressing F9 will
page over and display the second rack of DC inputs. This diagnostic screen can be used in
conjunction with pages 8 and 9 of the ALhp Wiring Diagrams to track down potential machine I/O
related problems.
MAINT (F2)
F2 MAINT button displays the Maintenance screen.
SLOT (F9)
F9 Slot button displays the next I/O slots.

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13.2 MFP (F3)
File Path: Main Screen F9 Maintenance F3 MFP
Displays a graphical representation of the Machine Front Panel (MFP), which is used to
determine if circuits and lamps are operational. When a button is pushed on the CNC, the
graphical display shows the same button as pressed. When the button is released, the graphical
button is displayed as normal. The feedrate override and rapid override dials also can be tested.
LAMPS (F9)
This function key is used to verify if any button lamps need to be
replaced. When pressed, the graphical board buttons and the
physical buttons on the CNC should all illuminate. Pressing F9
again will turn the lamps off.
13.3 LOGIN (F5)
File Path: Main Screen F9 Maintenance F5 Login
The Password Login screen is displayed. All passwords are case-sensitive.

Important: The assigned level of security does not change if
the power is disrupted or turned off.
13.4 PASSWORD (F6)
File Path: Main Screen F9 Maintenance F6 Passw
The Password Setup screen is used by a level four security rights user to view existing
passwords and correlating security levels. There are 16 possible passwords that can be assigned
to four levels of security. The roles are as follows:
Level 1 user is generally the Operator. The Operator can run existing programs, open
exiting programs, run a program check, view a program, change an offset, change a tool,
or change a safe zone.
Level 2 user is generally a Programmer.
Level 3 user is generally a Supervisor or Production Manager.
Level 4 user has full access to the system and is typically Maintenance personnel. The
full access user is the only group that can assign and change passwords.
The current level of security determines the access the user will have to screens and function
keys. For additional information, see Appendices A, B, C, and D.
Password Level
1111 1
2222 2
3333 3
4444 4
Figure 13-2: Sample Password Setup Screen

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TOP (F3)
Moves the cursor to the top of the table.
BOTTOM (F4)
Moves the cursor to the bottom of the table.
CLEAR (F8)
Resets the table to the original settings.
MSG (F10)
Displays all current messages.
13.5 Setup (F7)
File Path: Main Screen F9 Maintenance F7 Setup
The Machine Data screen displays the Machine Data Function table, as shown in Figure 13-3
below. Double clicking on each value will allow for modifications. Each setting is detailed below.


Figure 13-3: Machine Data Screen
- Safe Zones Active. The use of the clamp safe zones can be either enabled or disabled here. Note, if
set True then an M10 code must still be used to activate the safe zone during program execution.

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- Zone Avoidance Active. If this is set to True, the system automatically avoids any clamp safe zone
when a programmed move would take the tool through the safe zone to get to the commanded
position. Notes:
1. This only applies to G00 move types that the commanded end position is NOT in the safe
zone, yet the default traverse path would cross the safe zone.
2. This does not apply to interpolated moves such as G01/G02/G03. A fault condition will
occur if an interpolated program move attempts to go across a safe zone.
3. This does not apply to canned cycle moves, eg G61/G62/G64/G65/G67. If a canned
move attempts to cross a safe zone then the CNC will stop and generate a fault condition
as the tool attempts to enter the safe zone.
- G00 Vector Move. Set True will result in linear G00 moves. Set false will result in the standard dogleg
type move for G00 moves. The default is False and provides the fastest move type and so should be
used in a production machine.
- Clamps Face Rear. This setting varies depending on the machine configuration. It dictates the y-axis
direction the zone avoidance will go. Once set for your system you should not change this.
- Acceleration %. The acceleration and deceleration of programmed moves can be ramped down to
provide a soft start and finish to moves. Note, the same full speed is achieved, it will just take slightly
longer to reach the commanded feedrate.

It is suggested that when heavy gauge material is used the
acceleration % be lowered to much less than 100% to avoid
slippage and reduce the mechanical strain.

- Number of Clamps. This setting must accurately reflect the number of clamps being used. This
setting affects the Safe Zone and Zone Avoidance features. Most Whitney machines have two
clamps, but a total of four clamps may be used.
- Reference Offset (Axis 1). This value applies an offset to the home or zero position of the machine X
axis. It is used to calibrate the machine and ensure that the zero position on the part is in the correct
position under the punch. A simple program to make a punch at a known location can be used to
measure the error and update the reference offset. Once updated is it recommended that the
machine be unreferenced and re-homed to test the new setting.
- Reference Offset (Axis 2). This provides the same offset for the Y axis as described above.

To un-reference the CNC once already referenced go to MAN mode,
press HOME, press FEED HOLD and then press +Y to unreference the
Y-axis and/or press +X to unreferenced the X-axis. When the FEED
HOLD is removed the CNC will automatically home itself again.

- Invert Arc Directions. This feature will toggle the rotational direction of interpolated circular moves,
such as G02 and G03. This is required as not all Whitney machines were set with the same positive
direction of travel for the axes. Once this setting is correct for your machine this should not need to be
changed.
TOP (F3)
The F3 TOP button moves the cursor to the top of the table.
BOTTOM (F4)
The F4 BOTTOM button moves the cursor to the bottom of the
table.

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TIMES (F5)
The F5 TIMES button displays machine delays listed below.
Double clicking a value will allow for modification.
Machine Timer
Typical
Values Description
Punch Anticipate Time 0
The punch can be set to initiate the down cycle a set amount of
time before the move is expected to complete. The result is a
faster ram cycle, however it is not recommended that this
feature be used.
Ram Up Delay (G54) 0
When G54 is active, the ram continues to rise for this number
of seconds after operating the standard ram up switch is made.
Torch Lower Time 2.0
This is the delay that allows for the torch to lower before the
ignite signal is given to the plasma system.
Torch Pierce Time 0.3
This is the delay that allows for the torch to ignite and pierce
the material before the Arc Established input is watched for.
Torch Off Delay (M18) 0.5
Time delay after the torch is extinguished, to allow torch to
switch off and lift up clear of the material.
Filter Time 30
When the torch ignites, the filter (vacuum) also switches on.
The filter runs for specified time (in seconds) after the last torch
operation. When the filter stops, the shaker starts.
Shaker Time 4
The Shaker Time is used to dislodge any items or materials
caught in the bag. The shaker turns on for the specified time (in
seconds) after the filter has stopped.
Clamp Open Time 1 Time delay used to allow for the clamps to open.
Clamp Close Time 1 Time delay used to allow for the clamps to close.
Repo Lower Time 3
Delay time to ensure that the reposition clamp lowers
completely, during the reposition cycle.
Repo Raise Time 3
Delay time to ensure that the reposition clamp rises completely,
during the reposition cycle.
Locate Pin Delay 1
When the part change switch is used, this is the delay time
after the clamps are closed before the locating pin drops.
Table 6: Machine Timer Table Descriptions

13.6 Clamp (F6)
File Path: Main Screen F9 Maint F7 Offset F6 Clamp
This screen is used to set the physical size of each of the small, medium and large clamp safe
zones, as referenced by the Tool Data screen (Main Screen F7 Offset F4 Tool). Further to
the three punch related safe zones there are configurable safe zone sizes for when using the
torch or tapping tools. The safe zone sizes should be set such that both the punch and the
stripper are kept away from the actual clamps.
A graphical representation of the clamp safe zone setup screen is shown in Figure 13-4 below.

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Y+
X+
X-
Clamp Safe Zone
Work Clamp
Locate
Pin
Direction of
Material Movement

Figure 13-4: Clamp Graphic

button to scroll between the Y+, X-, or X+safe zone dimension. Then press F7

Use the F2 TAB
EDIT to display the Safe Zone Dimension table for the selected axis and direction.
13.7 F7 EDIT
An example editing screen for the Y+safe zone dimensions is shown below in Figure 13-

Table 7 below shows a typical set of clamp safe zone values. Notice that the X+values

5. Based on the tool and stripper sizes used on the machine, set the desired dimensions
for each tool type for each of the X directions and the Y+direction. Note, there is no Y-
direction as this is automatically set at the end of travel limit for that axis.
are greater then the X- values this accounts for the stripper that is only on one side of
the punch.

To activate the clamp safe zones the M10 code must be used along

with the applicable clamp definitions, CL1=xx.xxx and CL2=xx.xxx.

The MFP button ZONE INHIB can be used to temporarily deactivate
f
iolated.

the safe zones. This might be required to manually jog the CNC out o
a safe zone, or to run a program that the operator knows from
experience is safe to run, even though the clamp safe zone is v

During setup and testing of the various clamp safe zones it can be

useful to view the Status screen (Main Screen F9 Maintenance
F8 Status) to see the current size and location of the safe zones.

Further information on the clamp safe zones can be found in the ALhp

Software Reference Manual Section 4.3, M10/M11.

CNC User Manual


Figure 13-5: Work Clamp Safe Zone Y+Editing

Typical Values
Safe Zone Y+ Y+ X- X+
Punch (Small) 2.25 2.5 3.375
Punch (Medium) 3.0 3.3 3.75
Punch (Large) 4.125 4.375 5.75
Torch 3.75 3.25 3.625
Tap 2.25 2.5 3.375
Scribe 0 0 0
Table 7: Safe Zone Dimension Table

Note: The ALhp controller only actually displays one safe zone dimension set at a time but for the
purposes of documentation, all three safe zone dimensions are displayed in Table 7.
F1 BACK
Returns to Main screen.
F2 TAB
Used to move between the tables on screen.
F3 TOP
Moves the cursor to the first row of the table.

CNC User Manual
F4 BOTTOM
Moves the cursor to the last row of the table.
F5 +0.001
The +0.001 button is used to increase the value by exactly
0.001. Press and hold for faster editing.
F6 -0.001
The -0.001 button is used to decrease the value by exactly
0.001. Press and hold for faster editing.
F7 EXIT
The Exit function is used to exit the safe zone dimension table.
F8 CLEAR
Resets all values to zero.
F9 INCH/MM
Changes unit of measurement between inches and millimeters.
F10 MSG
Displays current messages.
13.8 Status (F8)
File Path: Main Screen F9 Maintenance F8 Status
The Status screen displays read-only information about the current status of the ram and torch,
the clamp safe zones, and the system inhibit codes.
A sample screen shot of the F8 Status screen can be seen in Figure 13-6 below.
A more detailed description of the information available is in the following sections.

CNC User Manual


Figure 13-6: Status Screen
RAM/TORCH DATA
The RAM/Torch Data displayed on this screen is read-only. It displays the current
commanded position of the ram (up/down/tool change/off), the actual position according
to the ram limit switches (up/down/tool change/unknown), the sequence state the ram is
in (idle/going up/going down) and the sequence state the torch is in (1/2/3/run).
CLAMP SAFE ZONES
This screen displays the read-only information about the current Clamp Safe Zone
dimensions and locations. The Safe Zone is the area around a clamp in which the punch
and torch cannot operate. The purpose of the Safe Zone is to prevent damage to the
tools or clamps.
INHIBIT CODES
Inhibit Codes can be useful when diagnosing a problem such as an e-stop not clearing or
the cycle start being rejected. Each bit (0 or 1) of each Inhibit Group corresponds to a
condition.
For example, any 1 in the Cycle Start Inhibit group will cause the Cycle Start request to
be rejected. If, for example, the third bit from the right is a 1 then the controller thinks the
clamps are open and so prohibits a cycle start.


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Cycle Start Inhib
Inhibit Name Code
RAM Inhib 00000001
Hyd Inhib 00000010
Clamp Inhib 00000100
Tool Inhib 00001000
Torch Inhib 00010000
Table 8: Cycle Start Inhibit

Punch Inhib
Inhibit Name Code
Program End Inhib 00000001
One blk inhib 00000010
M85 Inhib 00000100
MfpRam Inhib 00001000
Hyd Punch Inhib 00010000
Clamp Punch Inhib 00100000
Tool Punch Inhib 01000000
Torch Punch Inhib 10000000
Table 9: Punch Inhib

Feed Holds
Inhibit Name Code
ReposFdHold 00000001
M97FdHold 00000010
Locate Pin FdHold 00000100
TorchFdHold 00001000
Table 10: Feed Hold

Punch Wait Table
The Punch Wait Inhibit codes are not active for the Whitney 647. In the
event that a red inhibit code is generated for the Punch Wait Inhibit,
contact Altronics Service for assistance.
Table 11: Punch Wait Table


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Preludes
Inhibit Name Code
M87 Prel 00000001
Torch Prel 00000010
Repos Prel 00000100
Table 12: Prelude

Postludes
Inhibit Name Code
M87 Post 00000001
Stop Cyc Post 00000001
M97 Post 00000010
Tool Post 00000100
Torch Post 00001000
Repos Post 00010000
Table 13: Postludes

E-stop Requests
Inhibit Name Code
Ram Stop 00000001
Hyd E-stop 00000010
Servo E-stop 00000100
Low Air E-stop 00001000
Over travel E-stop 00010000
Torch E-stop 00100000
Table 14: E-stop Requests
Preludes
The preludes are used to force a pause in the program until an action is completed.
Example: If the prelude is used in conjunction with the torch ignite code, the prelude forces a
pause in the program until the torch ignites and signals the CNC that the torch is ready to move.
Postludes
The postludes are used to force a pause in the program until after an action is completed.
Example: If the Postlude is used in conjunction with the torch off code, the postlude forces a
pause in the program while the torch turns off and returns to a stopped state. Once in the correct
state the control software removes the postlude and execution of the next block will begin.


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Shared Memory (F9)

This screen is for Altronics use.

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14. F10 MSG
The F10 MSG button is only available if a system message has been generated. The current error
message is displayed on the Main screen and a list of additional messages can be viewed on the
Messages screen. If there are no active messages, the F10 MSG button is ghosted.
Pressing the CLEAR button on the MFP will remove any fault messages that are now obsolete.


Figure 14-1: Status Screen


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15. PROGRAMMING OVERVIEW
The first block of a program often consists of the housekeeping block. This block is used to remove any
remaining settings from the last program run. First block should typically contain: G00 (rapid), G90 or G91
(absolute or incremental programming), G70 or G71 (inch or millimeter dimensions), M75 or M85 ( punch
on or off), G40 (cancel cutter compensation) & G99 (cancel any preset position).
Decimal point programming is recognized by the ALhp. When programming a whole number (eg 45),
there is no need to write the number out with a decimal (ie 45.0).
When writing a block of code, be aware that each block can contain several G and M codes, but only one
G or M code from each group. The G codes are typically mutually exclusive within each group. If two G
codes from the same group are programmed in the same block, the last G code in the block overrides
any preceding G codes from the same group.
An overview of the different G and M-codes is given below in section 15.1. For more detailed description
of each code please refer to the ALhp Software Reference Manual.
15.1 G CODES BY GROUPS.
15.1.1 Movement Group
G00...................Rapid positioning with punch at completion of move (unless ram disabled)
G01...................Linear interpolation at programmed feedrate
G02...................Circular Interploation, Clockwise arc at programmed feedrate
G03...................Circular Interpolation, Counterclockwise arc at programmed feedrate
G21...................Linear move with slowdown and pull into position at completion of move.
G22...................Clockwise arc with slowdown and pull into position at completion of move.
G23...................Counter clockwise arc with slowdown and pull into position at completion of move.

Important: The Pull into position feature should be used
with caution when using the torch. As the torch pulls into
position and dwells at the position, the burn hole could be
larger than expected.
15.1.2 Dwell Group
G04...................Used with F code for a delay. Holds the block for the number of seconds programmed in
the F code.
15.1.3 Cutter Compensation Group
G40...................Turn off cutter compensation
G41...................Turn on cutter compensation with compensation to the Left of the programmed path.
G42...................Turn on cutter compensation with compensation to the Right of the programmed path.

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15.1.4 Work Coordinates Group

Important: Blocks containing a G54 or G55 are implied motion
blocks. If the M75 punch is enabled and the G54 or G55 code is
used, a RAM cycle will result.
The work coordinate offset values for G54 thru G59 are contained
in the work coordinate offset tables, In order for the torch offset to
be valid, the G55 table should include a typically -12 tool offset.
G54...................Work coordinates offset code for the Ram
G55...................Work coordinates offset code for torch
G56...................Work coordinates offset code for additional attachment 1
G57...................Work coordinates offset code for additional attachment 2
15.1.5 Canned Cycle Group
G61...................Straight Line Punch Pattern
G62...................Clockwise/CounterClockwise Punched Arc
G64...................Bolt Hole Circle Pattern
G65...................Rectangular Cut Out
G67...................Rectangular or Square Grid Pattern
15.1.6 Inch/Metric Group
G70...................Programmed dimensions are in inches
G71...................Programmed dimensions are in millimeters
15.1.7 Absolute/Incremental Group
G90...................Absolute programming
G91...................Incremental programming
15.1.8 Preset Group
G92...................Preset position registers
G99...................Cancel preset position

15.2 M CODES BY GROUP
M00..................Program Stop
M01..................Option Stop
15.2.1 Tool Change
M06..................Tool Change
15.2.2 Safe Zone
M10..................Activate Clamp Safe Zones
M11..................Deactivate Clamp Safe Zones

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15.2.3 Torch Control Group
M17..................Torch Ignite
M18..................Torch Extinguish
M19..................Torch Extinguish
15.2.4 Attachment Control Group
M23..................Enable right Tap
M24..................Enable Left Tap
M25..................Cancel Tap/Scribe Enable punch
M26..................Enable Scribe
15.2.5 End Program Group
M02..................Program Stop and Rewind
M30..................End of Program/Rewind
15.2.6 RAM Control Group
M41..................Pressure switch active.
M42..................Pressure switch off. Limit switch for ram down indicator (default)
M54..................Use timer for ram up
M55..................Use up limit switch for ram up (default)
M56..................Use tool change switch for ram up
15.2.7 Reposition Group
M51..................Reposition work clamps with preset
M71..................Reposition work clamps without preset (Standard for Whitney machines)
15.2.8 Punch Control Group
M75..................Enable Punch
M85..................Disable Punch
15.2.9 Material Control Group
M87..................Load position
M97..................Material Clamp Release
15.2.10 Sub-Program Group
M98..................Sub-program call
M99..................Sub-program end and/or program jump
15.3 MISCELLANEOUS CODES
A.......................Angle
B.......................Angle between each hole from the center of the circle
D.......................Offset to account for the cutter diameter

CNC User Manual
F .......................Override the programmed feed rate
P .......................Number of punches
T .......................Tool (Used with M06 code)
R.......................Radius
GOTO.J ump to specified block


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16. OPERATING PROCEDURES

Figure 16-1: Overview of Operation Process

CNC User Manual
16.1 POWER ON PROCEDURE
When the ALhp is initially turned on, the system is in an unreferenced E-stop state. The security settings
have not changed since the last login.
1. Turn on the controller. When the system is powered up, the Main screen is displayed with an
active E-stop.
2. Ensure the E-stop buttons are clear and deactivate the E-stop fault by pressing the following
buttons on the controller:
a. Press CLEAR.
b. Press CONTROL ON.

Important: The Safe Zones around the clamps are not active
until the axes have been referenced and the centerlines have
been defined. Use caution while jogging before this stage.
16.2 POWER OFF PROCEDURE
The ALhp contains a UPS (Uninterruptible Power Supply) to protect the system from power cuts.
To power down the ALhp simply turn the main disconnect off on the front of the blue power enclosure
door. After a short delay you should get a warning message that Windows is going to shut down. After
about 30 seconds the operating system will shut down and after another 30 seconds the UPS will shut
itself down. The red lamp mounted on the blue power enclosure door gives an indicator that the UPS is
still active.

IMPORTANT: DO NOT ATTEMPT TO TURN POWER BACK ON AT
THE DISCONNECT UNTIL THE RED LAMP HAS EXTINGUISHED.

If the disconnect is switched on again prior to the red lamp extinguishing then the PC will not boot as it
sees no interruption in the power supply. If this happens then you need to manually cycle the UPS:
1. Turn the disconnect switch to the OFF position.
2. Open the blue power enclosure door.
3. Manually turn the disconnect switch ON with the door open.

IMPORTANT: PROCEED WITH CAUTION AS POTENTIALLY
DANGEROUS VOLTAGES ARE PRESENT IN THE CONTROLLER.

4. Press and hold the ON button on the front of the UPS (mounted on inside of door) for approx
2 seconds. The UPS should turn ON and the PC start to boot.
5. Once the PC has booted up fully, manually turn the disconnect switch OFF and quickly close
the blue power enclosure door and switch the disconnect switch back ON. This must be done
before the UPS initiates the PC shut down cycle.

CNC User Manual
16.3 SECURITY SETTINGS
The security settings do not change when the CNC is powered down. All passwords are case sensitive.
16.3.1 Change to Different Security Level
To change the current security setting:
1. Press F9 MAINT.
2. Press F5 LOGIN.
3. Enter PASSWORD and press OK.
4. Security level has been changed to the level assigned to that password.
16.3.2 Change Security Settings
Only a Level 4 user can assign or change passwords and settings.
Complete the following steps to change the security settings:
1. Press F9 MAINT.
2. Press F5 LOGIN.
3. Enter Level 4 Password and press OK. The Security Assignment screen is displayed.
4. Change passwords and assigned security levels as needed.
16.4 MANUAL JOGGING
16.4.1 Continuous Jog
The axis continues to move as long as the axis button is depressed. J og speed is determined by using
the LO, MEDLO, MED, and HIGH buttons. The speed for the Continuous J og Speed buttons is as follows:
Low is 10 IPM
MedLo is 50 IPM
Med is 200 IPM
High is 400 IPM
To continuously jog a machine axis:
1. Press CLEAR and CONTROL ON
2. Select MAN mode, press CONT then select the desired speed (LOW/MEDLO/MED/HIGH)
3. Press and hold the yellow axis buttons to continuously move the machine
Note, the hydraulics dont have to be on to allow manual jogging, however the ram must remain UP.
16.4.2 Incremental Jog
When using the Incremental J og Speed Controls, the axis moves by a pre-defined distance each time the
button is pushed.
X1 moves 0.001 of an inch
X1000 moves 1 inch
To incrementally jog a machine axis:

CNC User Manual
4. Press CLEAR and CONTROL ON
5. Select MAN mode, press INC then select the desired incremental distance
(X1/X10/X100/X1000)
6. Press and the yellow axis buttons to jog the machine the specified incremental distance
Note, the hydraulics dont have to be on to allow manual jogging, however the ram must remain UP.

WARNING: Over travel limits are not enforced when the CNC is in an
unref state. Use caution while jogging. Manual force is needed to
move off of an over travel.

16.5 STARTING/REFERENCING THE MACHINE
The machine must be referenced, or homed, each time the power is turned on, or following the AL-CNC
application being re-started. Homing the machine provides the reference point for the machine coordinate
system. To home the machine, complete the following steps:
1. Power ON and clear any E-stops
2. Press CLEAR button.
3. Press CONTROL ON.
4. Press HOME button and then press 1 of each axis buttons. Or, press RTH/REFN to
automatically reference each axis in turn.

NOTES:
Because of the possibility of the material clamps physically colliding with the stripper assembly it is
strongly suggested the X axis be homed first and then the Y axis.
During the home cycle both of the axis +/- jog pushbuttons will illuminate and stay on until the home
cycle is complete.
The home position can be calibrated by applying offsets to each axis via the Setup screen (Main
Screen F9 Maintenance F7 Setup, see Section 13.5).

Important: The homing function only needs to be performed when
the CNC is first turned on. The CNC does not need to be homed or
referenced after E-stops or temporary stops such as limit switches.

16.6 SET ZERO PROCEDURE
This procedure allows the operator to establish the program zero (or program reference point) at a
selected point on the material to be processed. This can be used to execute a program at any point on
the material without any program modifications.

Note: If a starting reference point other than 0.000 is required it can be accomplished by using a G92
instruction block in the MDI mode.

To execute a program using the Set Zero procedure:

Open the program using F2 PROG, highlight the required program and press F5 Execute
Clear any faults and press CONTROL ON
In MAN mode jog the machine to the desired new program zero position

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Press SET ZERO on the MFP and then X+/X- to zero the X-axis and Y+/Y- to zero the Y-axis.
Select AUTO mode and then press CYCLE START to execute the program.
Upon completion of the program the program position will return to the absolute machine
position. Note, if you reset the program (FEED HOLD then CLEAR) the program position will
also return to the absolute machine position.
To exit the Set Zero mode just select on of the other MAN modes, ie INC or CONT.
16.7 EXECUTING A PART PROGRAM

WARNING: Ensure that the material is correctly loaded onto
the CNC and correctly secured before selecting and executing
a program for production mode.
To execute a part program, complete the following steps:
1. Clear any faults, press CONTROL ON and turn the hydraulics ON.
2. On the MFP, press AUTO in the Mode Select section.
3. On the Main screen, press F2 PROG. The Program screen is displayed.
4. Browse to find the desired program and highlight it.
5. Press F5 EXECUTE. The Main screen is displayed.
6. The first six blocks of code are displayed on the Main screen.

Important: As the program advances, only six blocks of code
are displayed at a time.
7. On the Controller, press CYCLE START to begin program execution.
The table below provides additional details about the fields displayed on the Main screen.
Name Description
Name Displays the file name of the currently running program.
Block Displays the current block being executed.
Mode
Displays the selected mode for this block or program. Options
are: Absolute or Incremental
Units
Displays the selected unit of measurement for this program.
Options are: Inch or mm.
G Current G codes.
M Current M codes.
A
T Active Tool code (1-32). Default setting is 1. .
F Programmed Feed rate.
Active
D Active offset for cutter compensation.
Figure 16-2: Main Screen Field Descriptions
16.8 PAUSING AND RESTARTING THE PROGRAM
The FEED HOLD button located on the Machine Front Panel is used to pause program execution.
To temporarily stop a program, press FEED HOLD on the Machine Front Panel.
To continue the program, press FEED HOLD again and the program continues where it stopped.
To restart the program, press FEED HOLD and then press CLEAR.

CNC User Manual
16.9 RECOVERY FOLLOWING A FAULT DURING PROGRAM EXECUTION
The ALhp controller provides the functionality to quickly recover from a fault and continue execution from
the appropriate program block before the fault occurred. There are two versions of this feature:
1. Standard J ump. Execution begins at the specified block and all prior blocks are skipped.
2. Search and Accumulate. All program blocks are processed in the background with the machine
and I/O offline until the specified block is reached and then execution continues with the machine
and I/O back online. This will ensure that variables such as feedrates, tool numbers, motion type
and cutter compensation values are set correctly before the program restarts.

Note, during the Search and Accumulate execution the following M-
Codes are ignored: M00, M01, M06, M17, M51, M71, M87 and M97.

WARNING: Care should be taken when using the Initial GOTO feature
especially the Search and Accumulate function. It is strongly
recommended that as soon as the machine is online after the Search
and Accumulate that a Feed Hold is applied to visually check the state
of the machine position and the active codes and variables.

To recover following a fatal fault in a program:
1. Clear the condition that caused the fault and then press CONTROL ON.
2. Ensure the CNC is still in AUTO mode, the hydraulics are ON and the ram is UP.
3. Press the INITIAL GOTO button on the MFP (button should illuminate).
4. Press the CYCLE START button, the Initial GOTO window as shown below should display.


CNC User Manual
5. The block that was last being executed is shown in bold and is highlighted by default. Blocks
shown in red are warning blocks that the operator should be aware of when deciding which block
to restart execution from. Red warning blocks include actions such as tool changes, repositions
and plasma initiation undesirable results may occur if execution is continued after these blocks.
6. Scroll up/down the program and highlight the desired recovery block.
7. If the standard jump recovery is required then uncheck the Search and Accumulate checkbox,
otherwise leave checked to use the intelligent recovery feature.
8. When ready to begin execution again press the Start button in the Initial GOTO window (not the
Cycle Start button on the MFP).
9. If you have selected a block that involves passing through or jumping over any red warning
blocks then a warning message is displayed with the warning blocks listed. If you wish to recover
to the selected block then press Yes or press No or Cancel to return to the Initial GOTO window
and select a different block.

WARNING: Machine motion will likely occur as soon as the Start
button is pressed on the Initial GOTO window.

16.10 STARTING PROGRAM EXECUTION FROM A SPECIFIED BLOCK
The above recovery procedure can be used to jump ahead in a new program or one that has already
completed in full. The only difference is that the default block highlighted in the Initial GOTO window is the
first block.
16.11 MDI MODE
The MDI (Manual Data Input) mode is intended for simple one-off operations that do not require a new
program file to be created. An example program in the MDI screen is shown in Figure 16-3 below.
To create and execute an MDI program:
1. Clear any faults and then press CONTROL ON.
2. Ensure the hydraulics are ON and the ram is UP.
3. Press the MDI button on the MFP to display the MDI text editor window.
4. Enter the desired program instructions and then press the Execute button on the window.
5. The Main screen will be shown with the MDI program displayed in green.
6. To execute the program press the CYCLE START button on the MFP.

WARNING: Unless the punch is disabled with an M85 then at the end
of MDI moves a punch cycle will likely occur.
7. Once the program has completed the MDI text editor will appear again. At this point you have
the following options:
a. Execute the program again.
b. Save the program for future use (it will be saved in the CNC Programs folder).
c. Clear the MDI program display to create another MDI program.

CNC User Manual
8. Once MDI operations have been completed press AUTO or MAN to return to the normal Main
screen.

Figure 16-3: MDI Screen

CNC User Manual
17. MAP OF FUNCTION KEYS

Figure 17-1: Map of Function Keys


CNC User Manual
an 2007) Page 55

17. APPENDIX A: LEVEL 1 ACCESS

Version 2.0 (23 J
CNC User Manual
18. APPENDIX B: LEVEL 2 ACCESS


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19. APPENDIX C: LEVEL 3 ACCESS


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20. APPENDIX D: LEVEL 4 ACCESS
Main Screen
F10 MSG F2 PROG F3 PRGCHK F9 MAINT
F8 PARAM
F7 OFFSETS F6 VIEW F5 EDIT F4 GRAPH F1 MACH
F1
BACK
F2
MACH
F5
LOGIN
F1
BACK
F3
TOP
F4
CONFIG
F1
BACK
F1
BACK
F3
TOP
F1
BACK
F6
PASSW
F2
I/O
F2
ZOOM
F10
MSG
F4
BOTTOM
F3
COMM
F2
TAB
F4
DTG
F4
BOTTOM
F10
MSG
F6
FEED
F5
ERROR
F5
EXECUT
F6
EDIT
F7
VIEW
F8
NEW
F9
RENAME
F10
MORE
F3
CANCEL
F4
DECR
F5
INCR
F6
SETUP
F7
CLEAR
F8
SLOW
F9
FAST
F10
MSG
F3
MFP
F7
SETUP
F8
STATUS
F9
MEMORY
F10
MSG
Opens the file in
Notepad for
modification.
F7 Utils
F1 Back
F2 Tab
F9 Delete
F8 MakeDir
F7 Copy
F6 Select
F5 All
F4 Bottom
F3 Top
Level 4 Security for Full Access
F10 Msg
F1 Back
F10 Msg
F9 Lamps
Available on
future release.
NOTE: Unused function keys are
not displayed on this page.
F2 Maint
F8 Clear
F4 Bottom
F3 Top
F10 Msg
F9 Slots
F10 Msg
F3 Top
F10 Msg
F8 Clear
F6 Clamps
F5 Times
F4 Bottom
F3 Bites
F2 Bits
F8 ASCii
F5 Longs
F4 Words
F9 Hex/
Dec
F10 Msg
F1
BACK
F2
WORK
F3
RADIUS
F4
TOOL
F10
MSG
F6 -0.001
F5 +0.001
F2 Tab
F10 Msg
F9 Inch/
mm
F8 Clear
F1 Back
F4 Bottom
F3 Top
F1 Back
F10 Msg
F9 Inch/
mm
F8 Clear
F6 -0.001
F5 +0.001
F4 Bottom
F3 Top
F1
BACK
F2
PLOT
F8
SLOW
F9
FAST
F10
MSG
F1 Back
F2 Zoom
F9 Fast
F8 Slow
F7 Clear
F6 Setup
F5 Incr
F4 Decr
F3 Cancel
F10 Msg
F8 Clear
F10 Msg
F1 Back
F10 Clear
F1 Back
F10
CLEAR
F1
BACK


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