MSF21512-L

Fabrication: Machine Setup in CAM

Darren Young
Southland Industries

Learning Objectives
• Setup a basic machine in CAMduct
• Reverse engineer CNC code
• Common problems and solutions
• Fast track troubleshooting

Description

We don't often get new shop equipment. When we do, it's often difficult to configure CAMduct to
work with it or we need to pay for an expensive consultant. This lab is designed to take the fear
our of machine setup in CAMduct by walking you through and the process, including how to figure
out what to do as well as what to do when things don't go as planned.

Your AU Expert(s)
A Midwestern transplant now based in Southern California, and a veteran Autodesk University
speaker, Darren Young has held a variety of positions over the last 20 years, including CAD and
CAM (computer-aided manufacturing) engineer, CAD administrator, and CAD/CAM systems
developer. Currently, Young is the Building Information Modeling (BIM) applications manager for
Southland Industries, one of the largest mechanical engineering and construction companies in
the United States. Young manages one of the largest installations of Fabrication software licenses
in the world. Young's true interest is the automation of manufacturing systems, and his experience
ranges from lean manufacturing to architecture. This has led him to projects varying in scope from
dress patterns to gas turbine piping. He has founded a consulting and development business,
and he has been a technical editor and publication author.

Page 1
Overview
Two years ago, I hosted a “Duct Machine – Setup and Configuration A-Z” session at the Autodesk
MEP Fabrication Forum. This lab is a “hands on” version of some of the topics discussed in that
session.

This lab will be interactive, with a lot of questions to the students asking for their opinions about
the information we’re reviewing. We will intentionally walk down some dead ends, reviewing
results and making decisions of how to proceed next. This is after all, what happens in real life.

My goals in this lab are not to teach you’re a step by step process or detailed technical information.
Instead, my goal will be to teach you how to look at the information and what types of questions
we can and should ask and the information we can determine.

• To setup a new machine, we follow a process outlined in Part III – Section 2 of the below
handout from two years ago.

• Refer to Part II – Section 3 to find where to create the actual machine configurations in
CAMduct for plasma tables, lasers, routers, etc. Of refer to Part II – Section 4 to see where
you would setup a coil line.

• Part III – Section 1 shows a diagram of how these machine configurations relate to
CAMduct and the Post Processors (the programs that translate from CAMduct to your
machine)

• Part II – Section 2 gives a good explanation as to what the post processors do and how
they work. In this lab, we’ll be trying to determine which post processor to use.

• To determine the proper post processor, we’ll be examining the CNC code. Part II –
Section 1 explains a little bit about the code and how to read it.

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Duct Machine – Setup and Configuration A-Z
Part I – Machine Controls Types

1. Machine Controls
Machine controls come in 2 primary types, Proprietary and PC (Windows) based. A third type
often encountered is a hybrid of the 2. Typically a Windows or other computer operating system
but customized in such a way you can’t really access traditional computer recourses like wired or
wireless networks or serial ports unless the control software allows for that functionality.

a) Proprietary based machine controls…

Burny 2.5 Plus Lockformer 128K PicoPath

Note: None look like a modern computer.

b) Windows Based machine controls…

Hypertherm Edge TI Hypertherm Edge Pro TI Burny Phantom ST

Note: Screen doesn’t look like a computer but upon boot, you’ll see Windows loading.

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 c) Example of Hybrid control…

Note: Older Autofold de-coiler running Windows but no software interface to access
drives/network.

2. Machine Communications
Machine controls typically have one or more methods for transferring NC programs into them.
There are 3 typical communications types that are used with a 4th, again being a hybrid
configuration of the others.

a) Serial Communications
Technically, many communications methods are “Serial” including the telegraph invented by
Samuel Morse as well as your computer’s Ethernet connection. However when most refer to
serial communications, they are referring to the use of a 9-pin or 25-pin Serial port configured
for RS232 communications. While considered old school by some, when configured properly,
it’s one of the widest used, most popular resilient forms of computer communications in
history. It’s likely not well understood by a lot of younger folks who didn’t grow up with it. If
your IT staff is a young bunch of tech savvy folks, they may have issues supporting serial
communications efficiently.

b) USB Communications
Many machine controls now come with a USB port. Most often, it’s used with a USB flash
drive to act as a portable hard drive to transfer NC programs from your computer to a machine.
If you’re controller comes with a UBS port, keep a few USB flash drives handy. If or when
machine communications fail, it’s a simple easy to use backup strategy for keeping you shop
running.

c) Ethernet communications
Most everybody uses Ethernet daily. This is the network cable or wireless connection most
likely in use on your computer and your company’s network. If’s fast and efficient and what
connects most modern computer networks today. It’s also what most IT staff are most familiar
and comfortable with supporting.

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 d) Hybrid communications
Hybrid communications can be all over the place. They involve a mixture of 2 or more
communications types and/or hardware components. The specifics of these many of these
communications types and hardware will be covered later. Here’s a few of the most common…
• Serial w/Short Haul Modem – Used to extend the transmission distance of RS232 or
other serial communications. Some Short Haul Modems also offer integrated optical
circuits to optically isolate the equipment from your computer so there’s no electrical
continuity in the event of a power surge.
• Serial w/Fiber Optics – Used when electrical interference from plasma, welding or
other industrial equipment interfered with the electrical signals used w/serial
communications.
• Serial to USB – As modern computers advance, with options like USB plug-and-play
mice and keyboards, many newer systems don’t include serial communications ports.
They can have an extra expansion card added to connect serial equipment or use
specialty USB-to-Serial drives allowing a system with only a USB port to connect and
communicate with a serial based machine.
• Serial to Ethernet – Same as USB-to-Ethernet, these devices allow serial
communications based machines to utilize your existing computer network for
connectivity and communications.

3. Control / Communications Cross Reference

The following chart is a quick cross reference between what’s most commonly found on of the
previously mentioned control types.
Communications Type
Serial USB Wired Wireless
Control Type (RS232) Ethernet Ethernet
Proprietary Yes No¹ No¹ No¹
Windows/PC Yes Yes Yes Yes²
Hybrid Yes No No No
¹ Modern proprietary controls (Siemens, Fanuc, etc.) may have modern interfaces for
communications. However due to their high cost, they are rarely found in our industry.
² Early generation Window/PC based controllers typically had only wired Ethernet. The latest
Windows/Pc based controllers also offer wireless Ethernet, primarily due to advances in plasma
and welding technologies and improvements in wireless networking which are have less issue
with electrical noise causing interference in the communications.

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Part II – Software / Program Overview

1. Machine Programs & Files

For each machine to operate and produce the material you need, it needs to be told what to do.
This is done with programming code written specifically for each machine. Each machine and
control combination can have its own unique programming style, many of which are very similar
but may have its own unique characteristics much like a spoken language can have its own
various dialects or regional accents despite being the same language. Others may speak a
complete different language all together.

a) NC Files (Plasma, Router, Water Jet, Laser, etc.)

NC Files are programs used to operate Plasma, Router, Water Jet and Laser equipment. Each
NC file is written using a special language used to tell the machine what to do and where to
go. Instructions tell the machine things like units used, positioning methodology (absolute vs
relative), turn cutting tools on and off, as well as positioning instructions. The program nor the
machine knows anything about what you are producing, it’s simply cutting various geometric
shapes.
The most popular language format is based on G-Code, a “Word Address” based language
that uses various alpha-numeric codes to tell the machine where to go and what to do when
it gets there. ESSI was another popular format that may be in use today but is far less
common. ESSI uses only numeric data and the +/- (plus/minus) operators.
These programs are written as plain ASCII text (non-binary) and can be open, viewed (even
edited) using a simple program like Windows Notepad. The below snippets of code generate
the same duct patterns and highlight some of the corresponding codes.
G-Code ESSI
(1001) 70
% 81
P1001 +18545 +25427
(STD WADR) 7
(ORIGIN=BOTTOM LEFT) 39+272
(INCH) +-150
G70 +-10894
(RELATIVE) -250-67
G91 +250-67
(PART 1/Back Wrapper) +-10894
G00X18.5Y25.4 -1000+
G41 +-2105
M04 +-770
G01X0.0Y-0.1 -83+
…etc… …etc…

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 b) DEC Files (Decoiler . Coil Lines)
DEC files are used to operate and control Decoilers or Coil Lines. They differ in one key way
from an NC program which is that they’re not really a program at all, rather a list if what to
produce and the specific parameters required to produce those items. Unlike the programs
controlled by an NC program which are not aware of what they’re producing other than
shapes, a Coil Line is a specialty built machine that produces one thing and one thing
only…straight coil line duct.
Similar to NC files which whose contents can vary between machine/control types, DEC files
also can vary according to the manufacturer of the coil line. Each manufacturer will have its
own specifics for how it wants to list the various pieces of straight duct it’s going to produce
and what it needs to define things like seam/connector types as well as stiffener size and
position. DEC files are also ASCII text files which can be opened with a plain text editor like
Microsoft Notepad.

2. Post-Processors (VPL / DPL)

CAMduct is one program, yet it can create programs for many different machine and control types.
Each machine and control combination can have its own language or slight variations of the
language and have specific requirements as to how it’s formatted. To solve this problem, we use
what’s called a “Post Processor”. A “Post Processor” is nothing more than a specific translator
that translates CAMduct’s language into a particular machine/control’s required language.
A list of Post Processors and the versions of software they’re in can be found here…
http://www.xtracad.com/forum/index.php?page=History

a) VPL Post Processors

Each machine Plasma, Router, Waterjet or Laser machine configured in CAMduct will use a
VPL Post Processor. These are what tell the machine setup in CAMduct how to write the code
used for that machine. Autodesk places a couple of the most common VPL’s in the root of the
CAMduct installation folder but the entire library of VPL’s that ship with the product can be
found here…
C:\Program Files\Autodesk\Fabrication 20##\CAMduct\VPLs

b) DPL Post Processors

Each machine Decoiler machine in CAMduct will use a DPL Post Processor. These are what
tell the Decoiler setup in CAMduct how to write the decoil list used for that particular Decoiler.
Autodesk places a couple of the most common DPL’s in the root of the CAMduct installation
folder but the entire library of DPL’s that ship with the product can be found here…
C:\Program Files\Autodesk\Fabrication 20##\CAMduct\DPLs

3. CAMduct Machine Setup

Each machine must be configured in CAMduct. To accomplish this, start CAMduct and go to…

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File -> Setup -> Installed Machines

In the Installed Machines dialog, there are several tabs, each representing various machine
functions.
CAMduct Version
Tab Name 2013 2014 2015 Type Purpose
Flatbed X X X NC Plasma, Router, Waterjet, Laser
Rotary X X X NC Pipe, Round Duct machines
Shear X X X NC Shears
Round Linear X X Reports Pipe & Round Duct linear nesting
Rectangular Linear X X Reports Electrical linear nesting
Ancillaries X X Reports Ancillary linear nesting

Most of the machines you’ll setup will be under the Flatbed tab and are designed for sheet
processing. Like Flatbed machines, Rotary and Shear also use VPL post processors to produce
NC code used to control machines.
Machines setup for reports, don’t actually produce NC and don’t use VPL post processors. These
machine configurations are for defining things like initial and final reserved lengths and cut kerf.
Setup and configuration of NC based machines is covered later. Machines setup for reporting
purposes are beyond the scope of this session.

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4. CAMduct Decoiler Setup
Unlike machines, CAMduct only allows a single decoil machine to be configured. To setup a
Decoiler machine, start CAMduct and go to…
File -> Setup -> Installed Decoiler

Decoiler configuration uses the DPL post processors. Setup and

configuration of a Decoiler machine is covered later.

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Part III – Process Overview

1. Configuration Diagrams
CAMduct must be configured with various machines and a Decoiler based on your particular
production equipment. These machine configurations create and save the NC programs they
create for your shop equipment to a folder (specified in the MAP.INI file) on a file server.

Fabrication CAMduct
Machines Plasma 1 (VPL)

Plasma 2 (VPL)

Waterjet (VPL)

Router (VPL)
File
Laser (VPL)
Server
…etc… (VPL)

Decoiler Decoiler (DPL)

Once the various NC programs are written, they get loaded into your shop equipment to operate
them. Some machines will have controllers which can connect directly to your network (Ethernet).
Others (typically older machines or proprietary controllers) may require an RS-232 Serial network
connection which requires a communications program to handle the transfer of the file on the
server into the machine control.

Plasma 1 (Ethernet)

File Waterjet (Ethernet)

Server Laser (Ethernet)

Communications Server / PC …etc…

Plasma Communications (Serial) Plasma 2 (Serial)

Router Communications (Serial) Router (Serial)

Decoiler Communications (Serial) Decoiler (Serial)

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2. Configuration Steps
To configure a machine, you can follow these basic steps….

1: Get a sample file if possible, 2: Configure Communications, 3: Determine the Post Processor,
4: Setup the Machine Config in CAMduct, 5: Create a Test file & compare with the sample 6:
Run on the machine when program structure looks the same.

Get Sample File

Configure
Machine
Communications

Determine Post
Processor (DPL/VPL)

Setup or Modify
Machine or Decoiler in
CAMduct

No Match

Similar Create Test File and

generate NC program or
decoil list

Compare Vendors
Review Code Sample with your
sample code (Notepad)

Match Process Complete

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Part IV – Configuration Details

1. Proprietary Controls
Each proprietary control could use any of a variety of communications methods. Some may have
only a single option while others may offer various options for getting NC programs into the
machine control. The type and number of options will likely vary depending on the age of the
controller. Older controllers will likely use RS-232 Serial only, while newer controllers may offer a
wider range of options. See the details on the following sections for the specific communications
type that your control requires. Often, a proprietary controller will need you to configure its
communication type and/or parameters using the interface it provides. Consult the controller’s
operations and configuration manuals for details.

2. Hybrid Controls
Similar to a proprietary control, each controls will allow whatever the control designer and software
developer intended. Because a hybrid control is also PC based, for those that are tech savvy, it
may (or may not) be possible to make some modifications yourself to allow different types of
configurations. For ideas, see some of the details under PC Controls. Consult the control
operation and configuration manuals for what configuration needs to be done on the control based
on the communication type you need.

3. PC Based Controls
Most modern PC based controls allow for multiple types of communications. This includes
everything from USB, Wired and Wireless Ethernet as well as RS-232 Serial communications.
Details of those communications types will be covered later however there are several things you
can do on the control itself to make your life easier.

While the main screen may not offer a way to get back to the Windows interface, simply plug in a
keyboard into an open USB port. If you type Ctrl-F4, this should exit the control software. You can
also pressing Alt-Tab to activate another Window or press the Windows key to bring up the start
menu.

a) Network Domains
Joining your machine’s controller to a network domain can make accessing NC files on your
network easier. Most IT folks would prefer this approach, perhaps even installing anti-virus
programs on the controller. If at all possible, avoid placing your machine control on your
network domain. Many controller manufacturers like Hypertherm recommend against it as this
can cause network group policies or untested Windows updates to cause issues with your
controller’s operation. Controlling machine motion in real time is a very sensitive process. The
company that built your machine controller has done extensive testing with it configured as is,
avoid putting additional constraints on it.

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b) Usernames & Passwords
Most PC based controllers will have a default username and password for you to use if they
are not configured to logon automatically upon start. As long as you don’t join your controller
to your network domain, this is the best option for use.
If you want to have a common username/password for all your shop equipment, you may be
able to get the machine builder to walk you through changing it. The technician installing your
machine may or may not have the skills to do the work, as they’re often very skilled in the
physical installation but light on computer skills.
Some controllers, changing the username and password is easy while others may require
jumping through more hoops. Whether you use the controller’s defaults or change them to
something you specify, keep this information documented well.

c) Auto Login
If your controller doesn’t automatically login when started up, this is one of the easiest things
to remedy. Armed with the username and password provided by your machine builder, you
can make a change in the registry to allow your controller to automatically login upon boot up.

Type REGEDIT to start the Registry Editor. (Start -> Run -> Regedit.exe)

Browse to the following key and add these values/data. If Values are missing, create them
and make sure the CaSe Is CoRrEcT.

HKEY_LOCAL_MACHINE\Software\Microsoft\Windows NT\CurrentVersion\Winlogon
Value Data
Type Value Name Off Domain On Domain (not recommended)
String AutoAdminLogin 1 1
String DefaultDomainName <domain name>
String DefaultUserName <user name> <domain name>@<user name>
String DefaultPassword <password> <password>
String ForceAutoLogon 1 1

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Samples of what the registry may look like are below…

OFF Network Domain settings…

ON Network Domain settings…

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d) Network Access & Drive Mapping
While adding your controller to your network domain isn’t recommended, it does make
accessing network resources easier. However this can be easily remedied with some simple
batch files.

To start, you’ll need a username/password for your network that will allow access to the
location you store your NC files. It’s recommended that a generic user account be created as
opposed to using one from a user.

Username should have only limited permissions to only the areas where needed to ensure
security. A password can then be set to not expire while maintaining security as it only has
limited access to the folder were your NC files reside.

This ensures that your machine communications are not rendered broken due to passwords
expiring or users leaving the company. As with the logon information provided with your
control, this account information should be documented.

Other considerations for a batch file….

• Operator Message (see Yellow section below).

When the batch file runs, it may display a DOS windows in on the screen. It’s
recommended to display a user friendly message to the operator so they know what
to expect.

• Delayed Execution (see Green section below)

Some machine control software consumes a lot of system resources when it launches.
This can cause things like drive mapping to fail if those attempt to occur before
networking resources are fully initialized. You can use the DOS “Ping” command to a
bogus IP address to introduce a delay. In this sample, a 45 second delay is specified
in milliseconds (45000).

• Map Network Drive (see Red section below)

Most machine controls will be able to access a mapped drive. You can use the DOS
batch file to map a drive letter using the network username/password you had created
for access to NC files on your server.

• Controller’s Network Address (see Blue section below)

If you know your machine’s network IP address, it can help an IT savvy person access
the control remotely. Whether it’s accessing the disk remotely or performing a screen
share, your machine control’s network address may be subject to change. Sending
the IP address to a file on your network records the machine’s current IP address each
time it’s turned on.

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 Once your Batch File is created, copy it to a location on your machine’s control. The simplest
method is to copy the batch file to the Start -> Programs -> Startup folder. You can also call
the program from the Windows Registry using the following information…

HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows\CurrentVersion\Run
Type Value Name Value Data
String <User Defined> C:\My Company\Map Drive.Bat

4. Serial Communications 101

Attempts at serial communications began as early as the late 1700’s. In 1810, a German man (
von Soemmering) used a device with 26 wires (each representing a letter of the alphabet)
connected to the bottom of an aquarium. As electrical current was passed, through electrolytic

Page 16
action bubbles were produced. By controlling which wires were energized, messages could be
sent via bubbles.

Today, one of the oldest and most popular forms of Serial communication refers to the
communication on a computer’s serial ports. Your network connection is technically also a form
of serial communications but for all practical purposes, serial communications in the computer
world refers to that which flows through your computers serial ports.

a) RS-232 (vs. RS-485, RS-422, etc.).

As there are many types of serial communications, you’ll often see the serial standard defined.
The most common is RS-232 which is an old industry standards that’s been revised, enhanced
and built upon over the years.

RS-232 uses a minimum of 3 data lines (send, receive and ground) for bi-directional
communication. Signals are determined by measuring the voltage between the signal lines
and ground. This means RS-232 has limitations over extended distances due to voltage drop
caused by things like resistance in the wires, electrical noise interference from other
equipment or even with systems where the sending and receiving devices are on different
electrical panels using different ground conductors.

Other serial standards like RS-485 are less common with machine controls but may be
supported on some controllers. These standards measure the difference voltage between
signal conductors differently offering better performance in electrically noisy environments or
longer distances. As they are less common, this document will focus on RS-232 as well as
several ways its limitations can be overcome.

b) Cabling
RS-232 serial cabling typically has is distance limit of 50-100 feet w/9 or 25 conductor cables.
Use of more than 5 conductors is very uncommon with most machine controls as the
additional conductors specified in the RS-232 standard are for special features not common
on a machine control. Regardless of the number of conductors, most cables will contain either
9-pin or 25-pin connectors or even one of each.

Higher quality cable tends to have higher quality components like shielding or more rigid
specifications in terms of the wire’s ability to transmit data without creating interference with
the other conductors.

c) Connectors (9-pin / 25-pin)

Serial connectors can be found in either 9-pin or 25-pin connectors. Connectors also come in
either male (pin) or female (plug) forms.

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 9-Pin 25-Pin

Male

DB9M DB25M

Female

DB9F DB25F

d) Pinouts
Each of the individual wires (conductors) in a cable is connected to a specific pin on a
connectors. Which pins on one end of a connector match to pins on the other end of the
connector or how they may be connected together (some connections require certain pins to
be connected together) is referred to the pinout.
In some cases, you may need to have a cable specially built or a custom connector with
certain pins connected a certain way. The following are specifications for how pins in a serial
connector are identified.
9-Pin 25-Pin

Male

DB9M DB25M

Female

DB9F DB25F
** Pin References are looking “into” the end of the connector. **

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The following documents the pin names, abbreviations and uses in the connection.
Pin Number
Signal Source Type Description
9-Pin 25-Pin
1 8 CD DCE Control Carrier detect
2 3 RX DCE Data Receive Data
3 2 TX DTE Data Transmit Data
4 20 DTR DTE Control Date Terminal Ready
5 7 SC - - Signal Ground
6 6 DSR DCE Control Data Set Ready
7 4 RTS DTE Control Request To Send
8 5 CTS DCE Control Clear To Send
9 22 RI DCE Control Ring Indicator
- 1, 9-19, 21, 23-25 Unused - - -
Note:
DTE = Data Terminal Equipment (Computer)
DCE = Data Circuit-Terminating Equipment (Modem)

While all these terms and definitions may seem daunting, have no fear. You can setup
communications without actually understanding most of this. What’s important to note are pins
#2 and #3 which transmit (3) and receive (2) data. If these data pins get reversed, the signals
run into one another meaning the wires must be reversed. Signal Ground (pin 5/7) is also
important.
If your look closely, you see that #2 & #3 pins are reversed in their purpose between a 9-pin
and 25-pin connector. If your cabling uses a mix of connectors (9 & 25-pin), you may
inadvertently cross the data lines when you don’t intend to. On the other hand, they may
already be reversed of what they should be (depending on how the control was built) and a
mix of connectors (9 & 25-pin) might actually un-cross the data lines the way they should be.

e) Tools of the Trade

There are many components that can be used in serial communications. Most are fairly cheap
and if you’re not 100% familiar with what’s needed, it’s often more efficient to buy a variety of
the things you think you might need so you have on hand, where’s needed.

i. Short Haul Model

As mentioned prior, length limitations apply to serial data connections. One way to
extend the range of serial connections is by using a short haul model. Actually, you’ll
most likely be using 2 short haul modems, one on each end of the connection.
What a short haul modem does, is take a serial cable connection, and convert it to a
different signal type which you can use a standard 4-wire phone cable. Depending on
the wire size, and data speed, a short haul model can extend a serial data connection
from 100 feet to 5 or 6 miles.

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 Black Box: ME800A-R4 (~$175) Dataforth: LDM70 (~$225)
http://www.blackbox.com http://www.dataforth.com/

ii. A/B Switch

Often the problem with a hard wired serial connection is that it’s physically tied to a
single computer. If you have multiple serial devices connected to the same computer,
you might even need an expansion serial card added. If (when) this computer fails,
your machine communications goes down. You can build 2 identical computers to offer
a backup system and tie both to a single machine using an A/B switch.
Likewise 2 machines could be connected to a single serial port on a single computer
using an A/B switch. While this can be done or even needed, it isn’t recommended as
it requires you to switch the connection to each machine prior to it loading NC code.
Your machine operator may even need to come into the office to do it.
The value of an If using an A/B switch is really to tie a backup computer to your
machine keeping you running if the main computer fails.
Serial A/B Switchbox (~$15)
http://www.amazon.com
Front Back

iii. Gender Changers

While you can get custom cables or specify the types of ends you want on it, it often
doesn’t pay to figure out everything ahead of time. You may find that additional devices
are needed during setup. It’s may be easier to by standard equipment like cables and
switch boxes and use a gender changer to switch as needed.
9-Pin Male 9-Pin Female 25-Pin Male 25-Pin Female

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 Standard

DB9M/M DB9F/F DB25M/M DB25F/F

Slim

DB9M/M DB9F/F DB25M/M DB25F/F

iv. NULL Modem / Reverse Adaptor

As mentioned before, Pins #2 & #3 are the primary data transmit and receive lines. If
the transmit or receive signals collide with each other, a NULL Modem adaptor or
Reverse Adaptor will cross them for you. The difference is that a NULL Modem
reverses additional pins where a Reverse adaptor may only reverse the data lines.

v. Adaptors
Adaptors serve a variety of purposes. Most commonly they can help connect a 9-Pin
connector to a 25-Pin connector. As mentioned earlier the standard between 9/25-Pin
connectors reverses the data lines. As such, use of a 9-Pin to 25-Pin adaptor is just
as likely to fix mix a matched pinout as it is to break it making the use of a NULL
Modem or Reverse adaptor a possibility.
There are several other types of adaptors for special situations like a 90-degree angle
connection, special reverse/null modem conditions or joined pin connections.
The best sources with the widest selection of adaptors are http://l-com.com and
http://www.blackbox.com.

vi. Test Adaptors

Troubleshooting serial connections without a lot of documentation or if you are not real
familiar with serial cabling can be difficult. For these situations, test adaptors can be

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 used. They typically plug in-line and have a series of LED lights you can watch as you
attempt to send files to your machine controller. As mentioned before, there’s a lot of
wires and not all are often used, pay particular attention to TX (Pin 3) and RX (Pin 2)
lights.

vii. Breakout Box

A breakout box is another good tool for determining proper pinouts. However it
requires more knowledge of pinout and the purposes for the various signal lines or a
lot of patience (perhaps both). A good breakout box allows you to easily try various
pinout connections.

viii. Loopback Plug

A loopback plug is used with special functionality with serial communications software
or hardware. It allows a computer or device to “talk” to itself as a means for testing.
While you can buy loopback plugs, they’re easy to make yourself using the female end
of any adaptor or an old cable. The following are images of bought loopback adaptors
as well as the pinouts you’d use to jump pins together to make your own.

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 http://www.passmark.com
~$10

f) Autodesk Communications
For serial communications, there’s a lot of configuration options to be aware of. It usually
requires the use of special software to facilitate communications between the files on your
network with the machine. The following are more details regarding this…

i. Programs
For serial communications, you need a program that handles the communication
details to/from your machine controller. While there’s many third party programs that
would work, Autodesk provides several different (16 actually) programs specifically
tailored for various machine controller types.
Communications Programs that ship with Autodesk Fabrication CAMduct

C:\Program Files\Autodesk\Fabrication ####\CAMduct

Burny.exe Iowa.exe
Cyb.exe Iowatcp.exe
D6.exe Jubilee.exe
Dnc.exe Komatsu.exe
Eastco.exe Mazak64.exe
Engelht.exe Nce.exe
Farley.exe Sharp.exe
Firmac.exe Ucnc7.exe

Most of the communications programs are specific for certain generation controllers.
You might have to use trial and error to find what works for you. BURNY.exe and
D6.exe are popular choices. JUBILEE.exe is used w/the Autofold coil lines.
The communications programs have been changed a bit since Autodesk bought MAP
software. If you have an existing setup that’s working for you, details may not be
exactly as in this document. A few examples….
• BURNY.exe use to store an INI file for its configuration settings in the Windows system
folder. D6.exe use to store it in the same folder as the EXE file. Now all
communications programs store their settings in the same folder as the MAP.INI file.

Page 23
• 2013 Communications programs also were still 32-bit programs even when installing
on a 64-bit operating system. As such, the “cloud” functionality added to the software
would produce an error on the 64-bit systems when the 32-bit communications
program tried to load the 64-it “Cloud” libraries. To fix that, you’d simply rename the
“Cloud” folder in “C:\Program Files\Autodesk\Fabrication XXXX\<product>\Cloud” to
something else so the software can’t load the incompatible DLL’s. You’d also need to
rename it for all products as sometimes one product
would reference the cloud folder of another product.

• Some older communications programs all use the

same INI file for storing their settings. Others would
use an INI file named the same as the EXE file.
Current versions of CAMduct’s communications
programs you can specify the name of the
configuration file by specifying its name after the EXE
file name in the shortcut allowing multiple machines to
use the same communications program but different
settings.

When you launch any one of the communication

programs the ship with CAMduct, they all look very
similar. That’s because they are all very similar in function. The number of different
programs, controllers and special options is too great to cover here. For the most part,
you’ll only use the core settings.
The “Change Settings” button is
where you specify the communication
settings.
The “Log” and “View” toggles are also
helpful in diagnosing communications
issues when setting up a machine.
“Log” will log ALL communications
sent through the data lines to a file,
including special codes that are used
to request a file, start and terminate
communications. This log can be
helpful in determining which of the
communications settings may be off.
The “View” toggle serves the same
purpose only instead of sending the
data to a file, it displays it in the dialog
where the machine image is instead.
Other buttons, dropdowns or Special
Features vary by communications program. You may need to do a bit of trial and error

Page 24
 if your machine needs them but start with the basics and rule out problems there first.
The CTS & DSR toggles only will come into play if you are using hardware
handshaking. They define if your system should be configured as the sending or
receiving system so it knows which direction the handshaking signals should be sent.
The controller you’re connecting to will determine if this is required.

ii. Settings
There’s several settings
associated with serial
communications. Exactly
“what” they do is not nearly as
important as that most match
between your
communications program and
what your machine controller
is expecting. None the less, it
often helps if you have an
idea what you’re looking at so
the following is a very brief
explanation of many of the
settings. From the
communications program,
click the “Change Settings”
button to display the dialog for setting the communication parameters.
In addition to the main communication settings at the top, Character, Line and Transmit
delays along with special control characters are really advanced functionality that most
users should need.
Also note that when you see written specifications for serial communication settings,
you’ll often see it expressed in the format “9600 8N1” or similar. In this form, “9600”
refers to the speed or Baud Rate, “8” refers to the number of “Data Bits”, “N” refers to
the type of “Parity” and “1” refers to the number of “Stop Bits”. An explanation of these
main settings follow.

• Port
Each serial port on a computer has a name. They’re typically referred to as COM1,
COM2, etc. For all practical purposes, only one program can access a COM port
at a time. For example, COM1 is often reserved by your system which means you
much use COM2, COM3, etc. If you run out of COM ports, you may need to have
an expansion card added to your system.
The COM Port is one setting that does NOT hate to match what you’re connecting
to. It simply tells the communications program which port to pull data from on your
computer. The Controller handles this function on the other end.

• Baud Rate
Serial communications use electrical signals to send data. Baud rate refers to the
number of symbols per second that can be sent. In a nutshell, it’s the speed at

Page 25
 which the data is transmitted. The further the serial communication, the less speed
may be supported. This communications rate needs to match what is set on your
controller.
Common Baud Rates are….110, 150, 300, 600, 1200, 2400, 4800, 9600, 19200,
38400, 57600, & 115200. The minimum you typically see on older systems is 2400,
9600 is fairly common. Newer systems can typically go much faster. If you think all
your settings are correct and communications still fail, try setting a lower Baud rate
like 2400 on your controller and communications software.
If it works it’s likely too fast a speed is suffering too much signal loss or your
controller just can’t keep up. Once working, you can try to bump it up (remember,
on both the controller and your Communications software) to get a faster transfer
speed.

• Data Bits
Bits are the smallest measure of data in computers. Bit is short Binary Digit. When
serial communications occur, each character is sent in either 7 or 8 bits of data
coordinated by a start bit and an optional stop bit (see next section).

• Parity
As data is sent through serial communication, there’s an extra bit of data used as
an error checking algorithm. This extra bit of data is referred to as Parity. Varity
values in the communications software much match that of your machine control.
Parity values can be….Odd, Even, None, Mark and Space. These are often just
referenced by letter….O,E,N,M and S.

• Stop Bits
Stop bits are extra data that follow the data bits and any parity data. They mark the
end of transmission of a piece of data such as a byte or character.

• Flow Control / Handshaking

If you work working with a person picking apples, you might be in tree, tossing
apples to the person below. They catch and place them in a bucket. All is well until
the bucket is full which requires the person on the ground to empty it or get a new
one. If the person in the tree doesn’t know this is happening, they keep throwing
apples and they hit the ground and get ruined.
Serial communications flow control serves the same purpose. The sending and
receiving systems use flow control or handshaking as a way to tell the other system
when it’s buffer can hold more information.
Settings for flow control are XON/XOFF (software flow control), Hardware, Combined
or None. Hardware flow control requires additional signal lines which may make
cabling, connectors and such a more difficult task. Software flow control (XON/XOFF)
on the other hand uses the standard data lines but as a result, does reduce the
bandwidth of the communications however it’s usually insignificant to matter.

Page 26
 The faster the serial communication setting, the more important flow control becomes.
This is especially true in older systems.

iii. Testing
While you might be tempted to redo your data connections when you click the “Test”
button from the communication program and see that it fails, this isn’t doing what it
appears. For the test button to work, you need to use a serial loopback. Your machine
control may have a mode that enables this, or the Black Box short haul modems shown
earlier also have an option to create a “loopback”. This is where the communications
are configured to talk to itself for testing communication.
If you’ve needed a lot of serial adaptors and such, disconnect the cable on the machine
end and add a loopback plug. Now click the test button. If all the cabling and pins are
configured properly, it should succeed.

iv. Files and Logs

Within the “Change Settings” dialog, you’ll also see where you can tell the
communications to read (or write if supported by your controller) the NC files from on
your network. This can be a local drive or network specified via drive letter or UNC
pathing.
Lastly, you can also specify a log file and location. This differs from the Log toggle on
the main communication dialog which logs all the data sent and received. Instead, this
log records which programs have been sent or received during communications. If you
wanted to see which NC programs were sent, this is where that location would be
stored.

5. USB Communications
If you have a PC based controller, the chances are very high
it supports USB connections. If that’s the case, the control
software also likely supports reading from a USB flash drive.
If you’re are installing a new machine and there’s a factory
technician there wanting to make sure the machine is
operating properly, they’re likely waiting for you to write some
programs from CAMduct. That in itself can be a task to get
dialed in, why wait longer while trying to setup serial
communications or networking.
Simply copy your NC program to a USB Flash Driver and transfer it to the machine control. The
technician likely can walk you through reading the file from the USB flash drive. This allows you
to focus on getting CAMduct setup properly to control the machine and work with the technician
on those settings they need to make. Once you’re sure the machine works and is cutting what
CAMduct is telling it to, you can redirect your attention to setting up the communications.

Page 27
6. Ethernet Communications
If your machine controller is a newer PC based control, there’s a good chance it can be plugged
into your network the same as any other computer. In my opinion, this is the best option for
communicating to a machine control for several reasons.
• IT staff more familiar w/Ethernet than Serial communications
• Network outages affect more people meaning more IT responsiveness when down
• Eliminates the use of additional “communications” programs found in serial connections
• Fastest loading of programs into the controller
• Allows many machine builders to remote into the control for troubleshooting
• Easier for you to support remotely

a) Cabling
Your IT staff or cabling contractor will likely know the length requirements for Ethernet cabling.
As a rule of thumb, 100 meters is the distance you’ll want to stay within in a single run. If you
need to go further, there’s a lot of options. Consult your IT staff and they’ll guide you in the
right direction.
Where possible use a wired connection, preferably run in electrical conduit to protect it from
physical damage. Cat5e or Cat6 shielded twisted pair cable is preferred and should be
specified as most cabling contractors will use unshielded by default. While unshielded cable
works in many cases, a shielded cable provides extra protection against electrical noise
contamination of the signals.
When cable needs to be run in flexible cable track, consider
using a cable with a more durable external jacket such as
found on cables rated for underground use. A good low
voltage cabling contractor is recommended as they’ll test
and warranty their work.

b) Wired / Wireless
Wireless and Wired connections to your network are usually
simple. Wireless would seem like the obvious choice,
however they can be problematic. Older plasma units and welding equipment can cause
interference with wireless signals. Additionally, wireless connections to your corporate
network may require additional logins or security codes depending on your IT Department’s
security policies especially if the controller isn’t joined to your corporate domain.

c) PoE (Power over Ethernet)

If you like the advantages of Ethernet networking for shop equipment but have older serial
based machine controllers, there is hope. There are a wide variety of Serial to Ethernet
devices available. Some of these devices can be powered from the network connection itself
or from an external voltage source. If your network supports it, or if it’s an option, you may
want to make sure the cabling in your shop supports PoE. This is typically done at the
switch/router by your IT staff. Why use PoE? Simple, one less plug (power) in the device
means once less point of failure.

Page 28
7. CAMduct Machines 101
Setting up a machine in CAMduct is explain in the help files and elsewhere on line. The following
are some good places to start…
Setting up a plasma/router/laser/Waterjet machine…
http://enceptia.com/fabrication-user-group-recording-nov-7-2014/#more-5072
Setting up a coil line (examples of an Autofold and Iowa are linked in the right side bar)….
http://knowledge.autodesk.com/support/fabrication-
products/troubleshooting/caas/sfdcarticles/sfdcarticles/Installing-a-coil-line-in-Autodesk-
Fabrication-CAMduct-s.html

a) Plasma/Laser/Router/Waterjet Setup
To setup one of these machines, you’ll need to make a configuration entry for it in CAMduct.
Stat CAMduct and go to File -> Setup -> Installed Machines.
You can create “Groups” of machines if you
want to generate NC code for multiple
machines at the same time. However, the
buttons under “Machine” setup will be your
primary concern. Click the “New” button to
create a new machine configuration.
Once the machine configuration is created,
use the “Setup button to specify the machine specifics.

Machine Tab Controller Tab

NC Settings Tab

While there are several tabs to choose from, the 3 tabs above are the primary tabs you’ll be
using to get your machine to cut properly.
The Machine Tab you specify the dimensions of the machines working area, where its origin
is located, where you want the tool to go after cutting, etc. You can also specify if it’s a dual
table machine, if it should alternate between tables as well as distance between the tables.
You can also define when and where to rip cut extra material that’s not used.

Page 29
The Controller Tab is where you’ll select the post processor to use. This is likely the most
important part of setting up a machine. You may need to try a couple likely candidates to find
the right one. Here you can also define positioning (absolute vs relative). Absolute positioning
tells the machine exactly where to go in defined coordinates whereas Relative defines tells
the machine how for to move in a particular direction. Most modern machine controls can be
configured to take either method or to determine the method via the program. If the machine
is expecting a particular way, your machine configuration must match. You can also specify
the default file extension which is usually ok but if you have multiple machines using the same
file extension, you may want to specify something else for one of them.
The NC Settings Tab has some lesser but sill important settings that you may need to specify.
Kerf is one such setting. When you cut a square, the cut itself has a width. If the machine
outputs the exact coordinates of your part and your machine cuts those exact coordinates,
your part will be small. To compensate, you have 2 options. You can apply kerf here within
CAMduct and CAMduct will adjust the coordinates per the kerf you define in the tool section.
The other option is that some controllers will allow you to specify the kerf on the machine and
the machine will compensate this distance. Either is a valid approach but the settings need to
match, you wouldn’t want to compensate for the kerf at both the machine and within CAMduct.
Some of these settings may be the most difficult things to setup when getting a new machine.
Often the factory technician isn’t versed in the software and when you ask specifics, they’ll tell
you the machine will do whatever you want it to (can be configured on the machine) or tell
you it’s up to you to do it in the software. Often, they just don’t know. Sometimes you’ll just
have to output code to the machine and see what works and what doesn’t and adjust on the
machine or CAMduct as best you can.
The Tools section of the Installed Machines dialog are where
you configure the tools your machine uses. If you setup a
machine properly and nothing is output, you likely forgot to
configure the tools.
Each machine will default with a NULL tool. You’ll need to
add the tool(s) your machine supports. Once added, you can
configure the tool with several settings. This is where
you can define the “kerf” value for the tool (how wide
the material it is that gets removed) along with other
factors like Feed Rate (how fast the tool cuts), etc.
Within this Tool Setup dialog, there’s 2 sections. The
Globals section allow you to set a value once for all
materials that tool may use. If the time it takes to raise
and lower a tool is constant no matter the material, it
should be a global setting allowing more accurate
forecasting of true cutting time.
The Details section allows you specify the same
settings but on a per material basis. Things like
Feedrate can automatically be changed based on the thickness and type of material being
cut.

Page 30
 Many of these settings can be output in the code or a lot of machine controls can be configured
to ignore them and allow the operator specify them. All tool settings can be moved between
the Global and Details section but they can only reside in one or the other.

b) Decoiler Setup
To setup a Decoiler, start CAMduct and go to File -> Setup -> Installed Decoiler. Unlike
machines, CAMduct will allow you to configure only one controller. There are other ways to
work around this limitation but they are unsupported. Email me for more details if you have
this need.

Machine Tab Other Tab Options Tab

There are multiple tabs. Seams and Connectors tabs are important for some coil lines
(AutoFold) but not others (Vicon). Start your Decoiler setup with the Machine tab as the post
processor you choose will affect the types and availability of the options on the other tabs.
The Machine Tab is where you specify the post processor (DPL) file to use. You can also the
folder location and files naming method for the Decoiler list files.
The Other Tab is where you define the machine limits. Can your Decoiler make a full box? U-
Shape or Only L-Shapes? What’s the Minimum site?
The Options Tab varies depending on the machine you are setting up. Once you select the
proper post processor, check the Options tab to see if your machine has any options that need
to be specified.
The remaining tabs you can specify the order items are processed (Blanks and Straights) as
well as selecting which coil station to use if supported.

8. G-Code 101
G-Code is the most common method of programming CNC Machine controls so that’s what we’ll
cover here. Each program can be opened in a program like Notepad which open plain ASCII text
files.

Page 31
While many codes used in CNC programs are common across controllers, there’s also a lot of
codes that are defined by the control manufacturer. There’s yet other codes in a CNC program
that are defined by the machine builder.
The following are all examples of NC programs…

a) What’s in a CNC program

A typical program often starts with things like notes or a program number. After that, there’s
typically a series of codes that setup the environment. They might specify the units
(imperial/metric), absolute or incremental programming, even feedrates. Next, the program
will position to its starting location and initiate the cutting tool. This could be a plasma torch, a
router head or even a water jet. At that point, the program starts instructing the machine about
what geometry it should cut.
If you remember high school geometry, you should be able to follow along as coordinates are
expressed in terms of X & Y. When it’s finished the cutting tool is turned off
(plasma/waterjet/laser) or may stay running (router) while it positions to the beginning of the
next part. This process is repeated until all geometry is cut. The program then instructs the
tool where it should park the cutting head before the program ends.
All these commands are specified in a CNC G-Code program using a number of characters
or word addresses which start with a letter. The following are a list is common Characters and
Word address code. The most common are shown in green.
The
Character Use Example
() Comments (Part 6 – Wrapper)
% Beginning / End of program
Block delete – skips a line of code of
/ /G04 D15000
control is in block delete mode
- Denotes a negative number G01X-2.3Y5.2
+ Denotes a positive number G01X-2.3Y+5.2
. Decimal used for fractional units G01X-2.3Y5.2
; End of block G01 X-2.3 Y5.2;

Page 32
 White space between Word Addresses
<space> optional. Used to make program more G01 X-2.3 Y5.2;
human readable
A Angular axis around X-Axis
B Angular axis around Y-Axis
C Angular axis around Z-Axis
Tool Diameter register used for cutter
D G01 G41 D4 X0.25
compensation
Precision feedrate on Lathes or angular
E
for special axis on Mills
F Feedrate F300
G Preparatory functions G02 X4.3 Y2.1 R0.25
Tool Height register for tool length
H
compensation
I Arc Center X-Axis G03X6.9Y6.9I6.9J0.0
J Arc Center Y-Axis G03X6.9Y6.9I6.9J0.0
K Arc Center Z-Axis
L Fixed Cycle Loop Count
M Miscellaneous Function M04
N Program block or line number N10 G00 X1.25 Y2.12
O Program name O12032
Parameter used w/many G/M codes
P M98 P12033
Also used for Program name
Q Peck increment in Fixed/Canned cycles
Radius
R G02 X4.3 Y2.1 R0.25
Canned Cycle Values
S Spindle Speed
T Tool Function T1
U Secondary axis parallel to X
V Secondary axis parallel to Y
W Secondary axis parallel to Z
X Primary Linear Axis
Y Primary Linear Axis
Z Primary Linear Axis

b) Common codes
Typically many of the word addresses have special formatting. Axis specification word
addresses (A,B,C,I,J,K,U,V,W,X,Y,Z) are followed by a number, typically a coordinate. Others
are parameters to the Preparatory functions (G) or machine/miscellaneous (M) word
addresses.
You can consult your machine’s controller documentation for more information on what it does
and does not support as well as the exact syntax used. However, if you have an idea what
the codes are for, looking at a sample program which you can often get from the machine
builder is all you need.

Page 33
Many of the preparatory functions are standard across most controllers. Others are subject to
change depending on the machine and control. Below is a list of common G-Codes with those
being fairly consistent highlighted in green.
Code Description Code Description
Cutter compensation (kerf)
G00 Positioning/Rapid traverse G41
Tool left of path
Cutter compensation (kerf)
G01 Linear cutting G42
Tool right of path
G02 Circular (CW) cutting G43 Tool length offset
G03 Circular (CCW) cutting G49 Cancel tool length offset
G04 Dwell (not modal) G52 Local coordinate system
G08 Acceleration G53 Machine coordinate system
Deceleration/Exact stop check G54-
G09 Work coordinate system
(not modal) G59
G10 Programmable data input G61 Exact stop check (modal)
G11 Data write cancel G62 Automatic corner override
Default cutting mode cancel
G17 XY plane G64
(cancel G61)
G18 ZX plane G70 Imperial/Inch programming
G19 YZ plane G71 Metric/mm programming
Thread cutting -
G33 G80 Fixed/Canned cycle cancel
Constant lead
Thread cutting – G81-
G34 Fixed/Canned cycles
Increasing lead G89
Thread cutting –
G35 G90 Absolute programming
Decreasing lead
Cancel cutter compensation
G40 G91 Incremental programming
(kerf)

Not as standard as the preparatory functions, there are a lot of M-Codes that can be used. A
smaller set of M-Codes are standard across machines. Many are specific to the machine and
its options. Below is a list of common M-Codes with those being fairly consistent highlighted
in green. Note that your machine very well may use one of the same M-Codes listed below
but for a different purpose.
Code Description Code Description
M00 Program Stop M07 Flood Coolant ON
M01 Optional Program Stop M08 Mist Coolant ON
M02 End of Program M09 Coolant OFF
M03 Spindle on CW M30 Program Stop
M04 Spindle on CCW M79 Go to Table Home
M05 Spindle Stop M98 Call Sub Program
M06 Tool Change M99 Sub Program End

c) Syntax nuances
There’s a lot of “rules” of thumb for the syntax in an NC program. A lot of these differences
can vary controller to controller or even machine builder to machine builder using the same
control. The following are rules of thumb and explain some of the variations you may
encounter.

Page 34
• Not all G-Codes are supported on all machines. Consult your documentation for
specifics for your machine.
• Not all G-Codes have the same function on different controls. The common standard
codes are listed earlier but consult your machine’s documentation for specifics.
• Most G-Codes are “model” meaning, they can be specified once and remain in effect
until canceled or another code is specified changing the machine’s mode.
• More than one G-Code can be specified on the same line. You need to make sure
you don’t specify codes that conflict with one another but others are perfectly fine.
(e.g. G01 and G41/G42 are often used together or G70 & G90)
• Some controllers allow codes G00 or G0, G01 or G1, G02 or G2 and are happy.
Others require the G00, G01 and G02 with the leading zero specified.
• Many G-Codes needs additional parameters using different Word addresses. Consult
your machine’s documentation for more specifics.
• M-Codes can only be specified one per line (block).
• Program name (O/P-Codes) are typically optional
• Program comments are optional
• Program start/end (%) is not required on all controls.
• End of Block (;) which marks the end of a line is not required on all controls.
• Coordinates may or may not contain decimals and instead be specified in 1000ths or
10000ths of an inch. Leading zeros for coordinates less than a single unit, may or
may not contain a zero after the decimal for whole units. They may or may not require
a positive (+) for positive coordinates or they could allow any number of variations of
this. Here’s a few examples of how a coordinates may be expressed…

X+10000 X1. X+1 X+1.0 X10000

X+10000 X0.1 X.1 X1000 X01000
• Line or Block numbers are typically optional
• Spaces between word addresses are optional and used only for “readability” by
humans.
• Some controls can cut a full 360 circle in one line of code, some only 180 degrees,
some only 90 degrees, others may require it to be cut in a series of short line segments.
• Some controls support an “R” specifying the Radius of a circular cut, others require I/K
coordinates specifying the center of the radius in addition to the end point if the arc
being specified with the X/Y coordinates.

(14668)
%
P14668
(WADR2)
M79 T2
(ORIGIN=BOTTOM LEFT)
(INCH)
G70
(RELATIVE)
G91
G00X7.934Y3.912
M03
F250.0

Page 35
 G01X-0.159Y0.121
a) Programming in a Nutshell G01X-0.125Y-0.033
G01X0.125Y-0.033
There’s not much about programming that you didn’t G02X-7.550Y0.000I-3.775J0.033
learn in high school geometry. It pretty much follows G01X0.125Y0.033
G01X-0.125Y0.033
these simple steps. G02X7.550Y0.000I3.775J-0.033
G01X0.017Y-0.098
M05
Note that not all listed possible functions are in the G00X-1.858Y6.728
M03
sample code and some items can be performed in G01X-0.159Y0.120
G01X-0.125Y-0.033
multiple areas. This is only a general outline and not a G01X0.125Y-0.033
G02X-5.550Y0.000I-2.775J0.033
hard fast rule. G01X0.125Y0.033
G01X-0.125Y0.033
i. Initialize Environment (RED) G02X5.550Y0.000I2.775J-0.033
G01X0.017Y-0.098

• Start Characters
M05
G00X-1.858Y4.703
M03
• Notes G01X-0.159Y0.120
G01X-0.125Y-0.033
• Absolute/Relative G01X0.125Y-0.033
G02X-3.550Y0.000I-1.775J0.033
• Imperial/Metric G01X0.125Y0.033
G01X-0.125Y0.033

• Table Position/Select
G02X3.550Y0.000I1.775J-0.033
G01X0.018Y-0.098
M05
• Feedrate G00X0.141Y3.753
M03
• Ripcut G01X-0.159Y0.120
G01X-0.125Y-0.033
• Other G01X0.125Y-0.033
G02X-3.550Y0.000I-1.775J0.033
G01X0.125Y0.033
ii. Position (Green) G01X-0.125Y0.033

• Traverse to next piece

G02X3.550Y0.000I1.775J-0.033
G01X0.018Y-0.098
M05
• Feedrate G00X0.141Y3.753
M03
• Tool change G01X-0.159Y0.120
G01X-0.125Y-0.033
iii. Cut (Blue) G01X0.125Y-0.033
G02X-3.550Y0.000I-1.775J0.033

• Initiate Tool
G01X0.125Y0.033
G01X-0.125Y0.033
G02X3.550Y0.000I1.775J-0.033
• Initiate Kerf Compensation G01X0.018Y-0.098
M05
• Feedrate G00X0.141Y3.753
M03
• Cut G01X-0.159Y0.120
G01X-0.125Y-0.033

• Cancel Kerf Compensation

G01X0.125Y-0.033
G02X-3.550Y0.000I-1.775J0.033
G01X0.125Y0.033
• Stop Tool G01X-0.125Y0.033
G02X3.550Y0.000I1.775J-0.033
iv. Finish Program (Purple) G01X0.018Y-0.098
M05
• Ripcut (PART RIPCUT AFTER)
G00X4.218Y-26.572

• Notes M03
G01X0.173Y-0.100

• Position Park/Home/Table
G01X0.000Y59.874
G01X-0.087Y-0.050
M05
• End Program (PARK)
G00X112.403Y0.613
(END OF SHEET)
(END OF PROGRAM)
M30

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A note when using kerf/cutter compensation in a program, you’ll need to lead in and out
of a profile for the tool to take time to compensate. The below illustration shows how kerf
(cutter) compensation affects the resulting geometry.
When setting up the machine entry in
CAMduct (explained earlier) the “Apply
Kerf” toggle on the “NC Settings” tab is
what controls if you’re CNC code will be
written to allow for kerf compensation or
not.
This toggle is misleading
however….clearing the toggle means that
CAMduct will NOT apply kerf, meaning your CNC code will use the G41/G42 codes and
program the X/Y coordinates using the GREEN toolpath below. This requires you to enter
the kerf value into your control to the machine knows how to compensate.
Checking this toggle (recommended) means the CNC code will written be CAMduct
according to the RED toolpath automatically applying the kerf value in CAMduct. As such,
the G41/G42 compensation codes are then not output in the code.

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Part V – Other Considerations

1. Non-Supported Machines/Options
CAMduct support most of the machines in the duct fabrication industry. None the less, each year
the list of Post Processors gets just a little bit longer. If you have a new generation machine or
something CAMduct doesn’t currently support, you’re not dead in the water yet. You might need
to take a little bit of time using trial and error to find a VPL post that gets you close.
From there, a specially formatted MACHINE.CFG file can be placed in the same folder as the
machine’s setup files. (.\Database\<machine>.mch>\Machine.Cfg). Use of this file and how to
generate it is not supported by end users and documentation is virtually non-existent.
While you can get an idea what’s happening by looking in a sample file if you find one, your best
bet it to bring in a consultant specializing in this type of work or using Autodesk support to get you
through it. This is something that 99.9% of customers should never need to do and by involving
a consultant or Autodesk, the next version of CAMduct may just ship with a native VPL that covers
your machine.

2. Hybrid-Communications
When it comes to connecting your CAM systems to your machines, there’s a lot of options. We
covered USB, Serial and Ethernet (standard networking) earlier. However, there’s more options
available. Ethernet by far is the best choice, plug your controller into your network and you’re
good to go.
But what if you have older serial based machine controllers? Is Serial really the only options?
Luckily no, there’s a couple good options…

a) Serial to USB
Most systems come with at least 1 or 2 serial ports. If you need more, you need an expansion
card. Some systems may not even have any. If you do a search, you’ll find a number of USB
to Serial devices available. These devices usually create a “virtual” serial port(s) on your
system and maps it to your computer’s USB port. Your communications software (which ships
w/CAMduct) then references those virtual COM ports (if you recall earlier, serial ports are
addressed as COM1, COM2, etc.). The communications software is none the wiser and
operates how it always has.
What’s nice about a system like this, is it’s easily portable from one computer system to
another in case one goes down. Just reinstall the USB to Serial drivers or software and its
plug and play to get a new system back on line.
The one drawback, is that USB ports can be susceptible to the resource demands of your
system. It’s not recommended to use a production system that’s performing processor
intensive operations or communications could fail if your controller requests a file and your
system is slow to respond via the USB port.

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 b) Serial to Ethernet
Similar to Serial to USB, there’s a variety of Serial to Ethernet devices available. This is
perhaps my preferred way to “Network” older serial based devices. They operate in a similar
fashion in that you install drivers on a system and create virtual serial (COM) ports. The
communications software references the serial ports as it always has.
The drivers handing the virtual serial ports convert the data traffic to
standard network traffic and the Serial to Ethernet server on the other
end converts it back to serial at the machine controller. You only need
a standard network cable (Cat 5e or Cat 6 rated is preferred) dropped
to each machine.
My personal favorite is Lantronix’s xDirect due to its “inline” design and
availability in a PoE (Power over Ethernet) version which eliminates an
additional power plug on the shop floor.
http://www.lantronix.com/device-networking/external-device-servers/xdirect.html
If you want to experiment, there’s also a variety of Serial to Wi-Fi devices that would eliminate
the need for a network cable at the machine.

3. Backup Systems
There’s nothing more important than your shop’s production. I’ve seen many installations where
the entire production is hinged on the operation of a single workstation performing input and
possibly machine communications functions. While you can fairly easily install CAMduct on a new
system. Communications to your machine on the other hand is another story if your machine
controller is using serial communications.
One way to remedy this situation fairly easily is to have a second system, carefully built and
configured to be identical to the first system. You can then employ a serial A/B switch that
connects both computers to a single machine. If one system goes down, simply toggle to the other
system and launch the communications software and you’re back up and running.
The only real down site is the cost of a second system. However that cost is typically minimal
compared to shop downtime.

4. Resilient Systems
There a lot of things you can do to beyond just building a second system for backup. The overall
strategy in designing a resilient shop/machine configuration, one that is resistant to failure and is
quick and easy to restore services if it does fail, requires a number of objectives.
Objective 1: Separate the processes of “Shop Input” (the work performed within CAMduct
processing MAJ’s) and “Machine Communications” (sending the NC files to the machine controller
via serial connection). By separating these processes to different systems, if any one system goes
down, the other process can stay running. Furthermore, to restore the failed process (Shop Input
or Machine Communications”), you’re only restoring and setting up one process instead of 2. This
makes restoration of services ½ the work it would be otherwise.

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Objecting 2: Move machine communications to a
“virtual” system instead of physical. A “virtual” system
is a computer running in a computer. Many IT
departments support virtual servers because they
allow them to run multiple virtual servers on limited
physical computers.
If your machine controller supports networking
directly, use that functionality for communication. If it
requires a serial connection, implement Serial to
Ethernet devices and use a virtual server to handle the
Communications software.
A virtual server can be backed up by your IT department with a
standard backup just like files. They can be rebuilt easily without
needing to acquire hardware and most importantly, it moves the
communications system out of the shop where they’re often left
prone to neglect with an “out of sight, out of mind” attitude. If your
shop communications setup looks like these images, consider
visualization.
Objecting 3: Minimize points of failure in your system. By virtualizing a communications system,
you eliminate a lot of hardware. By using a Serial to Ethernet device, you need one device per
serial based controller instead of 2 (one on each end of the connection) like is needed with a
Short Haul Modem. Adding the A/B switch to your serial connections to allow a second machine
to serve a serial communications linked adds a whole lot of physical connections and connectors
to loosen or fail.
Objective 4: Employ technologies that that are easily supported by your IT staff or will have greater
attention from IT staff if they fail. That “one” system under the shop desk sending files to your
plasma machine is old and dirty and used by “that one guy” in the shop. If it fails, how much
attention does he get and how quickly will your IT guys get him up and going again? Do your guys
in your IT staff even know what a serial connection is?
On the other hand, if the hardware fails that’s running your virtual communications system,
chances are it’ll automatically (virtually) move to redundant hardware already in place common in
virtual environments. If it fails completely or if your network goes down, it’s likely taken a lot of
other servers, data and/or users with it. How much attention will this get from your IT staff? I’m
guessing this would be the type of thing they’d work through the night to get back up and running.
How likely are they going to be to do that for “Sheetmetal Bob” stuck back in the corner of the
shop?
Objective 5: Network license software. By network licensing your CAMduct software, the license
can easily “float” to another system for shop input system if the first fails. Additionally, you could
install the software on every detailers system or even an accountant’s. Any system would work
for shop input as the license floats to it and communications aren’t tied to it. This has the added
benefit of allowing you to quickly scale up to additional CAMduct stations if needed by simply
adding licenses into the pool.
Below is an example of our communications environment BEFORE implementing those
objectives along with some bullet points of the issues it can cause.

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 (2B) (13B) (4B) (5B)
Network Switch A/B Switch BlackBox BlackBox (10B)
(1B) (3B) Autofold Coil Line
File Server Communications Terminal & Controller
CAMduct/PM2000 Input Station

(14B) (6B) (7B)

A/B Switch BlackBox BlackBox (11B)
Lockformer Plasma
Controller

(15B) (8B) (9B)

A/B Switch BlackBox BlackBox (12B)
Advance Cutting Plasma
(16B) Controller
BEFORE Communications Terminal &
CAMduct/PM2000 Input Station
Green: Unchanged
Infrastructure

Blue: Not present but

need to add for
backup/redundancy

Orange: Eliminated or
Changed Components

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The following is an example of a communications system AFTER employing the above strategies.

(2A) (4A)
Network Switch xDirect (6A)
(1A) (3A) Autofold Coil Line
File Server Communications Terminal Controller

(5A)
xDirect (7A)
Lockformer Plasma
Controller

3A – “Virtual” computer.
(8A)
o Easy to “Backup/Restore/Recreate”
Advance Cutting Plasma
o No specialty physical configuration. Controller
o Easily supported remotely
o Software license “network” based. “Floats” where needed.

AFTER 4A/5A – xDirect device servers for legacy controlers

o Can easily be supported/configured remotely
Green: Unchanged o Less than ½ cost of “black box” modems
(9A)
Infrastructure CAMduct/PM2000 Input Station
o Less than ½ the quantity of prior “black box” modems
o Powered via network, no additional power source required.

Blue: Existing and future 8A – Newer controllers

o Can be added directly to network.
backup/redundancy o Ability to remotely access/support
systems.
9A - Standard Computer
(10A) o Can use “Any” computer for Input Station
CAMduct/PM2000 Input Station
Orange: Changed o No specialty hardware or configuration

Components 10A - “Any Number” of computers

o Easily scaled for increased production capacity
o No special configuration/cabling for backup systems
o License pull automatically from network

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Here’s a few more photos of the installation…

Page 43