ITW Alpine ALS 4.0 XE User manual

EN
ALS 4.0 XE
Product Manual
IMPORTANT! DO NOT DESTROY!
It is the customer’s responsibility to have employees read and understand this manual.
Read instructions completely before using the equipment.
The Latest
Evolution of the
Industry’s Leading
Linear Saw
The Alpine ALS 4.0 takes linear cutting to
the next level. The ALS 4.0 is designed for
production efficiency, only requiring one
sawyer for operation. The result is a reduction
in labor, a boost in production and an increase
to your bottom line.
This is not only an operation manual, but a
tool that can be utilized to gain the maximum
potential from your ALS 4.0 linear saw. Each
plant runs differently and the ALS 4.0 stands up
to the challenge—providing ultimate flexibility
in setup and operation.

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ALS 4.0 XE
PRODUCT MANUAL EN
!WARNING
Read the following warnings before using this equipment.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.
ADDITIONAL COPIES ARE AVAILABLE, CALL ALPINE EQUIPMENT CUSTOMER SERVICE: 8005219790.
READ THE MANUAL
Before operating equipment,
read and understand all safety,
operation and maintenance
information provided in the
operation manual.
HOT SURFACE HAZARD
Contact may cause burns. Allow to
cool before servicing.
WEAR SAFETY GLASSES
Failure to wear safety glasses with
side shields could result in serious
eye injury or blindness.
KEEP EQUIPMENT GUARDS
IN PLACE
Do not operate the equipment
if the safety devices have been
removed.
OPERATOR TRAINING
All personnel must be trained
before operating equipment.
KNOW WHERE AND HOW TO
SHUT OFF THE EQUIPMENT IN
CASE OF AN EMERGENCY
DEENERGIZE, DEPRESSURIZE,
DISCONNECT AND LOCK OUT
ALL POWER SOURCES DURING
MAINTENANCE
Failure to de-energize, disconnect
and lock out all power supplies
before performing equipment
maintenance could cause serious
injury or death.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause
the equipment to rupture,
malfunction, or start unexpectedly
and result in serious injury.
Read the following safety information
before using this equipment:
In this installation guide, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
!
CAUTION
Hazards or unsafe practices that could
result in minor personal injury, product or
property damage.
!
WARNING
Hazards or unsafe practices that could
result in severe personal injury, death or
substantial property damage.
NOTE
Important installation, operation or
maintenance information.
For more information, see Alpine Manual M1002—“Equipment Safety Precautions”. Additional copies of the safety procedures can be ordered by calling 800-521-9790.
INSPECT EQUIPMENT DAILY
Broken or worn machine parts can
cause damage to equipment.
NEVER MODIFY EQUIPMENT
Modification could damage
equipment or cause it to operate
improperly. Modified equipment
could cause a safety risk to
operators.
PINCH POINTS
Moving equipment, sliding doors
and clamping devices can cause
pinch points for operators and
maintenance staff.
AUTOMATED EQUIPMENT
With automatic equipment,
the hazard of an unannounced
startup is present.
CUTTING EQUIPMENT
Cutting hazards are present with
Alpine Linear and Component
Saws. Be aware of sharp
equipment edges and spinning
blades.
ASSEMBLY EQUIPMENT
Crush hazard is present with
Alpine assembly systems. Failure
to inspect safety systems could
increase the probability of a crush
hazard occurring.
ELECTRICAL EQUIPMENT
High voltage equipment is
utilized. Arcing in areas of
flammable or combustible
materials may occur. Personnel are
exposed to high voltage during
operation and maintenance.
Protection against inadvertent arcing that may cause
a fire or explosion is lost if safety circuits are disabled
during operation. Loose electrical connections
could cause damage to components on your Alpine
Equipment. Electrical shock can occur while working
in the electrical cabinet.
CLOTHING AND JEWELRY
Loose clothing could be caught
on moving machine parts.
Jewelry, including rings, should
never be worn when operating
equipment.

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Contents
1. Introduction........................................5
1.1 Parts List ................................................ 5
1.2 General Specications ................................... 6
1.2.1 Machine Capacity ............................... 6
1.2.2 Equipment Specications ....................... 7
1.2.3 Service Requirements ........................... 8
2. Getting to Know the ALS 4.0 .........................8
2.1 System Overview ........................................ 8
2.3.1 Clamp .......................................... 8
2.3.2 Pusher .......................................... 8
2.4 Sensors.................................................10
2.4.1 Edge Detect Sensor (EDS) ......................10
2.4.2 Lumber Present Sensor (LPS) ...................10
2.5 Operator Console.......................................10
2.6 Getting Data to the Saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6.1 General ........................................10
2.6.2 Network .......................................10
2.6.3 USB Device ....................................11
3. ALS 4.0 Software ..................................11
3.1 ALS 4.0 Home Screen ...................................11
3.2 Auto Screen ............................................12
3.2.1 Job Select Menu ...............................12
3.2.2 Current Stock Length Menu ....................13
3.2.3 Utility Tools ....................................13
3.2.4 Create a Pick List ...............................14
3.2.5 Single Piece Run ...............................14
3.3 Automatic Screen Operations ...........................15
3.3.1 Load Lumber Screen ...........................15
3.3.2 Cut Status Screen ..............................16
3.3.3 Change Stock Screen (Single Stock Option) .....17
3.4 Semi-Automatic Operation .............................18
3.4.1 Board Select ...................................18
3.4.2 Semi-Auto Save ................................19
3.4.3 Bevel ..........................................19
3.5 Manual Control .........................................20
3.5.1 Manual Axis Control............................20
3.6 System Options Menu ..................................22
3.6.1 General Options (1) ............................22
3.6.2 Optimization Options (2) .......................22
3.6.3 Pick List Options (3) ............................23
3.6.4 Cutting Options (4).............................23
3.6.5 Saw-Production Reporter Options (5) ...........23
3.6.6 Standard Piece List (6) ..........................23
3.6.7 Pick List Sort Options (7)........................25
3.6.8 Printer Setup (8)................................25
3.6.9 Bevel Options (9) ............................... 26
3.6.10 Advanced Options (10) .........................27
3.7 Optimizer ..............................................29
3.7.1 Introduction ...................................29
3.7.2 How it Works...................................29
3.7.3 Optimizer Options .............................30
3.7.4 Nesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7.5 Non-Optimize Look Ahead .....................31
3.7.6 Pick List Options ...............................32
3.7.7 Stock Sorting ..................................32
3.7.8 Optimizing Example............................32
3.8 Additional Options: .....................................33
3.8.1 Names/Paths...................................34
3.9 Standard Pieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9.1 Introduction ...................................34
3.9.2 How it works ...................................34
3.9.3 Entering Standard Pieces .......................34
3.9.4 Capture a Piece from a Job .....................34
3.10 Creating a Pick List......................................35
3.11 Auto Infeed System ..................................... 36
3.12 XML Files ...............................................37
4. Calibration Procedure ..............................38
4.1 Turn O Power .........................................38
4.2 L1/L2 Belt Feeder Alignment ............................38
4.3 Infeed & Outfeed Conveyor Alignment ..................38
4.4 Calibrate Bevel Axis (B1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5 Calibrate the Cut Angle (A1).............................40
4.6 Calibrate Center of Rotation.............................41
4.7 Calibrate Centerline (T1) ................................43
4.8 L1/L2 Belt Tension Adjustment ..........................45
4.9 Calibrate Cut Length (L1/L2) ............................45
4.10 Check Alignment of the T/Z Slide & Belt Feeders .........47
5. Maintenance ......................................49
5.1 Parts Identication......................................49
5.1.1 Inkjet Printer ..................................49
5.1.2 Inside the Cutting Cabinet......................49
5.1.3 Automated Infeed..............................52
5.1.4 Outfeed........................................53
5.1.5 Main Saw Electrical Cabinet ....................55
5.1.6 Printer Electrical Cabinet .......................56
5.2 Cleaning ...............................................57
5.3 Machine Lubrication ....................................57
5.4 Automated Infeed ......................................59
5.5 EXLAR® Actuator Maintenance ..........................59
5.5.1. EXLAR Actuator Belt Change....................59
5.5.2. Removing the Z1 Actuator......................62
5.6 InkJet Printer ...........................................62
5.7 Conveyor Belt Replacement & Tensioning................62
5.7.1. Conveyor Belt Removal & Installation ...........62
5.7.2 Waste Conveyor Belt Tensioning ................63
5.7.3 Small Parts Conveyor ..........................64

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Contents (continued)
6. Troubleshooting ...................................65
6.1 Incorrect Homing/Cannot Home the Machine ...........65
6.2 Centerline is O ........................................65
6.3 Length is not Correct ...................................65
6.4 Conveyor will not Start..................................66
6.5 Printer will not Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.6 Prints Same Information ................................67
6.7 Cannot Read the Print Information ......................67
6.8 Inconsistent Print Placement ............................67
6.9 Automated Infeed Bad Lumber Load .................... 68
6.10 Automated Infeed will not Start .........................68
6.11 L1 Belt Runs in Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.12 Pneumatic Cylinder does not Actuate or Actuates Slowly. 69
6.13 Blade Motor will not Start ...............................69
6.14 Machine Stops during Cutting Operation ................69
6.15 Bevel Troubleshooting ..................................70
6.16 E-Stop Troubleshooting .................................71
7 Error Log Diagnostics ..............................72
7.1 System Diagnostics and Troubleshooting................72
Appendix A – Maintenance Intervals ...................73
Appendix B – Pneumatic System Schematic ............74
Appendix B – Pneumatic System Schematic – ..........75
L1/L2 Blow-o
Appendix C – Unit Conversion Tables ..................76
Appendix D – Terms Glossary..........................78
Appendix E – Warranty................................79
Appendix F – Bibliography ............................79

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• Power Cable, LXM 52, 32.80ft 41043
(Used in L1P Axis)
• Feed Back Cable LXM52,16.4 ft 39177
(Used in L1, L2, T, Z Axes)
• Feed Back Cable LXM52, 19.68 ft 41036
(Used in A Axis)
• Feed Back Cable LXM52, 22.96 ft 37245
(Used in B Axis)
• Feed Back Cable LXM52, 32.8 ft 41043
(Used in L1P Axis)
Quick Reference:
• Computer 38162
• Belt B1& A1 28979
• Small parts VFD 41069
• Safety Sticker Set 35194
All parts can be conveniently ordered from
our website. Visit: shop.alpineitw.com
Or email your order to [e-mail]
1. Introduction
1.1 Parts List
Suggested Stocking Parts:
• Emitter 23141
• Receiver 24679
• Door Switch 38207
• Door Switch Key 38208
• Module E-Stop 25990
• Lumber Present Sensor (Infeed) 24664
• Lumber Present Sensor (Printer) 20661
• SMC Valves Solenoid 36758
Common Wear Parts:
• Belt L1 & L2 29107
• Blade Kit 35127
Includes: Blade
Screws
Nyloc Nuts
Torx Bit
Motion Control Components:
• Servo Drive 3/12 amp #APN 37288
(Used in T Axis)
• Servo Drive 6/18 amp #APN 41075
(Used in A, B & L1P Axis)
• Servo Drive 10/30 amp #APN 41068
(Used in L1, L2 & Z Axis)
• Servo Motor 1.78 amp #APN 41010
(Used in T Axis)
• Servo Motor 3.91 amp without brake #41009
(Used in A ,B & L1P Axis)
• Servo Motor 3.91 amp with brake #41023
(Used in Z Axis)
• Servo Motor 7.69 amp #41020
(Used in L1 & L2)
• Blade Motor Mitsubishi #41027
• Blade Motor Drive Mitsubishi #41032
• Blade Motor Power Cable Mitsubishi 38471 Blade
• Motor Feedback Cable Mitsubishi 38472 Power
• Cable,Low Shield LXM 52 16.4ft 41037
(Used in T & Z Axis)
• Power Cable,LXM 52,16.4 ft 41039
(Used in L1 & L2)
• Power Cable,LXM 52,19.68ft 41040
(Used in A Axis)
• Power Cable,LXM 52, 22.96ft 41041
(Used in B Axis)
Throughout this manual, references
are made to contact Alpine Equipment
Customer Service. They can be reached at
800-521-9790 with any questions.
Disclaimer
The information contained in this document is believed to be accurate in all
respects but is not warranted by Alpine. The information is subject to change
without notice and should not be construed in any way as a commitment by
Alpine. Alpine assumes no responsibility for any errors or omissions in this
document. Every reasonable eort is made to keep this document current, but
in the event of discrepancy, Alpine engineering documentation, installation
and service and safety procedures shall prevail.
Copyright ©2021 by Alpine, a division of ITW Building Components Group Inc.
All rights reserved.
No part of this document may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without the prior written consent of
the publisher.

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1.2 General Specications
1.2.1 Machine Capacity
Lumber Size Range
Min Max
Width 2.38” (64mm) 14” (355mm)
Thickness 1.38” (35mm) 1.77” (45mm)
Length 6” (152mm) 24’ (without additional support)
Cut Types:
• Chords
• Webs
• Scissor bottom chords
• Wedges
• Sliders
• Single and double beveled ends
(if saw is equipped with optional bevel axis)
• Ripped valley bottom chords
(if saw is equipped with optional bevel axis)
• Floor truss webs
(if saw is equipped with optional bevel axis)
Pieces:
• Minimum: 1” (25mm) for all pieces with four angle cuts
• Maximum Recommended Scarf: 104 inches at 8 degrees

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1.2.2 Equipment Specications
High Performance (H/HB)
Saw Blade Diameter Custom 20.5”
Spindle Motor (S-axis) Max RPM 2800 rpm
Infeed (L1-axis) Accuracy
Max Speed
±1/16”
160 in/sec
Outfeed (L2-axis) Accuracy
Max Speed
±1/16”
160 in/sec
Translation Cutting (L1-T1) Max Speed 28 in/sec
Angle (A-axis) Travel
Accuracy
-0° to +270°
±0.05°
Bevel (optional) (B-axis) Travel
Accuracy
5° (bevel) to 70° (very sharp bevel)
±0.05°
Traverse (T-axis) Travel
Accuracy
-10” to +14”
0” references the fence
Vertical (Z-axis) Travel
Max Speed
7 ½”
13 in/sec
Controller
PC
Monitor
Communications
Industrial PC w/ Windows 7 Professional Operating System
22” at panel
Ethernet
Operating Temperature 41 to 104°F
Humidity 10-95%, non-condensing
Max Altitude 6500 ft.
Shipping Weight 3500 lbs
Foundation Requirements ≥4” thick
Voltage Draw 480VAC 3PH 60A,WYE, 60 Hz/FLA 48A@460 VAC
Air Draw 25 CFM @100 Psi
Footprint
8’-11”
6’-4”
42’-7”
*ALS 4.0 HB Model shown with optional automated infeed

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PRODUCT MANUAL EN
1.2.3 Service Requirements
!
CAUTION
The use of a qualified electrician is required to ensure the
following service specifications are properly met.
Electrical
•Main Service
•480VAC, 60A, 3PH, 60HZ (50 Hz Optional)
• Y-configuration preferred (delta acceptable)
•Phase Voltage Imbalance – 6 V
•e (Vt) – ≤ 50 Vsec @ ≤ 1 occurrence per half
hour
Vt= Vi× t
Where:
Vt= Transient Voltage (Vsec)
Vi= Instantaneous Voltage (V)
t = time (sec)
• Secondary Service
• 120 VAC, 20A, 1PH, 60 Hz (50Hz optional)
• This must be a dedicated line.
• Line conditioner recommended.
Air
• Place coalescer immediately prior to machine to
insure dry, oil-free air.
• Machine has a factory installed lter with pressure
regulator.
!
CAUTION
Introduction of oil to air system will damage seals.
NOTE
110 PSI is the minimum recommended pressure
in the main air line.
2. Getting to Know
the ALS 4.0
2.1 System Overview
Figure 1 (on page 7) indicates the names of the various
major components of the ALS 4.0 system.
NOTE
Standard infeed and small parts conveyor not shown in Figure 1.
2.2 Axes of Motion
Refer to Figure 2 (on page 9).
SBlade Motor Spins the saw blade
(not shown, motor located inside enclosure)
L1P Printer Motor Feeds lumber beneath the printer head and into
L1 (not shown)
L1 Infeed Feeds lumber and measures length
L2 Outfeed Coordinates with L1 axis to feed lumber and
measure length
AAngle Sets the cut angle
BBevel Sets the bevel angle (optional)
TTraverse Translates the saw blade across the lumber
ZVertical Raises and lowers the blade
2.3 Infeed and Outfeed System
The Pushers and Clamps are sets of rollers attached to
the L1 and L2 drives. These rollers help maintain control
of the lumber as it moves through the saw to ensure
cuts are made accurately.
CLAMP
PUSHER
Figure 3
2.3.1 Clamp
The Clamp is a set of three black urethane-coated
rollers that“clamp” the lumber down onto the drive belt.
The picture on the right shows the L2 Clamp, located
directly above the drive belt. L1 contains an identical
Clamp.
2.3.2 Pusher
The Pusher is a set of small rollers that that “push” the
lumber against the back fence rollers as it is fed through
the saw. It is part of the L-drive assembly toward the
front of the saw, as shown in the picture of L2 on the
right. An identical Pusher can also be found on L1.

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PRODUCT MANUAL EN
Figure 1
Figure 2

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2.4 Sensors
There are two sensor sets in the ALS 4.0. They are used
to control the feeding and clamping of the lumber.
2.4.1 Edge Detect Sensor (EDS)
This is a set of through-beam sensors located in the L1
feeder. The receiver, shown on the left in the picture
below, is embedded in the rollers of the L1 Pusher.
EMITTER
RECEIVER
Figure4
The emitter, on the right, is in the rollers of the back
fence directly opposite the receiver. When lumber
passes it breaks the LED beam between the emitter and
receiver which signals the computer that the trailing
edge of the lumber has exited L1.
2.4.2 Lumber Present Sensor (LPS)
This is a set of through-beam sensors located in the
L2 feeder. The lumber presence sensor detects the
presence of lumber in the L2 drive.
EMITTER RECEIVER
Figure 5
2.5 Operator Console
Major functions of the machine are controlled from the
keyboard, mouse, and at panel or touchscreen monitor
(optional) in the Operator’s Console.
Figure 6
2.6 Getting Data to the Saw
2.6.1 General
Cutting information must be in the format of TRS les.
TRS v3.0 les are required to cut bevels on the HB model
saw. H model saws can be operated using TRS v2.0
les as they are not equipped to cut bevels. All major
truss engineering software can develop these les
automatically. Contact the supplier for details. Alpine
can supply the le specication if necessary.
2.6.2 Network
An Ethernet adapter card is provided with the computer
inside the console. The saw can be connected to any
network using Cat 5 Ethernet cable. Alpine will not
provide the equipment to connect the saw to a network
connection by any other means (ber-optic, wireless, etc.)
Except for its distance from the server, the saw
computer is just like most other computers on the
network. Distance can be an issue, Alpine recommends
that the network cable installed and connected by a
network professional.
If TRS les are being sent to the ALS 4.0 over a network
connection, it is mandatory that the saw computer
be able to write to the TRS les on the network. This is
how completed cuts are recorded. However, the saw
will require certain network rights. If this is a problem
for a network administrator, have them contact Alpine
Equipment Customer service for more information.

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PRODUCT MANUAL EN
1. AUTOMODE – Automatic saw operation mode.
Data is read from the saw computer, USB drive, or
network location (Section 4.2.1).
2. SEMIMODE – Semi-automatic saw operation mode.
Allows operator entry for cutting data (Section 4.3).
3. System Status – Shows the current state of the
machine
4. E-Stop – Indicates if the E-Stop Button is activated.
5. Language – Indicates the current language in use.
Trilingual – English,French and Spanish.
6. Communication – Opens the team Viewer
pop up window to connect remote users for
troubleshooting.
7. System troubleshooting – Opens the Schneider
Control System Status Screen.
8. Utility Tools – Opens the Manual Screen menu
(Section 3.2)
9. Options – Opens the Options Menu (Section 3.3).
10. Auto-Infeed – Opens Auto-Infeed Timer Menu
(Section 3.4)
11. Exit – Closed/Shutdown the ALS 4.0 program.
NOTE
It is strongly advised to cancel out of all active screens and back to
the Main screen before quitting as there are times when this
procedure will save valuable in-process information.
It is also recommended that the saw computer have
internet access. This will allow for remote access by
Alpine for troubleshooting and diagnostic evaluation.
2.6.3 USB Device
Sometimes called “jump drives” or “thumb drives”, these
devices are necessary if the saw is not connected to a
network. The ALS 4.0 has a dustproof USB port mounted
on the front panel of the operator’s console for these
devices, or any other USB device. The ALS 4.0 program
communicates with these devices in the same manner
as it would to a hard drive or network connection.
3. ALS 4.0 Software
3.1 ALS 4.0 Home Screen
Figure 7
The top bar of the screen is present during most
operations of the program. It allows navigation to other
parts of the program without closing the screen being
used. QUIT can be selected from any screen where the
top bar is showing.

12
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PRODUCT MANUAL EN
4. CHANGE JOB LOCATION – Allows user input to
specify the computer path to the location where
the jobs are stored. This path can be any location
that is accessible from the saw computer. The hard
drive of the computer, USB, or a network drive can
be the source of the job location.
5. UTILITY – Allows user to access the utility function
which has a lot of dierent options (Section 3.2.3)
6. CREATE PICK LIST – Allows user to create pick list
(Section 3.2.4)
7. DELETE PICK LIST – Allows user to delete pick list.
8. GRAPHICAL VIEW – Allow user to view graphical
pick list.
9. PIECE DETAILS – This area shows detailed
information of all the pieces to be cut from the
selected job list
10. PREV – Go back to previous piece.
11. NEXT – Advances the next piece.
12. SINGLE PIECE RUN – Allows user to run one piece
at a time (Section 3.2.5).
13. MULTIPLE PIECE RUN – Allows user to run more
than one piece or the whole job.
14. CANCEL – Cancels the current operation and
returns the software to the Main Menu.
3.2 Auto Screen
Figure 8
3.2.1 Job Select Menu
The Job Select Menu displays all the information about
the job as contained in the TRS le.
1. Indicates all the available TRS les within the Jobs
directory.
2. Displays the following information:
• TOTAL SETUPS – The total number of unique
setup in the job.
• TOTAL PIECES – The total pieces in the job.
• CURRENT STOCK LENGTH – Shows the size of the
stock currently chosen. (Section 3.2.2)
• PIECES LEFT IN CURRENT JOB – The total number
of pieces for each grade and size required in the
job. It is not a pick list.
3. JOB SEARCH – Allows user to search for a TRS le
by name within Jobs directory.
NOTE
When running “MATCH ALL”, the program MUST find a solution in
the lumber definitions for the piece to be cut or the piece will be
skipped. Currently, the program allows for a maximum of 112
different combinations of length, grade, and size of lumber.

13
ALS 4.0 XE
PRODUCT MANUAL EN
Figure 9
3.2.2 Current Stock Length Menu
This screen is only available if running
single stock option and without Auto-
Infeed. This screen allows you to select the
stock length the user want to use. Touch
the white area inside the box to bring the
screen up. Select the desired length of
stock by checking the small box next to
the length.
NOTE
There is no EXIT button for this screen.
Selecting any board length from lumber list
will exit this screen.
3.2.3 Utility Tools
Click on the utility tool icon and the following menu screen will
appear:
Figure 10
1. MARK PIECE CUT – Will mark the piece you
have selected as completely cut. The piece
will turn red. Be sure you have selected the
piece you want to mark before touching this
button.
2. RESTORE PIECE – Removes any stored cut
information for the selected piece restoring it
to uncut status.
3. MARK JOB CUT – Will mark the job you have
selected as completely cut. Be sure you have
selected the job you want to mark before
touching this button.
4. RESTORE JOB – Removes cut information for
the selected job restoring it to uncut status.
5. RESTORE PARTIAL PIECES – Restores Partial
pieces.
6. CHANGE PIECE QUANTITY – Allows you to
change the quantity of the selected piece.
When you touch this button, another screen
will pop up. If the selected piece is used in
more than one location, you will need to
choose the one you want to change. When
that is done, a screen will appear that will
allow you to set the quantity for that piece to
whatever you need.
7. ADD TO STANDARD PIECES – Will
automatically add the selected piece to
the list of Standard Pieces. See 4.4.1.6 for a
discussion of Standard Pieces.
8. DELETE PIECE – Deletes the selected piece
9. MERGE JOB – Merges two or more jobs in to
one job.
10. CHANGE LENGTH – Allows user to change
the selected piece length.
11. CANCEL – Will cancel out of this screen and
leave all cut data intact.

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ALS 4.0 XE
PRODUCT MANUAL EN
Figure 12
1. The top bar shows the stock board that was just cut
or in the process of cutting.
2. The middle bar shows the stock board that was cut
previously.
3. The bottom bar shows the stock board that is set up
and ready for cutting next.
4. OK – This button is used only during Oce Mode
operation of the program. It switches the program
to the Cut Screen simulating detection of a board.
5. PAUSE – This button allows you to pause cutting
process. Machine will not stop until current cut
board is nished. If you need to stop the saw
immediately during cutting operations, use the
Emergency Stop.
6. RESUME – This button allows you to resume cutting
the Next Cut Order will be the same as when you
pause.
7. CANCEL – This button will return you to the Job/
Piece Select Screen. All cut status information for
all previous cuts will be saved, and you will be able
to review it on the Job/Piece Select Screen. If no
changes are made to the cut status information
or stock length after you CANCEL here, when you
touch RUN ALL and return to this screen the Next
Cut Order will be the same as when you left.
3.2.4 Create a Pick List
When you touch the button and have the Create Pick
List option checked in General Options the program will
create a pick list for the current job. You can create the
Pick List at the saw in regular operating mode or in the
oce in Oce Mode.
A le will be created with the same name as the job and
the extension .STK. The le will be placed in the same
directory as the job. You can create two versions of this
le. Both versions contain the Pick List and Summary
information. If you check Stock File Details under
Program Options, the le will also contain details about
each piece of stock that will be cut. Each line of these
details contains the stock length, lumber description,
lumber code, lumber size, and information about the
pieces placed on the stock. If desired, you can interface
this information with other programs.
Here’s an example of the complete le with Stock File
Details, Summary, and Pick List:
Figure 11
3.2.5 Single Piece Run
Will cause the saw to cut only the piece that you have
highlighted. When you touch this button, the saw will
start and the Piece Layout Screen will appear showing
the piece placed on the stock you have specied. The
computer will place as many of the selected piece on
the stock as it can, but it will not look through the le
for other pieces to place on the stock. When you push
the stock lumber into the feeder, the cutting operation
will begin. If the quantity of the selected piece is greater
than the number that could be placed on the stock,
additional stock pieces will be used until the total
quantity of the selected piece has been cut. When all
the pieces have been cut, you will be returned to the
Piece Select Screen so that you can select another piece
for cutting. The OPTIMIZE feature is non-functional in
Single Piece mode.

15
ALS 4.0 XE
PRODUCT MANUAL EN
2. OK – This button is used only during Oce Mode
operation of the program. It switches the program
to the Cut Screen simulating detection of a board.
When running a single stock length, the OK button
will be visible but once the cut is completed the
screen will return to the Cut Screen automatically.
NOTE
OK is only visible if a single stock length is being run.
Figure 14
3. CANCEL – This button can be used to return to the
Job/Piece Select Screen. All cut status information
for all previous cuts will be saved. This information
can be reviewed on the Job/Piece Select Screen. If
no changes are made to the cut status information
or stock length click or touch cancel CANCEL. Then,
RUN ALL can be used to maintain the Next Cut
Order as set previously.
4. OK – This button is used only during Oce Mode
operation of the program. It switches the program
to the Cut Screen simulating detection of a board.
3.3 Automatic Screen Operations
3.3.1 Load Lumber Screen
Figure 13
This screen displays what size and grade of stock lumber
to feed into the saw.
1. NEXT CUT ORDER – Displays a preview of the next
board to be cut
The gray bar near the bottom of the screen show how
the computer has placed pieces on the stock. The gray
bar shows the stock board that is set up, ready and will
be cut next. The red and yellow colors of the pieces
are alternated so that it noticeable where each board
begins and ends. There is no other signicance to these
two colors.
NOTE
When the stock is changed, the Next Cut Order will be
recalculated and the new piece layout will be shown.
Occasionally, this recalculation will cause the Previous Cut Order
layout to go off scale, but that will have no effect on upcoming
cuts. It is not possible to make changes to the stocks
if a picklist has been created for the job.
When there are pieces on the stock that have beveled
ends, the beveled edges will be green for double bevel,
blue for single bevel front, or fuchsia for single bevel
back.
• The information shown on the rst line on each
piece is truss name.
• The second line shows the piece name.
• The third line shows the index of the piece and the
piece length.
The index number is assigned by the saw computer
when the job is loaded. It corresponds to the position
of the piece in the list on the Piece Select screen. It is
not the quantity of the piece. It is shown on this screen
for reference. It can be used when it is necessary to o
nd the piece in the job list on the Piece Select Screen
(Figure 8).

16
ALS 4.0 XE
PRODUCT MANUAL EN
1. NEXT STOCK PIECE LAYOUT – Provides advance
notice of the next piece of stock that will need to
be loaded into the saw for cutting. This information
is always to view what is coming next. It’s essential
when the Multiple Stock feature active since the
required stock is chosen by the computer from the
multiple stock list for each stock that is run. When
Multiple Stock is active, the Next Stock Piece Layout
will identify which stock has been chosen for the
next cut. While the current stock is being cut, the
proper stock length for the next cut can be loaded.
2. PREVIOUS STOCK PIECE LAYOUT – Indicates the
last stock ll the saw cut, if applicable.
3. NEXT STOCK – This button is used during Oce
Mode operation of the program only.
4. PA USE – This button allows the cutting operation
to be paused and cancel back to the Piece Layout
Screen, or to continue cutting when ready. The
button label will change to“CONTINUE” and
pressing this button will resume the cutting
process.
5. STOCK LENGTH – Length of the current stock
STOCK WIDTH – Width of the current stock
LUMBER GRADE - Grade of Lumber currently used
CUR PC/ CUT – Current Piece being cut, current cut
(1-7)
FRONT WASTE – Length of Waste on front end of
stock
BACK WASTE – Length of waste at the back end of
stock, after all pieces cut
TOTAL WASTE – Sum of all kerf. Piece to piece plus
end waste
6. NEXT CUT – Debug Use only, cycles from cut #1 to
cut #4 for each piece on stock.
7. EXIT - Exits the current Screen and takes you back
to job select screen - Figure 8
8. VIEW CUT DATA – Used for troubleshooting, it will
gather up of the les involved at the time (job le,
user conguration le, machine conguration le)
and zip them into a single le utilizing the date and
time as the le name. This is all of the information
needed to recreate the problem, and will be
needed by Alpine Equipment Customer Service to
troubleshoot a particular cutting problem.
3.3.2 Cut Status Screen
Figure 15
This screen will be active while the saw is cutting each
stock piece. Its purpose is to display cutting progress
information in case there is a problem with the saw or
with the motion control system. This information can be
useful in diagnosing those problems.

17
ALS 4.0 XE
PRODUCT MANUAL EN
3.3.4 Change Stock Screen
(Multi Stock Option)
Figure 18
When Match Grade-Size is selected, the Multiple Stocks
screen will appear as shown in Figure 18. Each line
across the page represents one combination of length,
size, and grade of stock. Make sure to enter all the
possible combinations available. Only the combinations
indicated by a check mark will be used by the ALS
program. If certain stocks are unavailable click or touch
the yellow LENGTH to turn it o.
Figure 19
If there are more than the 14 combinations that will t
on one page, click or touch this button (Figure 19) and
enter the total combinations up to 112. The computer
will add pages to this screen based on the number of
combinations entered. The page names can be left as
default or changed. Click or touch LABEL (Figure 18) to
add a custom label to the page.
NOTE
Always change the number of max stocks in multiples of 14, since
the saw only looks at the total number indicated. For instance, if
105 is selected then the saw will not look at the last 7 stock
options on page 8. However, all 14 stocks will be listed on page 8.
3.3.3 Change Stock Screen
(Single Stock Option)
Figure 16
Figure 17
This screen allows stock length selection. The selection
is made by clicking or touching the yellow numbers
corresponding to the length located in the column on
the left side of the screen. The LENGTH buttons are used
when it is necessary to change the value of the stock
length in the yellow numbers. It is recommended that
this value be the exact length that of the stock being
used.
NOTE
The saw will make no judgment on stock overage. For example,
when cutting two 8-0-0 boards from a single piece of stock, the
minimum length required by the saw is 16-0-12. The saw assumes
it must make three cuts (trim at both ends and cut at 8 ft) to get
the two 8-0-0 pieces and each of those cuts will remove the ¼”
kerf. This is why a 16-0-0 board cannot be used for this cut.

18
ALS 4.0 XE
PRODUCT MANUAL EN
3.4.1 Board Select
Click or touch SEMIMODE on the main menu to
advance to the Board Select Menu.
1. Conguration Buttons – Click or touch the gure
that is closest to the desired cut. The panel on the
left “L” controls the left side of the board. The panel
on the right “R” controls the right side of the board.
2. Angle Buttons – Click or touch the angle buttons
to open the Angle Input Dialog Box. Angles 1 and
2 are shown on the left side of the board. Angles 3
and 4 are shown on the right side of the board
Figure 22
3. Height Buttons – Click or touch the height buttons
to open the Height Input Dialog Box. Height 1 is
the overall height of the lumber. Heights 2 and 3
correspond to the pivot axis heights.
4. Length Buttons – Click or touch the length buttons
to change the various lengths.
•OA Len – Overall board length
•Center Len – Centerline length
•Top Len – Top length
•Bot Len – Bottom length
•PAL – Pivot axis length
Figure 23
The SIZE and GRADE buttons will bring up screens when
clicked. Here, the appropriate entries can be chosen.
Within this dialogue box the following can be changed:
• SPEED – Allows the system speed to be adjusted
per stock entry. It is percentage based with 100%
being full speed.
• CHECK ALL – Selects all with a single selection
• CLEAR ALL – Deselects all with a single selection
• EXIT – Exits the dialog
COST can be entered allowing the saw to calculate the
lumber cost per the job pick list. Cost is based on board
feet. The cost information must be manually entered
and updated.
The SAVE button will save all progress.
3.4 Semi-Automatic Operation
Figure 20
Enter the Semi-Automatic Mode by clicking or touching
the button shown in Figure 20 on the Main Screen.
The following screen will appear (Figure 21):
Figure 21
The default piece for this screen has square cuts on each
end. Choose the ends that most closely match the piece
required. In the example above, the single cut button
has been selected for the left end and the single cut for
the right end. The selections can be changed at any time
as cuts are setup in this mode.

19
ALS 4.0 XE
PRODUCT MANUAL EN
3.4.3 Bevel
BEVELS brings up the following screen.
Figure 25
Using the popup box, click or touch EDGE repeatedly
until the edge of the piece requiring a bevel is red.
Then click or touch the NONE button (below the EDGE
button) until the bevel condition need is shown.
Please note, in Figure 25 the button under EDGE
displays DOUBLE. The double bevel condition has been
selected for this edge and the display text has changed
accordingly.
The condition selected above is for a double 45° bevel
on the plumb cut at the right end of the board. If a bevel
angle other than 45° is needed, click or touch FRONT
ANGLE or BACK ANGLE box and enter the desired angle.
Front Angle means the bevel face that is facing up when
the board is oriented as shown in the diagram. Back
Angle means the bevel face on the opposite face of
the board. The saw will cut a single bevel when only a
Front Angle or a Back Angle is shown. The button that
says DOUBLE above will say SINGLE when a setup is
generated to cut a front or back angle bevel only.
Click or touch the SET button after entering all the bevel
information. The SETUP button will not appear until this
is done.
The SET button will also allow the placement of a bevel
on more than one edge of the piece. When the bevel
has entered for one of the edges, click or touch SET. This
will hold the bevel data for that edge and allow the use
of the EDGE button to proceed to another edge of the
board where an additional bevel can be entered. This
process is necessary when manually entering a oor
truss web.
5. QTY TO CUT – Click or touch the box and enter the
quantity required for the setup.
6. SAVE – Allows the user to save the Semi Auto Piece
to a le (Section 4.3.1.1).
7. SIMULATION OFF – Click or touch the button to
turn o the simulation of cuts on the board real
time.
8. BEVEL SETTINGS – Allows user to manually set
the Bevel Angles on Individual sides of the lumber
(Section 4.3.1.2)
9. CANCEL – Cancels the current operation and
returns the software to the Main Menu.
10. SETUP – Advances the software to Run Menu using
the dened cut parameters.
Now follow the instructions to setup the ALS 4.0
Upgrade in Section 4.3.1.3 which covers the Run Menu.
3.4.2 Semi-Auto Save
Entering pieces using Semi Auto is a more exible
method. Use the Semi Auto input process to create the
piece you would like to add to your Standard Pieces
List. All the Semi Auto options can be used to create
whatever piece you may need. Be sure to enter a large
quantity to cut. 999 is recommended.
When you have entered all the information, touch
on the Semi Auto input screen.
On the pop-up screen, the only entry item that the
computer will take is the Piece Name. Enter the piece
identication you would like to have printed for the
Standard Piece when it is cut.
Figure 24
Job Name is ignored for Standard Pieces. The Truss
Name is always“StdPc”. And the Lumber Grade is
ignored.
Add to Standard Pieces will automatically enter your
piece information with the Piece Name into the
Standard Piece List.

20
ALS 4.0 XE
PRODUCT MANUAL EN
1. SAFETY SENSORS – This area shows the status of
all the Operator Safety sensors .
2. PROXIMITY BOARD SENSORS – This area shows
the status of all the Lumber sensors.
3. DRIVE AXIS STATUS – This area shows the status of
all the drive axes.
4. AXIS POSITION SCREEN –
This area shows the current
positions of all the axes,
touching any of the
individual boxes will show
the corresponding axis on area“5”.
5. AXIS SELECT – This area will show the
position of the selected axis from area
“4” with additional functions to JOG,
HOME, CALIBRATE OR MOVE functions.
6. OUTPUT STATUS – This area will show
the various status of machine components such as
the saw, trash conveyor, pusher clamps, live deck
and infeed and outfeed conveyors.
7. L1/L2 CLAMP ICONS-
• L1/L2-CLAMP-UP/DOWN – These
control clamp rollers that grip the
top of the board on each drive.
• L1/L2-PUSHER-IN/OUT – These
control the pusher fence that
locates and maintains the location
of the board against the back-
fence rollers.
• L1-Clamp_Pusher Hold/Release –
These controls both clamp and pusher
Up/Down and In/Out.
• L2-Clamp_Pusher Hold/Release –
These controls both clamp and pusher
Up/Down and In/Out.
8. Z1 AXIS – These are short cuts for moving
the Z1 axis. UP moves the blade to its normal
up position. DOWN moves the blade to its
maximum down position. FULL causes the
blade to make a full stroke down and back
up like it does when cutting lumber. All these
moves are performed at full system speed.
9. HOME Function – These buttons will
cause a single axis to Home. Normally, you
should Home the entire system, but certain
diagnostic procedures may require homing a
single axis.
NOTE
When settings have been completed the bevel section, check the
remainder of the Semi-Automatic screen to make sure all the other
data is correct. Then click or touch SETUP to cut the piece.
NOTE
SAVE a bevel piece in the same manner described above.
Just make sure all the data entered correctly before starting the
SAVE process.
3.5 Manual Control
3.5.1 Manual Axis Control
Figure 26
The primary purpose of this screen is to provide manual
control of all the axes as well as some other parts of
the machine. There are a number of system functions
available from this screen as well. The manual controls
are on the right and across the bottom, and the system
controls are on the left side.
Before we discuss the manual controls, note the
red and green checkmark above them. This
array of checkmarks gives the status of all sensors on
the machine. Red means o, green means on. This
information may be useful if you are diagnosing certain
problems. It is normal for these checkmarks to change.
It is also normal for some of them to be red during
operation of the machine.
If you think you may be having trouble with one of
the sensors on the machine, call Alpine. We will help
you diagnose the problem with a combination of the
manual controls and this status bar.