DIMENSIONS NOT LINING UP WITH PART

Take a look at your alignments!!  You level and origin on PLN1, then you origin at CIR1, then ROTATE to CIR1 with nothing else and origin to CIR1.

The level to CIR2 and ROTATE to CIR2 (with nothing else)

How about this:

LEVEL to PLN1

ROTATE XPLUS CIR1 to CIR2 about Z plus

Origin PLN1 (Z+), CIR1 (X + and Y+)

Take a look at your alignments!!  You level and origin on PLN1, then you origin at CIR1, then ROTATE to CIR1 with nothing else and origin to CIR1.

The level to CIR2 and ROTATE to CIR2 (with nothing else)

How about this:

LEVEL to PLN1

ROTATE XPLUS CIR1 to CIR2 about Z plus

Origin PLN1 (Z+), CIR1 (X + and Y+)

ART NAME  : test
REV NUMBER : 
SER NUMBER : 
STATS COUNT : 1
 
STARTUP    =ALIGNMENT/START,RECALL:USE_PART_SETUP,LIST=YES
            ALIGNMENT/END
            MODE/MANUAL
            MANRETRACT/0.02
            PREHIT/0.04
            RETRACT/0.04
            FORMAT/TEXT,OPTIONS, ,HEADINGS,SYMBOLS, ;MEAS,NOM,TOL,DEV,OUTTOL, , 
            TEMPCOMP/METHOD = AUTOMATIC,MATERIAL = Zerodur; Nexcera,CTE=0
              ,SET WARNING LIMIT = FALSE,MINIMUM = 10,MAXIMUM = 40
              ,PART SENSOR NUM=DEFAULT,X SCALE= 25.0177,Y SCALE= 24.4215,Z SCALE= 25.086,PART TEMP=24.6865
            LOADPROBE/SPHERE PROBE
            TIP/T1A0B0, SHANKIJK=0, 0, 1, ANGLE=0
MAN_ALIGN  =GROUP/SHOWALLPARAMS=YES
PLN1         =FEAT/PLANE,CARTESIAN,TRIANGLE
              THEO/<-0.0062,0.0224,0.032>,<0,0,1>
              ACTL/<5.5988,3.0905,-15.1779>,<-0.0002656,-0.0037079,0.9999931>
              MEAS/PLANE,4
                HIT/BASIC,NORMAL,<-0.4643,0.1774,0.032>,<0,0,1>,<5.1183,3.2049,-15.1778>,USE THEO=YES
                HIT/BASIC,NORMAL,<-0.4581,-0.1435,0.032>,<0,0,1>,<5.1182,2.9585,-15.1784>,USE THEO=YES
                MOVE/POINT,NORMAL,<6.0823,3.0337,-14.6521>
                HIT/BASIC,NORMAL,<0.4612,-0.1188,0.032>,<0,0,1>,<6.0793,2.9585,-15.1784>,USE THEO=YES
                HIT/BASIC,NORMAL,<0.4365,0.1744,0.032>,<0,0,1>,<6.0794,3.2401,-15.1771>,USE THEO=YES
              ENDMEAS/
A1           =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1
                ALIGNMENT/TRANS,ZAXIS,PLN1
              ALIGNMENT/END
CIR1         =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,OUT,LEAST_SQR
              THEO/<0,0,0.088>,<0,0,1>,0.725,0
              ACTL/<5.5884,3.0626,0.088>,<0,0,1>,0.7379,0
              TARG/<0,0,0.088>,<0,0,1>
              START ANG=0,END ANG=360
              ANGLE VEC=<1,0,0>
              DIRECTION=CCW
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                REMEASURE=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=NOMINALS
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=5,DEPTH=-0.05,PITCH=0
                SAMPLE METHOD=SAMPLE_HITS
                SAMPLE HITS=0,SPACER=0
                AVOIDANCE MOVE=BOTH,DISTANCE BEFORE=0.3937,DISTANCE AFTER=0.3937,DIRECTION=ALONG FEATURE VECTOR
                FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
              SHOW HITS=YES
                HIT/BASIC,<0.3625,0,0.038>,<1,0,0>,<5.9471,3.068,0.0364>
                HIT/BASIC,<0.112,0.3448,0.038>,<0.309017,0.9510565,0>,<5.6339,3.445,0.0291>
                HIT/BASIC,<-0.2933,0.2131,0.038>,<-0.809017,0.5877853,0>,<5.3503,3.3275,0.0327>
                HIT/BASIC,<-0.2933,-0.2131,0.038>,<-0.809017,-0.5877853,0>,<5.285,2.8499,0.0568>
                HIT/BASIC,<0.112,-0.3448,0.038>,<0.309017,-0.9510565,0>,<5.6681,2.6968,0.0572>
              ENDMEAS/
A2           =ALIGNMENT/START,RECALL:A1,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1
                ALIGNMENT/TRANS,ZAXIS,PLN1
                ALIGNMENT/TRANS,XAXIS,CIR1
                ALIGNMENT/TRANS,YAXIS,CIR1
              ALIGNMENT/END
CIR2         =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
              THEO/<0.625,0,0>,<0,0,1>,0.134
              ACTL/<0.6228,-0.0088,0>,<0,0,1>,0.1335
              TARG/<0.625,0,0>,<0,0,1>
              START ANG=0,END ANG=360
              ANGLE VEC=<1,0,0>
              DIRECTION=CCW
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                REMEASURE=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=NOMINALS
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=5,DEPTH=0.06,PITCH=0
                SAMPLE METHOD=SAMPLE_HITS
                SAMPLE HITS=0,SPACER=0
                AVOIDANCE MOVE=NO
                FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
              SHOW HITS=YES
                HIT/BASIC,<0.692,0,-0.06>,<-1,0,0>,<0.6843,0.0174,-0.0423>
                HIT/BASIC,<0.6457,0.0637,-0.06>,<-0.309017,-0.9510565,0>,<0.6483,0.0528,-0.0423>
                HIT/BASIC,<0.5708,0.0394,-0.06>,<0.809017,-0.5877853,0>,<0.5637,0.0222,-0.0423>
                HIT/BASIC,<0.5708,-0.0394,-0.06>,<0.809017,0.5877853,0>,<0.5712,-0.0514,-0.0421>
                HIT/BASIC,<0.6457,-0.0637,-0.06>,<-0.309017,0.9510565,0>,<0.6455,-0.0714,-0.0421>
              ENDMEAS/
A3           =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1
                ALIGNMENT/TRANS,ZAXIS,PLN1
                ALIGNMENT/TRANS,XAXIS,CIR1
                ALIGNMENT/TRANS,YAXIS,CIR1
                ALIGNMENT/ROTATE_CIRCLE,XPLUS,TO,CIR1,AND,CIR2,ABOUT,ZPLUS
              ALIGNMENT/END
            ENDGROUP/ID=MAN_ALIGN
DCC_ALIGN  =GROUP/SHOWALLPARAMS=NO
            ENDGROUP/ID=DCC_ALIGN

changed it its still not doing the DCC check

Do the same thing with the DCC alignments.

But before you do that ensure your theos are correct

They seem to get jumbled up when you change the alignments around.

A bit of advise (LEVEL, ROTATE, then ORIGIN)

PART NAME  : test
REV NUMBER : 
SER NUMBER : 
STATS COUNT : 1
 
STARTUP    =ALIGNMENT/START,RECALL:USE_PART_SETUP,LIST=YES
            ALIGNMENT/END
            MODE/MANUAL
            MANRETRACT/0.02
            PREHIT/0.04
            RETRACT/0.04
            FORMAT/TEXT,OPTIONS, ,HEADINGS,SYMBOLS, ;MEAS,NOM,TOL,DEV,OUTTOL, , 
            TEMPCOMP/METHOD = AUTOMATIC,MATERIAL = Zerodur; Nexcera,CTE=0
              ,SET WARNING LIMIT = FALSE,MINIMUM = 10,MAXIMUM = 40
              ,PART SENSOR NUM=DEFAULT,X SCALE= 24.9595,Y SCALE= 24.3689,Z SCALE= 25.0227,PART TEMP=24.6008
            LOADPROBE/SPHERE PROBE
            TIP/T1A0B0, SHANKIJK=0, 0, 1, ANGLE=0
MAN_ALIGN  =GROUP/SHOWALLPARAMS=YES
PLN1         =FEAT/CONTACT/PLANE/DEFAULT,CARTESIAN,NONE,LEAST_SQR
              THEO/<-0.4562,0.0488,0.032>,<0,0,1>
              ACTL/<5.5777,3.1188,-15.178>,<0.0000529,-0.0050461,0.9999873>
              TARG/<-0.4562,0.0488,0.032>,<0,0,1>
              ANGLE VEC=<1,0,0>,SQUARE
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=MASTER
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=2,NUMROWS=2
                SPACER=0
                AVOIDANCE MOVE=BOTH,DISTANCE BEFORE=0.3937,DISTANCE AFTER=0.3937,DIRECTION=ALONG FEATURE VECTOR
              SHOW HITS=YES
                HIT/BASIC,<-0.4778,0.1541,0.032>,<0,0,1>,<5.1093,3.1976,-15.1778>
                HIT/BASIC,<-0.486,-0.174,0.032>,<0,0,1>,<5.1093,2.9996,-15.1784>
                MOVE/POINT,NORMAL<5.9367,3.1011,-14.334>
                HIT/BASIC,<0.4689,-0.1505,0.032>,<0,0,1>,<6.046,3.0004,-15.1788>
                HIT/BASIC,<0.4733,0.1405,0.032>,<0,0,1>,<6.0461,3.2776,-15.1771>
              ENDMEAS/
A1           =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1
                ALIGNMENT/TRANS,ZAXIS,PLN1
              ALIGNMENT/END
CIR1         =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,OUT,LEAST_SQR
              THEO/<0,0,0.088>,<0,0,1>,0.725,0
              ACTL/<5.5906,3.0302,0.088>,<0,0,1>,0.7249,0
              TARG/<0,0,0.088>,<0,0,1>
              START ANG=0,END ANG=360
              ANGLE VEC=<1,0,0>
              DIRECTION=CCW
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                REMEASURE=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=NOMINALS
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=5,DEPTH=-0.05,PITCH=0
                SAMPLE METHOD=SAMPLE_HITS
                SAMPLE HITS=0,SPACER=0
                AVOIDANCE MOVE=NO
                FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
              SHOW HITS=YES
                HIT/BASIC,<0.3625,0,0.038>,<1,0,0>,<5.9519,3.048,0.0505>
                HIT/BASIC,<0.112,0.3448,0.038>,<0.309017,0.9510565,0>,<5.8047,3.3233,0.049>
                HIT/BASIC,<-0.2933,0.2131,0.038>,<-0.809017,0.5877853,0>,<5.2854,3.2255,0.0463>
                HIT/BASIC,<-0.2933,-0.2131,0.038>,<-0.809017,-0.5877853,0>,<5.3932,2.7265,0.0491>
                HIT/BASIC,<0.112,-0.3448,0.038>,<0.309017,-0.9510565,0>,<5.7469,2.7026,0.0493>
              ENDMEAS/
A2           =ALIGNMENT/START,RECALL:A1,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1
                ALIGNMENT/TRANS,ZAXIS,PLN1
                ALIGNMENT/TRANS,XAXIS,CIR1
                ALIGNMENT/TRANS,YAXIS,CIR1
              ALIGNMENT/END
CIR2         =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
              THEO/<0.625,0,0>,<0,0,1>,0.134
              ACTL/<0.6257,0.0028,0>,<0,0,1>,0.1336
              TARG/<0.625,0,0>,<0,0,1>
              START ANG=0,END ANG=360
              ANGLE VEC=<1,0,0>
              DIRECTION=CCW
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                REMEASURE=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=NOMINALS
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=4,DEPTH=0.06,PITCH=0
                SAMPLE METHOD=SAMPLE_HITS
                SAMPLE HITS=0,SPACER=0
                AVOIDANCE MOVE=NO
                FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
              SHOW HITS=YES
                HIT/BASIC,<0.692,0,-0.06>,<-1,0,0>,<0.6796,0.0426,-0.0713>
                HIT/BASIC,<0.625,0.067,-0.06>,<0,-1,0>,<0.6436,0.0671,-0.0713>
                HIT/BASIC,<0.558,0,-0.06>,<1,0,0>,<0.5651,0.031,-0.0712>
                HIT/BASIC,<0.625,-0.067,-0.06>,<0,1,0>,<0.6014,-0.0593,-0.071>
              ENDMEAS/
A3           =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1
                ALIGNMENT/TRANS,ZAXIS,PLN1
                ALIGNMENT/TRANS,XAXIS,CIR1
                ALIGNMENT/TRANS,YAXIS,CIR1
                ALIGNMENT/ROTATE_CIRCLE,XPLUS,TO,CIR1,AND,CIR2,ABOUT,ZPLUS
              ALIGNMENT/END
            ENDGROUP/ID=MAN_ALIGN
DCC_ALIGN  =GROUP/SHOWALLPARAMS=YES
              COMMENT/OPER,NO,FULL SCREEN=NO,AUTO-CONTINUE=NO,OVC=NO,
              Changing to DCC mode! Do not continue unless avoidance moves have been added.
              MODE/DCC
PLN1_DCC     =FEAT/CONTACT/PLANE/DEFAULT,CARTESIAN,NONE,LEAST_SQR
              THEO/<-0.4562,0.0488,0>,<0,0,1>
              ACTL/<-0.4562,0.0488,0>,<0,0,1>
              TARG/<-0.4562,0.0488,0>,<0,0,1>
              ANGLE VEC=<1,0,0>,SQUARE
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=MASTER
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                CIRCULAR MOVES=STRAIGHT
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=2,NUMROWS=2
                SPACER=0
                AVOIDANCE MOVE=BOTH,DISTANCE BEFORE=0.3937,DISTANCE AFTER=0.3937,DIRECTION=ALONG FEATURE VECTOR
              SHOW HITS=YES
                HIT/BASIC,<-0.4448,0.1645,0>,<0,0,1>,<-0.4448,0.1645,0>
                HIT/BASIC,<-0.4507,-0.1829,0>,<0,0,1>,<-0.4507,-0.1829,0>
                MOVE/POINT,NORMAL<5.9367,3.1011,-14.334>
                HIT/BASIC,<0.4807,-0.1716,0>,<0,0,1>,<0.4807,-0.1716,0>
                HIT/BASIC,<0.4846,0.1402,0>,<0,0,1>,<0.4846,0.1402,0>
              ENDMEAS/
A3_DCC1      =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1_DCC
                ALIGNMENT/TRANS,ZAXIS,PLN1_DCC
                ALIGNMENT/TRANS,XAXIS,CIR1
                ALIGNMENT/TRANS,YAXIS,CIR1
                ALIGNMENT/ROTATE_CIRCLE,XPLUS,TO,CIR1,AND,CIR2,ABOUT,ZPLUS
              ALIGNMENT/END
CIR1_DCC     =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,OUT,LEAST_SQR
              THEO/<0,0,0.088>,<0,0,1>,0.725,0
              ACTL/<-5.6043,-3.0041,15.3133>,<-0.0000299,0.0050463,0.9999873>,0.725,0
              TARG/<0,0,0.088>,<0,0,1>
              START ANG=0,END ANG=360
              ANGLE VEC=<1,0,0>
              DIRECTION=CCW
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                REMEASURE=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=NOMINALS
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                CIRCULAR MOVES=STRAIGHT
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=5,DEPTH=-0.05,PITCH=0
                SAMPLE METHOD=SAMPLE_HITS
                SAMPLE HITS=0,SPACER=0
                AVOIDANCE MOVE=NO
                FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
              SHOW HITS=YES
                HIT/BASIC,<0.3625,0,0.038>,<1,0,0>,<-5.2418,-3.006,15.2633>
                HIT/BASIC,<0.112,0.3448,0.038>,<0.309017,0.9510565,0>,<-5.4907,-2.6601,15.2615>
                HIT/BASIC,<-0.2933,0.2131,0.038>,<-0.809017,0.5877853,0>,<-5.8966,-2.79,15.2622>
                HIT/BASIC,<-0.2933,-0.2131,0.038>,<-0.809017,-0.5877853,0>,<-5.8986,-3.2161,15.2643>
                HIT/BASIC,<0.112,-0.3448,0.038>,<0.309017,-0.9510565,0>,<-5.4939,-3.3496,15.265>
              ENDMEAS/
A3_DCC2      =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1_DCC
                ALIGNMENT/TRANS,ZAXIS,PLN1_DCC
                ALIGNMENT/TRANS,XAXIS,CIR1_DCC
                ALIGNMENT/TRANS,YAXIS,CIR1_DCC
                ALIGNMENT/ROTATE_CIRCLE,XPLUS,TO,CIR1_DCC,AND,CIR2,ABOUT,ZPLUS
              ALIGNMENT/END
CIR2_DCC     =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
              THEO/<0.625,0,0>,<0,0,1>,0.134
              ACTL/<0.5615,-0.2744,15.2253>,<0.0021648,0.0045584,0.9999873>,0.134
              TARG/<0.625,0,0>,<0,0,1>
              START ANG=0,END ANG=360
              ANGLE VEC=<1,0,0>
              DIRECTION=CCW
              SHOW FEATURE PARAMETERS=YES
                VOID DETECTION=NO
                REMEASURE=NO
                SURFACE=THICKNESS_NONE,0
                MEASURE MODE=NOMINALS
                RMEAS=NONE,NONE,NONE
                AUTO WRIST=NO
                CIRCULAR MOVES=STRAIGHT
                GRAPHICAL ANALYSIS=NO
                FEATURE LOCATOR=NO,NO,""
              SHOW CONTACT PARAMETERS=YES
                NUMHITS=4,DEPTH=0.06,PITCH=0
                SAMPLE METHOD=SAMPLE_HITS
                SAMPLE HITS=0,SPACER=0
                AVOIDANCE MOVE=NO
                FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
              SHOW HITS=YES
                HIT/BASIC,<0.692,0,-0.06>,<-1,0,0>,<0.6216,-0.3041,15.1653>
                HIT/BASIC,<0.625,0.067,-0.06>,<0,-1,0>,<0.5908,-0.2145,15.165>
                HIT/BASIC,<0.558,0,-0.06>,<1,0,0>,<0.5012,-0.2453,15.1653>
                HIT/BASIC,<0.625,-0.067,-0.06>,<0,1,0>,<0.532,-0.3349,15.1656>
              ENDMEAS/
A3_DCC3      =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
                ALIGNMENT/LEVEL,ZPLUS,PLN1_DCC
                ALIGNMENT/TRANS,ZAXIS,PLN1_DCC
                ALIGNMENT/TRANS,XAXIS,CIR1_DCC
                ALIGNMENT/TRANS,YAXIS,CIR1_DCC
                ALIGNMENT/ROTATE_CIRCLE,XPLUS,TO,CIR1_DCC,AND,CIR2_DCC,ABOUT,ZPLUS
              ALIGNMENT/END
            ENDGROUP/ID=DCC_ALIGN

New program but still having the same issue 

Something else is going on. 

Your numbers are way off from where they should be.

Have you qualified the tips?

Yes I have tried everything but just keep getting stuck 

I also just updated my sma license me and then my windows did an automatic update  

Something is amiss here:

The measured data for (measured) PLN1 is showing a move point of 5.936, 3.1011, -14.334:  By previous alignments and measured data; this can't be correct.

It will not measure (in DCC) unless the move point is removed or changed.  (Is it stopping at the DCC?)

Did you setup workplane?