ACU-RITE MILL PWR G2 Technical manual

February 3, 2017
MILLPWRG2 2 & 3 Axis
Release of Version R4SP5
For Use with Consoles (ID# 745604-NN) ONLY
NOTE: HEIDENHAIN Corporation recommends making a backup of the control with the USB
Recovery Drive before updating the control software. Please refer to the manual included with
the drive for the backup procedure. Reference compatibility chart below.
R4SP5 cannot be installed unless you have R4SP4 installed first. If you have previous
version of software such as R1, R2, or R3 SPx (release 1, release 2, or release 3 with
any service pack) download and install R4 SP4 prior to updating to R4SP5.
Consoles with ID# 745604-NN cannot be upgraded to R5 and will continue to receive
service packs under the R4 release. Please do not attempt to install release 5 (R5) onto
these consoles.
If required contact your authorized ACU-RITE dealer to purchase the USB recovery drive
1201909-01 includes a compatible USB Recovery Drive ID# 680480-03 for original G2 consoles
(ID#745604-NN).
If a special PLC for AMI functions was created for your MILLPWR system. The PLC for R5SP1
may need to be modified in the same manner. Any OEM/User customizations to the PLC will
need to be reintegrated into the new PLC project.
All users can verify your software version from the DRO screen by pressing SETUP. If one of
your soft keys is labeled More Commands, you have release 1 (R1) software. If one of your soft
keys is labeled Install Setup, press this key. Enter the password 8891 and press Enter. The
installed software version will be displayed at the bottom left of your screen.
If any issues are encountered, please contact your service representative for assistance.
You can download the software release update free of charge from our web site at www.acu-
rite.com. If you wish to purchase the software and operation manual from ACU-RITE, contact
your authorized dealer to place an order.
Installing the software onto your MILLPWRG2 system:
Use a blank USB memory stick (1 GB or larger) to update the software. Do not use any memory
stick with a smaller storage capacity. The software installation files are required for updating the
software. When a USB memory device in placed in a USB port prior to boot up with the update
files setup.zip, and setup.ini located within a folder named “install”, at boot up your G2 control
will detect the upgrade software files and proceed to install.
Procedure for downloading the update files and placing them on a USB drive.
Download the update from http://www.acu-rite.com/software-updates.html found under the
Controls Tab.

Unzip the downloaded archive insuring the target is the root level of your USB drive.
Insure the files setup.zip and setup.ini are transferred to a folder at the root level of your
USB drive named install, //MY USB DRIVE/install/
Procedure for updating the software
Shut down the control software using the normal method of pressing the Shutdown soft
key and then confirming the shutdown by pressing Yes.
Wait for the screen message which indicates that it is safe to switch off power, or restart.
Insert the USB memory device containing the folder named “install” on the USB memory
device.
Press ENTER to restart the system.
The software update will now be done automatically, taking approximately 10 - 20
minutes.
! A confirmation box will appear. If necessary, use the LEFT or RIGHT ARROW keys to select
Yes and then press ENTER.
When the update is complete, it will prompt you to remove the USB drive and restart. At this
time, remove the USB drive and press ENTER to restart. If the USB memory stick used for
installation is not removed, then the prompt to install the software will continue to appear on
subsequent power cycles.
! After installation and upon restart, you may receive a message prompt to confirm a firmware
update, accept the changes and RUN UPDATE.
-(Note: This particular NC startup screen can take several minutes to display. Please be
patient. Do not shutdown control and reboot.)
After the system has restarted, it will start up normally to the control software.
- Confirm that your count directions are correct.
- Press the SETUP hard key, then the “Install Setup” soft key, enter passcode 8891, press
ENTER
- In the “Installation” dialogue, scroll down to the last option “Machine Functions” and
press ENTER
- Configure the dialog to match your machine Note:(only required if special machine
function options are installed like demo, ami, guards, etc.)
- Press the USE hard key, then press the “Save Changes” soft key
- After a moment, you will get a reboot prompt
- Acknowledge the reboot and you are all done at the next startup.

MILLPWRG2 Recovery Drive Compatibility
Due to hardware differences the original MILLPWRG2 console and the current console
require different software upgrade paths.
Consoles can easily be identified by the color of the front bezel. The current design has
a darker grey color than the original design.
The current G2 console will proceed to release 5 (R5) and all its service packs.
The original G2 console will remain with release 4 (R4) and all of its service
packs.
Console ID#
and Software
Revision Recovery Drive
ID# 1114023-01
Recovery Drive
Kit ID# 1201909-
01
USB ID#
680480-03
Recovery Drive
Kit ID# 1127022-
01
USB ID#
680480-04
745604-NN Yes Yes No
R1 Yes Yes No
R2 Yes Yes No
R3 Yes Yes No
R4 Yes Yes No
R4 SP4 Yes Yes No
1113777-NN No Yes Yes
R1 No Yes Yes
R2 No Yes Yes
R3 No Yes Yes
R4 No Yes Yes
R4 SP4 No Yes Yes
R5 No No Yes
Post R5 No No Yes

Console ID # 745604-NN Console ID # 1113777-NN
G2 consoles (ID#745604-NN)
These consoles cannot be upgraded to R5 and will continue to receive service
packs under the R4 release. Please do not attempt to install release 5 (R5) onto
these consoles.
System drive restructuring on this original design consoles will cause the console
to become un-operational and require in house service to correct the issue. Do
not restructure the drive on these consoles.
Not all software enhancements will be included in future R4 releases. We
will continue to support console ID# 745604-NN with service packs through the
R4 released software that will mainly include minor enhancements or fixes.
USB Recovery Drive Kit 1201909-01 includes a compatible USB Recovery Drive
ID# 680480-03 for original G2 consoles (ID#745604-NN) and should be ordered
when replacing a recovery drive for these consoles. This drive does not include
the restructuring option, so the unit cannot be restructured accidentally.
G2 consoles (ID#1113777-NN)
R5 cannot be installed unless you have R4SP4 installed first. If you have previous
version of software such as R1, R2, or R3 SPx (release 1, release 2, or release 3 with
any service pack) download and install R4 SP4 prior to updating to R5.
Due to the enhanced features of release 5, it has become necessary to restructure the
console's hard drive. USB Recovery Drive ID# 680480-04 is now included in Recovery
Drive Kit ID# 1127022-01 which supports all G2 consoles and all software versions to
date or planned for the near future. This new recovery drive includes an option for
resizing the control’s hard drive partitions. This must only be performed on current
consoles (ID#1113777-NN) that are running software release 4 service pack 4 (R4 SP4).
Please insure the console is updated to this release prior to restructuring the drive and
installing release 5 (R5). Hard drive restructuring is required on these consoles prior to
the upgrade to release 5 (R5).

These enhancements/changes were made:
Improved the visibility of shutdown messages by using a dark text color.

The following functionality has been restored to the “Graphics Only” run
option. 1. “Graphics Only” button added to Run Options menu. 2. Pause
and display OIM messages. 3. Support limited VIEW dialog functionality.
Added ability to edit values for addresses R, D, U & W in drilling cycles; previously, it
was not possible to edit the values for addresses.
A Redraw (F6) softkey has been added when in the View form dialogue. Redraw
performs the same as the decimal point hot-key. In addition, both methods now re-start
the graphics if in progress when executed.
Added fields to Change Steps dialog to change Z Pass and Z Peck.
Programming of the “staging” point is now optional for custom pockets. If a “staging”
point is programmed the control will move to this location at start and end of custom
pocket step execution.
Added support for setting a datum during single cycles.
Improved the visibility of shutdown messages by using a dark text color.
These errors have been corrected:
When starting a program, the rendering of the tool path (and tool) was delayed if the
program had previously been stopped at the tool prompt.
Fixed an intermittent issue in Program Functions in which the system may create a
software failure while attempting to overwrite files during a Copy or Move operation.
Handling of unit conversions is corrected in step dialog, bottom finish fields.
Use of the Zero hard key now works in the Quick Save dialog when entering a name for
a new program.
When updating from pre-R4 software to R4-SP3 or later versions, an error was
displayed on every startup in regards to the touchprobe.tp system file. This issue has
been corrected, such that the error is no longer displayed.
Machine Guards are now disabled on startup if the AMI type is set to Disabled in
Machine Functions.
The finish feedrate specified in the advance custom pocket cycles (Bottom and Side
Finish cycles) takes precedence over the finish feed value specified in the custom
pocket step.
The block form is no longer resized once values are manually entered.
The shutdown timeout was adjusted to prevent a possible software failure during
shutdown.
Z INC position is reset to 0 when Z datum is set. This was not being reset if the current
tool had a length offset.
Corrected an issue in which the Paused and Running status messages were not
displayed correctly during Single Cycle execution.
Corrected an issue with the Machine Functions dialogue which made it impossible to
utilize the full 10VDC range of the Spindle DAC output. Existing systems should re-enter
all four RPM values and re-calibrate their spindle inverter to ensure correctly matched
programmed-to-actual RPMs.

If any issues are encountered, please contact your service representative for assistance or
contact technical support at [email protected] if you have any questions.