ACU-RITE Mill PWR G2 Technical manual

May 27, 2019
MILLPWRG2 2 & 3 Axis
Release of Version R8SP2
For Use with Consoles (ID#1113777-NN) ONLY
These release notes include enhancements/changes for R8SP2.
Please read below for the list of enhancements.
NOTE: HEIDENHAIN Corporation recommends making a backup image of the control with the
USB Recovery Drive before updating the control software. Please refer to the manual included
with the USB drive for the backup procedure. Reference compatibility chart below.
 Prior to updating to R8SP2 you must have R8 loaded, if you have a previous version of
software, confirm that R5 SP1 is installed and that you have resized the hard drive
partitions. Due to the enhanced features since release 5, repartitioning the console's
hard drive is required. USB Recovery Drive ID# 680480-04 includes an option for
resizing the control’s hard drive partitions. This can only be performed on consoles
ID#1113777-NN that are running software release 4 service pack 4 (R4 SP4) or R5.
Please insure the console is updated to one of these releases prior to restructuring the
drive and installing release 8 (R8).
 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 then proceed to update to R5.
 Recovery Drive Kit ID# 1127022-01 can be purchased from your local ACU-RITE
distributor.
If a special PLC for AMI functions was created for your MILLPWR system. The PLC for R8SP2
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. (These values should not change when
upgrading software.)
- If special machine functions were active, Press the SETUP hard key, then the “Install
Setup” soft key, enter passcode 8891, press ENTER
- In the “Installation” dialogue, arrow 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 8 (R8) 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 SP9 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 R8 or service packs within R8 and
will continue to receive service packs under the R4 release. Please do not
attempt to install release 5 (R5) R6 R7 or R8 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 repartitioning option, so the unit cannot be repartitioning accidentally.
G2 consoles (ID#1113777-NN)
 R8 and its associated service packs R8SPX cannot be installed unless you have
R5SP1 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 repartition 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 repartitioning is required on these consoles prior to
the upgrade to release 5 (R5).

These enhancements/changes were made:
For AC Bed Mill systems only; Added support for reference switches (active when using Rotary
encoders for axes), as well as Max Servo Speeds greater than 100 in/min.
The tool path’s start/end point for a closed path is calculated correctly if the first or last step is
an ARC defined without a radius (i.e. FROM/TO/CENTER).
The validation check for arc radius was also adjusted. The tolerance check for if the radius is
“too small” for the defined FROM and TO points was loosened so as not to report false errors
for arcs of 180 degrees.
Corrected an issue in which the calculated blockform and contour did not correctly handle tools
which were defined in the tool table rather than in the program.
Corrected an issue in which the Quick Save feature was always prompting for program name,
which should only happen if it is a New Program.
Corrected an issue with AMI systems in which manual spindle control would become impossible
after opening and closing machine guards, unless a program run was done to reset the spindle
state.
Corrected an issue where the Machine Functions soft key was not visible when the program
was paused.
Note: Release 8 (R8) software includes many enhancements, prior to downloading this
version be aware that the graphics of the user interface has changed. The user interface now
uses a modern theme congruent with the latest versions of the newly released ACU-RITE digital
readout products. Here are just of few of the changes, fonts, larger pop up menu’s large qwerty
keyboard, color highlighting of steps.
IF YOU WANT TO STAY WITH THE GRAPHICS YOU CURRENTLY HAVE DO NOT INSTALL
R8.

Here are some side by side comparisons:

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