ACU-RITE MILL PWR G2 Technical manual

October 10, 2017
MILLPWRG2 2 & 3 Axis
Release of Version R6
For Use with Consoles (ID#1113777-NN) ONLY
This is our sixth major release of software and it includes some very exciting and
anticipated features. Please read below for the list of enhancements.
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.
Prior to updating to R6, confirm that R5 SP1 is installed and that you have resized the
hard drive partitions.Due to the enhanced features since release 5, restructure 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 6 (R6).
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 R6 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 6 (R6) 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 SP6 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 R6 and will continue to receive service
packs under the R4 release. Please do not attempt to install release 5 (R5) or R6
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)
R6 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 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:
New and improved program simulation graphics. Resolution has been increased so three
dimensional solid models more closely resemble a CAD/CAM solid model.
Reference mark indication is now available in the System Monitor section of Diagnostics.

New off-line programming software for Windows computers. The software is now the same as the
actual hardware. The new format operates within an included Oracle VirtualBox platform.
Additional Languages have been added.
A new 2D Solid View now greatly enhances two dimensional representation and toolpath
simulation.
Solid tool representation is now possible in 2D and 3D Line View graphics to aid visually when
multiple depth passes are made, as well as to more easily verify correct tool compensation
offsets. The new “Tool” feature in the VIEW dialogue will show or hide the solid tool in any
available view mode.
An even spacing option has been added to the FACE cycle. It can be run as “shortest path” or
“even spacing”. The cycle can start from any corner by specifying positive or negative values for
the sizes.
When a Position/Drill is programmed, the Z information and other data will be cleared. It will not
fetch any information from the previous steps.
A Recycle Bin has been added to store deleted files and folders and can be either recovered or
permanently deleted from the bin.
Multiple line engraving is now possible for both Line and Arc engraving. Up to 5 lines can be
engraved within a single step at a capacity of 80 characters per line. New soft keys are available
to navigate and edit engraving text.
The ‘Goto Tool Number’ soft key in the tool table can now be used to directly jump to the specific
row for a tool number.
Added a shortcut softkey to Installation Setup, for access to the system screensaver.
The amount of motion allowed in the W-Axis while running a program or Single Cycle is now
configurable.
Added G code support for multiple M and S variables within a single block (i.e. M3 M8 S1000).
Modal parameters are now set to the state corresponding to the mid-program start in G code.
This applies to G0/1/2/3, G20/21, G70/71 and G90/91.
These corrections are solved:
“Software Travel Limit” is now used, in place of ‘Table Limit’ or ‘Software Limit’.
Tools now retracts to Z begin between passes for Rectangle pocket, Rectangle slot and Circle
pocket.
Arc Slot now allows slot definition using an end position and sweep angle.
Bottom Finish will now default to zero (none) if it is not specified. Previously, if Bottom Finish was
blank, it would use the same value as the Side Finish field.
Under certain conditions, the tool path fails to correctly cut around an ARC.
Corrected a Z Pass calculation issue when switching between number and distance.
Corrected a rare potential issue in which the system could start up with the wrong tool data.
Corrected an issue in which in certain situations, one could get axis faults when pressing the e-
stop button.
Prevented a possible error in PGM mode with intensive G2 programs or when switching back
from the geometry calculator.
To avoid potential problems when running without a defined tool, a Set Tool step will now appear
within the program before a custom pocket step that uses advanced cycles (i.e. Pilot Drill).
If any issues are encountered, please contact your service representative for assistance or
contact technical support at [email protected] if you have any questions.