To prepare new thumb drive for use

Any thumb drive 1GB or larger can be used because this procedure installs an "image" of the original operating system onto the stick. Both the installation software and the "image" file must be downloaded before installation.

First download the "image" file g4img1gb.zip. This zip file contains a disk image of a drive that’s formatted with the new operating system. After downloading it, right-click it and select "Extract All" from the menu that pops up. It will create folder called g4img1gb in the same folder that contains g4img1gb.zip. In the new folder will be a file called g4img1gb.img. Be sure to note where your browser downloaded the file because you will need to navigate there from the installation software.

Next, download the Balena Etcher imaging software. Double-click it and follow the instructions that come up to install the program.

After the disk imaging program is installed, put a thumb drive (at least 1GB: no matter how big it is it will look like a 1GB drive once the image is installed) in your computer. Double-click the balenaEtcher icon. It will open with "Flash from file" highlighted. Click "Flash from file". Etcher will open an Explorer window: navigate to the g4img1gb folder and select g4img1gb.img, then click "Open". The Etcher main screen will reappear with "Select target" highlighted. Click "Select target": a window will open showing the USB drive to be used. Click the drive and "Select 1" will be highlighted. Click "Select 1". The main Etcher screen will reappear with "Flash!" highlighted; click "Flash!". A User Acccount Control box will appear: click "Yes" to continue. An Insert disk dialog box will appear; ignore it; the flashing takes a few minutes, then the the image will be validated and the "Flash Completed!" screen will appear.

Next, customize the drive for your machine, if necessary. The thumb drive you just created is suitable for the standard 5HP spindle drive. If your machine is a C-Axis you must delete the runfiles\filepath.cfg file, and copy either filepath.yas (if you have Yaskawa C-Axis drive) or filepath.bml (if you have Baumuller C-Axis drive) as filepath.cfg.

Finally, Update the software. The g4img1gb image is appropriate for creating a bootable thumb drive from scratch, but the image is not kept up to date.

(Better yet, order a replacement thumb drive from the factory.)

Open balena Etcher image program.

At balena Etcher main menu, click on "Flash from file"

Navigate to Downloads > g4img1gb

Select g4img1gb.img, then click "Open"

At balena Etcher main menu, click on "Select target"

You will be shown the USB thumb drives connected to your computer.

Highlight the one you wish to write the image to, then click "Select 1"

At balena Etcher main menu, click on "Flash!"

You may be shown a "permissions" dialog:
Click "Yes" to continue

The etcher "Starting..." screen may briefly appear, followed by an "Insert Disk" dialog:
Pres Esc to clear it

The Etcher "flashing progress" screen will appear

The Etcher "validating progress" screen will appear

The Etcher "Flash Completed!" screen will appear

Navigate to the OmniTurn system thumb drive. The drive is named "1GBIMAGE".

If your folder view is set to "Large Icons", it can be difficult to see the files in the RUNFILES folder, so click on the "View" tab, and select "Details".

Double-click on the "RUNFILES" folder.

Right-click on "FILEPATH" to open the dialog box, then select "Delete".

(Note: if your folder view is set to show all extensions, you will see FILEPATH.CFG).

Select "Yes" to confirm delete.

Right-click on "FILEPATH.YAS" to open the dialog box, then select "Copy".

Note: If your C-Axis drive is a Baumuller, right-click on "FILEPATH.BML".

Right-click anywhere to open the dialog box, then select "Paste" to create a copy.

Right-click on "FILEPATH ‑ Copy.YAS" to open the dialog box, then select "Rename".

Note: If your C-Axis is a Baumuller, the filename will be FILEPATH ‑ Copy.BML.

Rename FILEPATH ‑ Copy.YAS
(or FILEPATH ‑ Copy.BML, if Baumuller) as FILEPATH.CFG.