I don’t remember what version @NicholasL is using, he’ll have to chime in on that. You’d have to hunt back through the posts of people trying to get the 6442 to use the U axes for a rotary.
Don’t… You will lose your vendors setup information. These are generic controllers and the vendor information varies by manufacturer. Who made the controller didn’t build your laser.
All the values that determine movement and distance will be lost. That’s great that you done a backup from RDWorks, but I don’t have an available Windows machine.
Out1 and Out2 are, as far as I know, not user configurable. They are used for the stack lights to indicate what state the machine is in.
Here’s a short video, <1 minute, of Status, Out1 and Out2, top to bottom on mine.
I’ve always been uncomfortable loading firmware into a controller… I’ve seen too many of them get bricked in the process. Unless I need a specific function that the firmware offers, I don’t upgrade it.
Have fun 
