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Fanuc R-30iB Controller Backup & Restore

Note

This assumes, that you know how to use the Fanuc teach pendant as described in the chapter Setup.

Fanuc provides different ways to backup and restore data:

File Backup

A Fanuc File Backup will backup all files accessible in the teach pendant one to one to an USB Stick. This are for example

  • TP (.ls/.tp) and KAREL (.kl/.pc) programs
  • System configurations (I/O configuration, Frames, Mastering, Menu settings, etc.)
  • System variables

File Backups are not a complete controller backup. If you lose a main board or FROM/SRAM module, or otherwise have to completely reload your robot controller, a File Backup will not get you up and running by itself.

Create File Backup

To create a File Backup perform the following steps:

  1. Plug a USB-Stick (pendrive) into the teach pendants USB port. Its recommended that the USB Stick size is not bigger than 2GB as the whole drive is read when backing up.
  2. Press the soft button , enter the FILE menu and there the File section.
  3. Press the UTIL button at the bottom bar, select the entry Set Device and there the entry USB on TP (UT1:).
  4. Create a directory on the USB stick with the UTIL button at the bottom bar. Select the option Make DIR and then Options/Keybd. Press the button KEYBOARD at the bottom bar and type a directory name.
  5. Press the BACKUP button at the bottom bar and select the entry All of above. Confirm with YES in the bottom bar.

Restore File Backup

To restore a File Backup perform the following steps:

  1. Obtain a USB-Stick with a previous IMG backup for the robot you are working on.
  2. Plug a USB-Stick into the teach pendants USB port.
  3. Restart the robot controller and enter the Configuration Monitor menu by holding the soft buttons PREV and NEXT on the teach pendant as soon as the robot starts to power back up.
  4. Type 3 and press the soft button to initiate a controlled start.
  5. Once the teach pendant is booted back up, press the soft button , enter the FILE menu and there the File section.
  6. Press the UTIL button at the bottom bar, select the entry Set Device and there the entry USB on TP (UT1:).
  7. Navigate to the directory in which your File backup backup is stored. If no files or directories are shown, you will have to press ENTER on (all files) to see the USB-Sticks contents.
  8. Press the RESTOR button at the bottom bar.
  9. Select the type of restore action you want. If you don't know which you need, use 'All of above':
    • System files (system variables, servo parameter data, and mastering data)
    • TP programs (.TP, .DF, and .MN files)
    • Application ("Non-program application files")
    • Applic.-TP (All of the above, except system files)
    • Vision data
    • All of above
  10. You will be prompted with “Restore from UT1: (OVERWRT)?”. Press YES at the bottom bar.
  11. The TP will show “Accessing device. PREV to exit.” for about 30-60 seconds, then the restore will commence. Once it begins, typical restore time is about 2-6 minutes, depending on the contents of your robot.
  12. As many files as possible will be restored. Once the restore is complete, you will need to perform a Cold Start.

Controller Image Backup

A Controller Image Backup is a complete image of the robot controller’s contents – both FROM and SRAM. If you have an image, you can fully restore the robot in the event of FROM/SRAM module or main board failure. An image stores everything that an File Backup stores, plus the robot’s core software, patches, and any software customizations that have been loaded for your facility.

Image backups do have one major disadvantage. Their contents are not easily readable. As a result, they don’t offer the same value in reference and simplicity that’s found with File Backups.

Create Controller Image Backup

In opposite to a File Backup a Controller Image Backup compresses the controller content into not readable image files. Furthermore it also saves software options and licence information.

Warning

The robot has to be in mastering position, before performing a backup or restoring it. Otherwise all pose and joint data may be shifted. It's always recommended to do a File Backup along with a Controller Image Backup.

  1. Obtain a USB-Stick with enough of room available: A typical IMG is around 64 to 128MB, depending on your robot model
  2. Plug a USB-Stick into the teach pendants USB port.
  3. Press the soft button , enter the FILE menu and there the File section.
  4. Press the UTIL button at the bottom bar, select the entry Set Device and there the entry USB on TP (UT1:).
  5. Create a directory on the USB stick with the UTIL button at the bottom bar. Select the option Make DIR and then Options/Keybd. Press the button KEYBOARD at the bottom bar and type a directory name.
  6. Press the BACKUP button at the bottom bar and select Image backup.
  7. On the desination device menu that pops up, select Current Directory
  8. You will be prompted to “Cycle power?”. Press OK in the bottom bar.
  9. The robot will restart and the image backup will begin. The Controller Image Backup process takes about 4-5 minutes and then the robot will start back up.

Restore Controller Image Backup

Warning

The robot has to be in mastering position, before performing a backup or restoring it. Otherwise all pose and joint data may be shifted.

  1. Obtain a USB-Stick with a previous controller image backup for the robot you are working on.
  2. Plug a USB-Stick into the teach pendants USB port.
  3. Restart the robot controller and enter the Boot Monitor menu by holding the soft buttons F1 and F5 on the teach pendant as soon as the robot starts to power back up.
  4. Type 4 and press soft button to go to the controller backup/restore menu.
  5. On the controller backup/restore menu, type 3 and press soft button to select Restore Controller Images.
  6. Type the appropriate number to select the USB device on the teach pendant (UT1) and press soft button .
  7. Type the appropriate number to select the directory in which your image backups are stored, or type 0 for the next listing of directories or -1 for the previous listing of directories, and press soft button .
  8. Once you are in the appropriate directory, type 1 for OK (Current Directory) and press soft button .
  9. Make sure the FROM and SRAM images are the appropriate size. If everything looks good, type 1 and press soft button .
  10. The restore process will begin. Once initiated, the controller image restore process takes about 5 minutes.
  11. When the restore is complete, you will be prompted with “Press ENTER to return >”. Press soft button .
  12. Type 1 for configuration menu and press soft button .
  13. Once the configuration menu loads, type 2 for cold start and press soft button .

After the robot restarts, check if mastering errors appear. If so, you might be able to restore the mastering files from a File Backup, which was done along the Controller Image Backup.