Robotics in Manufacturing

Backups & recovery

Backup Before a Software Update

For a technician protecting all programs, configuration, and mastering data before applying a controller software or firmware update.

Intermediate~25 min7 steps
  1. Step 1.

    Stop production

    Confirm the robot is idle and no program is running before starting the backup.

  2. Step 2.

    Insert the USB drive

    Plug in a drive with enough space for a full image backup.

  3. Step 3.

    Take a full image backup

    Run a complete controller image backup, not just an MD backup, since the update may change system files broadly.

  4. Step 4.

    Verify the backup

    Check the file list on the drive to confirm the backup completed and files look correctly sized.

  5. Step 5.

    Note the current software version

    Record the controller's current software version number for reference in case a rollback is needed.

  6. Step 6.

    Label and store the backup separately

    Keep this pre-update backup on a drive that will not be reused until the update is confirmed successful.

  7. Step 7.

    Proceed with the update

    Only begin the software update once the backup is verified complete.

Common questions

How long does Backup Before a Software Update take?
Backup Before a Software Update is rated Intermediate and takes about 25 minutes across 7 steps.
What tools do I need?
You will need Teach pendant, USB drive with sufficient space.
What should I do before starting?
Update is scheduled with production stopped.
What is the first step?
Stop production. Confirm the robot is idle and no program is running before starting the backup.

Attribution

Procedure steps on this page are checked against the site's editorial safety rules and manufacturer-manual sourcing standards.

Last reviewed: 2026-07-21.

Edited by Mike Ramsey / Reliable Media.Editorial process