Updating Controller Software on a FANUC Robot

Review the release notes

Check compatibility with installed hardware, options, and any known issues for the target software version.

Take a full system backup

Save an all-image or full backup to a USB drive and confirm the backup completed without errors.

Notify affected personnel

Inform production that the cell will be offline during the update and expected duration.

Load the update media

Insert the prepared update media and boot the controller into the boot monitor (BMON) mode per FANUC's instructions. From the BMON menu you can reach the All Software Installation and controller backup/restore items.

Run the update process

Follow the on-screen steps to install the new software version. Don't interrupt power during the process.

Restore the backup as directed

Follow FANUC's guidance on restoring programs and configuration data appropriate for the update type.

Re-validate the safety configuration

Bring up the DCS screens and confirm zones, limits, and I/O assignments still read as expected. DCS changes are protected by the Mode Select code number, so keep that available if you need to re-apply anything. There isn't a post-update checksum feature to rely on, so review the settings visually against your documented configuration.

Caution: Don't assume a checksum or signature check confirms DCS integrity after an update. Verify the config against your records.

Run a full function test

Before any motion, confirm the cell is clear of personnel and all guarding is in place. First run the test programs in T1 at low speed from the teach pendant and verify motion, I/O, and safety stops behave as expected. Only after a successful T1 verification should you consider stepping up toward production speed, and then return the cell to production.

Caution: Do not run at production speed until the cell has been cleared and T1 low-speed verification has completed successfully.