Restoring a Robot Backup

Decide which kind of restore you need

A partial restore reloads selected TP programs, registers, or I/O config from the file screen in the normal running state. A system-file restore (system variables, servo parameters, mastering, macros, frames) can only be read from the controlled start menu. A full image restore rewrites F-ROM and S-RAM from the boot monitor and returns the controller to the exact saved state.

Confirm the backup matches the robot

Check that the backup came from the same robot model and a compatible controller software version. For an image restore, confirm the saved *.IMG files match this controller's current FROM and SRAM module sizes, shown on the boot monitor RESTORE screen.

Caution: Restoring image files from a different FROM or SRAM size can cause fatal damage to the controller. Verify the module sizes match before you start the image restore.

Stage the storage device and set the I/O device

Insert the memory card or USB drive holding the backup. On the pendant press MENU, select 7 FILE, then press F5 [UTIL] and choose Set device, selecting Mem card (MC:), USB Disk (UD1:), or USB on TP (UT1:) to match where the backup lives.

Stop production and secure the cell

Confirm the program is aborted and the cell is safe before overwriting any data. Apply lockout/tagout so no one can start the robot while files are being replaced.

Restore selected programs and registers (partial restore)

In the file screen press F2, DIR, choose a file type such as *.TP, then load the program file. Register and position data restore from their data files (NUMREG.VR, POSREG.VR, STRREG.VR, PALREG.VR).

Caution: If a program with the same name already exists during a read, the existing program is overwritten automatically. Confirm you are loading the intended version before you accept the read.

Restore I/O configuration if needed

The I/O configuration data file DIOCFGSV.IO can be loaded from the file screen. After it is loaded, cycle power or perform a cold start so the restored I/O configuration takes effect.

Enter controlled start for system files

Hold the PREV and NEXT keys and switch the controller breaker to ON. At the CONFIGURATION MENU (1 Hot start, 2 Cold start, 3 Controlled start, 4 Maintenance) select 3 Controlled start.

Caution: Controlled start needs more than 600KB of free FROM, viewable under the memory status menu (0 Next, 4 status, memory). If free FROM is below 600KB, remove unnecessary data from FR: or FRA: first; the menu will not let you select controlled start otherwise.

Read the system files at controlled start

On the controlled start file screen F4 is shown as [RESTORE]; pressing it reads all files automatically. System files such as SYSVARS.SV, SYSSERVO.SV, SYSMAST.SV, SYSMACRO.SV, FRAMEVAR.VR, and SYSFRAME.SV load only from this controlled start file screen.

Understand the batched read order

Selecting [RESTORE] with All of above reads files in order: those saved as System files, then those saved as Application, then the *.TP, *.DF, and *.MN files on the device. The *.SV and *.VR files are read automatically when you select Convert=YES.

Restore from an automatic backup version

If the source is the Automatic Backup area (FRA:) or an initialized card, open MENU, 7 FILE, F1 [TYPE], Auto Backup. On the Loadable version item press F4 [CHOICE], pick the dated version, and that version is copied to the root directory so you can then read it from the file menu.

Perform a full image restore from the boot monitor

Press and hold both F1 and F2 and turn on the controller to reach the Restore Controller Images device selection menu (1 Memory card, 2 Ethernet TFTP, 3 USB UD1, 4 USB UT1). Choose the device, select 1 OK (Current Directory) at the directory menu, and when the detected image file count matches the module size, enter 1 to start the restore.

Caution: The boot monitor warns that image files must match the FROM and SRAM sizes or the operation can fatally damage the controller. Only answer yes once the reported module size and detected file count agree.

Do not interrupt the restore

Let the read run to completion; the screen shows each file as Reading FROM00.IMG ... Done. Do not turn off the power and do not remove the memory card or USB drive while a restore is in progress.

Return to normal operation with a cold start

From controlled start, press FCTN and select 1 START (COLD); an image restore restarts on its own into an ordinary start. A cold start turns each I/O signal off or to 0, aborts the program, resets the feed rate override, sets the JOINT frame, and releases the machine lock.

Verify mastering and calibrate

Open MENU, SYSTEM, F1 [TYPE], Master/Cal; the condition is that $MASTER_ENB is 1 or 2. Confirm the restored mastering is valid, then select 7 CALIBRATE and F4 (yes); the screen should read Robot Calibrated! with current joint angles, then press F5 DONE.

Caution: If the position data is incorrect the robot can move abnormally. Do not run production until the restored mastering is confirmed valid.

Run a low-speed test cycle

Jog the robot to a known reference position and compare it against the taught value to confirm the restore landed correctly. Run the program once at low speed with your hand on the teach pendant emergency stop before returning to full speed.

What can go wrong: robot not calibrated after restore

If SRVO-033 Robot not calibrated appears, the controller tried to calibrate but the needed adjustment was not complete. Check whether the restored mastering is valid; if it is invalid, master the robot again, then calibrate from the Master/Cal screen.

Caution: Correct the mastering rather than forcing the robot to run uncalibrated. An uncalibrated axis can move to unexpected positions.

What can go wrong: absolute position lost after restore

SRVO-062 BZAL indicates the Pulsecoder absolute-position backup battery is empty, often from a dead battery or a broken battery cable, and it means mastering will be needed. Replace the battery and check the mechanical unit cable, then have a qualified technician set $MCR.$SPC_RESET to TRUE and power cycle before re-mastering.

Caution: Fix the battery or cable cause first; clearing the alarm without correcting it lets the position data be lost again. Re-master and re-verify calibration before any production motion.

What can go wrong: image restore rejected or fails

If the boot monitor reports that the detected image file count does not correspond with the module size, stop and re-check that the *.IMG set matches this controller's FROM and SRAM sizes. If an image backup or restore fails, the controller posts an image failure to the alarm log with a cause code; read that code and confirm the storage device and image set are intact before retrying.