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Work instruction - Manual Update KUKA.RecoveryUSB V1.0 to V2.0

Description This work instruction describes how an existing KUKA.RecoveryUSB Stick can
be updated to the higher Version V2.0.

1 Preconditions
1.1 Equipment
To perform this manual Update the following equipment is required:

 KUKA.RecoveryUSB V1.0 #2 Stick

[ Art.Nr.: 00-198-642 ]

 Windows PC [ XP, Win7 , …]

 ZIP-Archive with Update Files:

1.2 Preparation
[1] Unzip the Update files from the Zip-Archive into a directory.
The required password is:

RecoveryUpdate2.0

[2] Check the directory with the unzipped Files against the
UpdateV100_to_V201_9.md5 checksum file with a
Software checksum tool like “CheckCD” or similar.

It is highly recommended to check the integrity of the unzipped files after

downloading before using them in the Update process. Using unchecked
files for the Update may corrupt the functions of the KUKA.RecoveryUSB
Stick.

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2 Update
[3] Connect the KUKA.RecoveryUSB Stick V1.0 to a USB Port of the
Windows PC.

Content of the ZIP-Archive:

[4] Copy the content of the Zip Archive into the Root-Directory [ E:\ ] of the
KUKA.RecoveryUSB Stick

The Folder BIOS is new and has to be added into the root directory of the
USB Stick.

The Folder Doc contains the updated documentation of

KUKA.RecoveryUSB V2.0. The contend is added to the existing folder.

The Folder Mode contains the file controller.ini with new default settings
regarding the partition sizes of the KRC system and changed execution
mode configuration.
Existing controller.ini file must be overwritten.

The Folder sources contains the updated boot.wim and new

MSCOMCTL.OCX.
Existing boot.wim file must be overwritten.

The KSR_Configurator.exe is a new file. The new (KUKA System

Recovery) Configurator can be started by double clicking on the
KSR_Configurator.exe when USB Stick is attached to a Windows PC.
Since Version V2.0 the KSR Configurator is used to configure
KUKA.RecoveryUSB Stick exclusively.

The file UpdateV100_to_V201_9.md5 is a Checksum file to check the

data integrity of the content of the ZIP-Archive after downloading from the
FTP-Server.
The Check could be performed using a Software Tool like “CheckCD” or
similar

[5] Answer the following dialogs regarding files to be overwritten with “Yes”

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View of the Folders before and

after the Update:

Root-Directory V1.0 Root-Directory V2.0

Some Folders and Files on the USB Stick are hidden.

It depends on your system settings if the File BOOTMGR and the Folders
BOOT, EFI and sources are visible or not.

[6] Navigate into the root directory of the KUKA.RecoveryUSB Stick and
open the Configurator by double clicking on the
KSR_Configurator.exe.

[7] In the upcoming HMI of the KSR_Configurator click in each TAB on the
button “Default” (if present) and afterwards onto the Button “Save”.
The “Save”-Popup must be answered with “OK”.

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[8] Update is finished. Now the Stick is ready to be used with all new
features.

For further Information regarding please check the new

manual in the “Doc” folder.

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