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KUKA System Technology KUKA Roboter GmbH

KUKA.RecoveryUSB 3.0

For KR C2 ed05, KR C4 and Sunrise Cabinet

KUKA.Recov-

eryUSB 3.0

Issued: 09.12.2016

Version: KST RecoveryUSB 3.0 V1


KUKA.RecoveryUSB 3.0

© Copyright 2016
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub KST RecoveryUSB 3.0 (PDF) en


Book structure: KST RecoveryUSB 3.0 V1.1
Version: KST RecoveryUSB 3.0 V1

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Contents

Contents
1 Introduction .................................................................................................. 5
1.1 Industrial robot documentation ................................................................................... 5
1.2 Representation of warnings and notes ...................................................................... 5
1.3 Terms used ................................................................................................................ 6
1.4 Trademarks ................................................................................................................ 6

2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9

3 Product description ..................................................................................... 11


3.1 Overview of KUKA.RecoveryUSB .............................................................................. 11

4 Safety ............................................................................................................ 13
5 Operation ...................................................................................................... 15
5.1 System requirements ................................................................................................. 15
5.2 Operator control – PC/laptop ..................................................................................... 15
5.2.1 Overview of the user interface – PC/laptop .......................................................... 15
5.2.2 Configuration ........................................................................................................ 17
5.2.2.1 Configuration – “Execution mode” tab ............................................................. 18
5.2.2.2 Configuration – “Log-on” tab ............................................................................ 19
5.2.2.3 Configuration – “TCP/IP addresses“ tab .......................................................... 20
5.2.2.4 Configuration – “Network drives” tab ............................................................... 21
5.2.2.5 Configuration – “Utilities” tab ........................................................................... 22
5.2.3 Expert settings ...................................................................................................... 23
5.2.4 Creating an image of an external disk .................................................................. 25
5.2.5 Restoring an image to an external disk ................................................................ 26
5.3 Operator control – robot controller ............................................................................. 26
5.3.1 Starting the graphic operating mode ..................................................................... 26
5.3.2 Overview of user interface – robot controller ........................................................ 27
5.3.3 Creating and restoring an image .......................................................................... 28
5.3.3.1 Restoring an image to a disk ........................................................................... 29
5.3.3.2 Creating an image of a disk ............................................................................. 30
5.3.4 Network configuration ........................................................................................... 31
5.3.4.1 Configuration – “Log-on” tab ............................................................................ 31
5.3.4.2 Configuration – “TCP/IP addresses“ tab .......................................................... 31
5.3.4.3 Configuration – “Network drives” tab ............................................................... 33
5.3.5 Expert settings ...................................................................................................... 33
5.3.6 System information ............................................................................................... 35
5.3.6.1 System information – “General” tab ................................................................. 36
5.3.6.2 System information – “BIOS” tab ..................................................................... 36
5.3.6.3 System information – “Logical drives” tab ........................................................ 37
5.3.6.4 System information – “USB devices” tab ......................................................... 37
5.3.7 Utilities .................................................................................................................. 38
5.3.7.1 Checking the hard drive or USB devices ......................................................... 38
5.3.8 Executing Automatic mode ................................................................................... 38
5.3.8.1 Creating a KR C4 image in Automatic mode ................................................... 39
5.3.8.2 Restoring a KR C4 or Sunrise Cabinet image in Automatic mode ................. 39

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5.3.8.3 KR C4 CSP operating state indicator .............................................................. 39


5.3.9 Exiting KUKA.Recovery ........................................................................................ 40

6 KUKA Service ............................................................................................... 41


6.1 Requesting support ................................................................................................... 41
6.2 KUKA Customer Support ........................................................................................... 41

Index ............................................................................................................. 49

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1 Introduction

1 Introduction
t

1.1 Industrial robot documentation


t

The industrial robot documentation consists of the following parts:


 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable


that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may


occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if


no precautions are taken.

These warnings mean that damage to property may oc-


cur, if no precautions are taken.

These warnings contain references to safety-relevant information or


general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy


emergencies or malfunctions:

Procedures marked with this warning must be followed


exactly.

Notices These notices serve to make your work easier or contain references to further
information.

Tip to make your work easier or reference to further information.

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1.3 Terms used

Term Description
CSP Controller System Panel
Display element and connection point for USB and
network (KR C4)
DHCP Dynamic Host Configuration Protocol
DHCP enables the assignment of the network con-
figuration to clients by a server. DHCP can be used
to integrate a computer into an existing network
without having to configure the network manually.
IPv4 Internet Protocol Version 4
KCB KUKA Controller Bus
KCB is the designation for the drive bus. (KR C4)
KLI KUKA Line Interface
KLI is a line bus for integrating the system into the
customer network. (KR C4)
KPC KUKA PC in the control cabinet (KR C4)
KSB KUKA System Bus
KSB is a bus to the KCP and to customer EtherCAT
I/Os. (KR C4)
Multicast Simultaneous transmission of a data packet in a net-
work to multiple receivers.
Non-finalized Image released for an installation.
(master) image
Finalized image Image that can only be installed on the robot control-
ler from which it originates.
SID Security identifier
A unique security identifier that is issued automati-
cally in order to be able to identify every system,
every user and every group permanently.
UNC Uniform Naming Convention (also Universal Naming
Convention)
Standard format for designation of network
addresses
VGA Video Graphics Array (computer graphics standard)
VxWorks Real-time operating system
WES7 Windows Embedded Standard 7
WIM Windows imaging format
Non-hardware-specific Windows format for an
image
WinPE Windows Preinstallation Environment
WinPE enables installation of a Windows operating
system if no operating system has previously been
installed on the hard drive.

1.4 Trademarks

VxWorks is a trademark of Wind River Systems Inc.


Windows is a trademark of Microsoft Corporation.

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1 Introduction

WinPE is a trademark of Microsoft Corporation.

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2 Purpose

2 Purpose
2

2.1 Target group


s

This documentation is aimed at users with the following knowledge and skills:
 Advanced knowledge of the robot controller system
 Advanced knowledge of the Windows operating system
 Basic knowledge of network connections

For optimal use of our products, we recommend that our customers


take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.

2.2 Intended use

Use of KUKA.RecoveryUSB is only permissible for the following applications:


 Loading non-finalized master images or finalized images (resetting a con-
troller)
 Creating and restoring a hard drive image of a controller (to back up an ex-
isting configuration, data backup)

The creation of non-finalized master images can only be performed


by KUKA Service.

Duplication of a controller that has already been finalized (factory set-


tings) is not permissible and can lead, for example, to network prob-
lems, blue screens, etc.

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed.

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3 Product description

3 Product description

3.1
t
Overview of KUKA.RecoveryUSB

KUKA.RecoveryUSB is a WinPE-based archiving software package for creat-


s

Description
ing and restoring an image (backup) of the hard drive of a robot controller.
The following user interfaces are available:
 User interface – PC/laptop
This user interface is only available on an external PC or laptop.
(>>> 5.2 "Operator control – PC/laptop" Page 15)
 User interface – robot controller
This user interface is only available on the robot controller, the KCP or an
external screen.
(>>> 5.3 "Operator control – robot controller" Page 26)

Functions Restoration of a hard drive image


 From:
 A network drive
 A KUKA.RecoveryUSB stick
 A hidden hard drive partition (only on the robot controller user inter-
face)
 An external USB hard drive
 A local laptop/PC hard drive (only on the laptop/PC user interface)
 To:
 A local controller drive
 An external USB hard drive (only on the laptop/PC user interface)
Creation of a hard drive image
 From:
 A local controller drive
 An external USB hard drive (only on the laptop/PC user interface)
 To:
 A network drive
 A KUKA.RecoveryUSB stick
 A hidden hard drive partition (only on the robot controller user inter-
face)
 An external USB hard drive (only on the laptop/PC user interface)
 A local laptop/PC hard drive (only on the laptop/PC user interface)

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4 Safety

4 Safety
4

y This documentation contains safety instructions which refer specifically to the


software described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.

The “Safety” chapter in the operating and programming instructions


of the KUKA System Software (KSS) must be observed. Death to per-
sons, severe injuries or considerable damage to property may other-
wise result.

Users are responsible for ensuring that their system has


sufficient virus protection. Data may otherwise become
damaged or lost.

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5 Operation

5 Operation

5.1 System requirements


t

Hardware  KUKA.RecoveryUSB stick


 KR C2 ed05, KR C4, KR C4 compact, KR C4 extended, Sunrise Cabinet
 At least 512 MB RAM
 At least 20 GB hard disk

Software For KR C2 ed05


 BIOS V4.06 R1.05-08.1688.01 (booting with the F10 key)
 Operating system Windows XP embedded 2.0
For KR C4, Sunrise Cabinet
 Operating system Windows XP embedded 3.0
Or
 Operating system WES7 4.0

Licenses Valid licenses for the following software must be present on the robot control-
ler:
 Windows system license
 Windows XP embedded
Or
 Windows WES7
 VxWorks

5.2 Operator control – PC/laptop

5.2.1 Overview of the user interface – PC/laptop

Description If the KUKA.RecoveryUSB stick is connected to a normal PC or laptop, all the


settings can be made in advance.
The following main functions are possible on the user interface of the lap-
top/PC:
 Configuring KUKA.Recovery for use on the robot controller
 Restoring an image to an external USB hard drive
 Creating an image of an external USB hard drive

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Fig. 5-1: User interface – laptop/PC

Button Description
Configuration This button can be used to make the following
configuration settings:
 Execution mode
 Log-on
 TCP/IP addresses
 Network drives
 Utilities
(>>> 5.2.2 "Configuration" Page 17)
Create image of ex- This button can be used to create an image of an
ternal disk external disk.
Note: The external disk must be connected to the
PC or laptop via a USB adapter.
(>>> 5.2.4 "Creating an image of an external
disk" Page 25)
Note: If KSS 8.3 is used, this function can only be
performed with 8.3.15 Build 109 or higher since
the boot configuration on the computer that is
used would otherwise be modified.
Restore image to ex- This button can be used to restore an image to an
ternal disk external disk.
Note: The external disk must be connected to the
PC or laptop via a USB adapter.
(>>> 5.2.5 "Restoring an image to an external
disk" Page 26)
Note: If KSS 8.3 is used, this function can only be
performed with 8.3.15 Build 109 or higher since
the boot configuration on the computer that is
used would otherwise be modified.
Expert settings This button can be used to make settings for the
partitions and the images.
(>>> 5.2.3 "Expert settings" Page 23)

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5 Operation

Button Description
Update USB stick This button is used to update the KUKA.Recov-
eryUSB stick.
Note: For this function, the Windows user must
have administrator privileges.
Eject USB device When using external USB devices, these must be
ejected via this function after use since there
would otherwise be a risk of losing data.
Language selection This button can be used to set the language of
KUKA.Recovery.
Tips and tricks This button can be used to display tips and tricks
for KUKA.Recovery. Further tips and tricks can
be added by the user via RecoveryTips.kxr.
Help This button can be used to open this documenta-
tion for KUKA.Recovery.
About This button can be used to display information
about the software.
Exit This button can be used to close and exit the KU-
KA.Recovery user interface.

5.2.2 Configuration

Description The Configuration button opens a window. The configuration window of the
KUKA.RecoveryUSB stick is subdivided into 5 tabs.
 Execution mode
 Log-on
 TCP/IP addresses
 Network drives
 Utilities

Overview

Fig. 5-2: “Configuration” window

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Item Description
1 Tabs:
 Execution mode
(>>> 5.2.2.1 "Configuration – “Execution mode” tab" Page 18)
 Log-on
(>>> 5.2.2.2 "Configuration – “Log-on” tab" Page 19)
 TCP/IP addresses
(>>> 5.2.2.3 "Configuration – “TCP/IP addresses“ tab"
Page 20)
 Network drives
(>>> 5.2.2.4 "Configuration – “Network drives” tab" Page 21)
 Utilities
(>>> 5.2.2.5 "Configuration – “Utilities” tab" Page 22)
2 Reload button
The most recently saved values are restored.
3 Default setting button
The specified basic settings are restored.
The basic settings cannot be defined via the user interface. They
can be modified at file level via the Default.INI file – for example,
to map a Group standard.

5.2.2.1 Configuration – “Execution mode” tab

Description The following settings can be made on this tab:


 Graphic operating mode
Once the controller has been booted from the KUKA.RecoveryUSB stick,
the creation and restoration of the partitions must be started by the user.
Precondition:
 Graphics interface
 Monitor (only for KR C4, Sunrise Cabinet), mouse and keyboard
 Silent mode
Automatic mode enables the automatic creation and restoration of a hard
drive image following booting of the robot controller, without the need for
additional operator actions. During the booting of the robot controller, the
KUKA.RecoveryUSB stick must be connected to the robot controller.

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5 Operation

Fig. 5-3: “Execution mode” tab

Item Description
1 Action:
 Create image of disk
An image of a hard drive is created here.
 Restore image to disk
An image is restored to a hard drive here.
 Persistent
If this is not selected, the mode Create image of disk is auto-
matically selected after the installation of an image.
This ensures that a KUKA.RecoveryUSB stick inadvertently
left plugged in cannot cause any damage.
2 Image:
 USB stick
The directory .\Image on the KUKA.RecoveryUSB stick is used
as the source and target directory.
 Hidden partition
The 3rd partition is used as the target or source for the image.
 Network
The configured network path is used as the source or as the
target. The network connection is established using the config-
uration under Log-on and TCP/IP addresses.
 Image file
The name of the image file is entered here. The suffix C.WIM
or D.WIM is automatically added by KUKA.Recovery.

5.2.2.2 Configuration – “Log-on” tab

Description The log-on data, domain, user and password are entered on this tab. They are
used in the automatic execution mode for logging onto the network if it is con-
figured as the source or target of the image file. These log-on data are required
for connecting the configured network drives.

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Fig. 5-4: “Log-on” tab

Parameter Description
Domain The name of the domain is entered here.
User The user name for the network log-on is entered
here.
Password The password is entered here.
Retype password For security, the password must be entered a
second time.

5.2.2.3 Configuration – “TCP/IP addresses“ tab

Description The TCP/IP addresses used by the system for establishing a network connec-
tion are defined on this tab.

Fig. 5-5: “TCP/IP addresses” tab

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5 Operation

Item Description
1 Static IP address:
Here, a selection is made as to whether to use a static IP address.
If so, the following parameters must be configured:
 IP address
The static IP address for the network connection is specified
here.
 Subnet mask
The subnet mask for the network connection is specified here.
 Standard gateway
The standard gateway for the network connection is entered
here.
Note: If Static IP address is not activated, a dynamic IP address
is automatically used.
2 Static DNS and WINS servers
Here, a selection is made as to whether to use a static configura-
tion for the DNS and WINS servers. If so, the following parameters
must be configured:
 Preferred DNS server
Here, the preferred DNS server is specified.
 Alternative DNS server
Here, the alternative DNS server is specified.
 Preferred WINS server
Here, the preferred WINS server is specified.
 Alternative WINS server
Here, the alternative WINS server is specified.
 DNS suffix
Here, the alternative DNS suffix is specified.
Note: If static DNS and WINS servers are not activated, a dynamic
IP address is automatically used.
3 Activate Windows firewall
Here, a selection is made as to whether the Windows firewall
should be active or inactive when the network connection is active.

5.2.2.4 Configuration – “Network drives” tab

Description On this tab, the network paths which are to be available to the robot controller
as a source or target for the image file are defined in UNC format. The lines
can be activated and deactivated via the check boxes.

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Fig. 5-6: “Network drives” tab

5.2.2.5 Configuration – “Utilities” tab

Description This tab enables the configuration of WinPE-compatible applications for the
graphic operating mode.
The menu names and the associated local paths must be specified. The lines
can be activated and deactivated via the check boxes.
The applications can be called in the graphic operating mode via the Utilities
button.

Procedure 1. Connect the KUKA.RecoveryUSB stick to the laptop or PC.


2. Click on the Configuration button.
3. Click on the Utilities tab.
4. Enter the path for the desired program here and assign a name.
5. Click on OK.

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5 Operation

Overview

Fig. 5-7: “Utilities” tab

5.2.3 Expert settings

Description The Expert settings button opens a window for advanced configuration.

Overview

Fig. 5-8: Expert settings

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Item Description
1 Automatic size of partitions
If automatic partition size is selected, the following partitions are
created depending on the target operating system:
For XP:
 Partition 1 (KUKA_DISK): drive C:\ = 15 GB
 Partition 2 (KUKA_DATA): drive D:\ = 5 GB
 Partition 3 (KUKA_RECOVERY): hidden partition with the re-
maining space
For WES7:
 Partition 1 (KUKA_DISK): drive C:\ contains 10/16 of the avail-
able space (hard drive size).
 Partition 2 (KUKA_DATA): drive D:\ contains 3/16 of the avail-
able space (hard drive size).
 Partition 3 (KUKA_RECOVERY): the hidden partition contains
3/16 of the available space (hard drive size).
If automatic partition size is not selected, the values must be en-
tered manually:
 Partition C:
In the example, 15360 MByte has been entered.
 Partition D:
In the example, 5120 MByte has been entered.
Note: Partition C and partition D must be included. Otherwise, au-
tomatic partition size cannot be activated.
2 If Include partition C: is activated, drive C:\ is taken into account
when creating or restoring images.
3 If Include partition D: is activated, drive D:\ is taken into account
when creating or restoring images.
4 Copy image to hidden partition
The image files used for restoration can be saved in the 3rd parti-
tion.
Note: If this option is not set, later restoration from the hidden par-
tition is not possible.
Note: With older versions of the control software, it is possible
that the hidden partition of the hard drive will not become available
until the image has been restored once with KUKA.Recovery.
5 Check data storage medium before image creation
If this option is selected, an error check and debugging is carried
out for the individual partitions prior to image creation using
CHKDSK.exe /R.
6 Remove hibernate file
If this option is selected, the file hiberfil.sys on the robot control-
ler is deleted before an image is created.
Note: If this option is not selected, a check is carried out to see if
the robot controller for which an image is to be created has been
shut down in hibernate mode. If the robot controller was shut
down from hibernate mode, the robot controller must be termi-
nated in cold start mode before an image is created.

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5 Operation

Item Description
7 Support only KUKA controllers
A configuration setting can be made here, allowing KUKA.Recov-
ery also to be operated using unknown hardware. If this is not
done, KUKA.Recovery can only be operated using known KUKA
hardware.
Note: If the check box is not activated and, for example, the
KUKA.RecoveryUSB stick is connected to a laptop, the entire
hard drive will be overwritten.
8 Time Zone
The time zone of the location where KUKA.Recovery is currently
in operation is configured here. This setting is essential for ensur-
ing that created images receive the correct time stamp. The
WinPE time zone is immediately set in the graphic operating
mode (robot controller user interface).

5.2.4 Creating an image of an external disk

Description The Create image of external disk button opens a window.


The USB drive for which an image is to be created must be selected here. The
location where the image file is to be saved and the file name must be speci-
fied.

Separate images are created in WIM format for partition C:\ and par-
tition D:\ and saved with the same name. The suffix C.WIM or D.WIM
is automatically added by KUKA.Recovery.

Precondition  Configuration of the partitions has been completed.


(>>> 5.2.3 "Expert settings" Page 23)
 Windows users require administrator privileges.

Procedure 1. In the menu, click on Create image of external disk.


2. Select a path and drive for saving the image.
3. Click on OK.

If partition C:/ and partition D:/ are selected individually in the config-
uration, the procedure must be performed twice since the image is
created individually for each partition.

Overview

Fig. 5-9: Creating an image of an external disk

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5.2.5 Restoring an image to an external disk

Description The Restore image to external disk button opens a window.


The image file and the target drive on which it is to be installed are selected
here.

If KSS 8.3 is used, this function can only be performed


with 8.3.15 Build 109 or higher since the boot configura-
tion on the computer that is used would otherwise be modified.

Precondition  Configuration of the partitions has been completed.


(>>> 5.2.3 "Expert settings" Page 23)
 Windows users require administrator privileges.

Procedure 1. Click on the Restore image to external disk button. A window opens.
2. Select the image file and the drive.
3. Click on OK.
4. A message stating that the hard drive will be overwritten appears. Ac-
knowledge the message with OK.

Overview

Fig. 5-10: Restoring an image to an external disk

5.3 Operator control – robot controller

5.3.1 Starting the graphic operating mode

KUKA.Recovery can also be started in Automatic mode.

Precondition  Robot controller with VGA or DVI interface


 External monitor
 External keyboard and mouse

Procedure For KR C2
1. Connect the KUKA.RecoveryUSB stick.
2. Boot the robot controller and press F10.
The user interface is opened.
For KR C4, Sunrise Cabinet
1. Connect the KUKA.RecoveryUSB stick.

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5 Operation

2. Boot the robot controller.


The user interface is opened.

5.3.2 Overview of user interface – robot controller

Description This user interface appears if the KUKA.RecoveryUSB stick is connected to


the robot controller. For the KR C2 robot controller, the user interface is dis-
played on the KCP. For the KR C4 robot controller and Sunrise Cabinet, an
external screen must be connected to see the user interface.

Fig. 5-11: User interface – robot controller

Button Description
Create image of disk This button can be used to create an image of the
disk of the robot controller.
(>>> 5.3.3.2 "Creating an image of a disk"
Page 30)
Restore image to This button can be used to load an image onto
disk the disk of the robot controller.
(>>> 5.3.3.1 "Restoring an image to a disk"
Page 29)
Shutdown This button can be used to close and exit the KU-
KA.Recovery user interface.
Network configura- This button can be used to make the following
tion configuration settings:
 Log-on
 TCP/IP addresses
 Network drives
Note: The settings made here are not saved and
are only valid for the current session. Afterwards,
the settings must be made again.
(>>> 5.3.4 "Network configuration" Page 31)

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Button Description
Expert settings This button can be used to make settings for the
partitions and the images.
(>>> 5.3.5 "Expert settings" Page 33)
Note: The settings made here are not saved and
are only valid for the current session. Afterwards,
the settings must be made again.
Eject USB device When using external USB devices, these must be
ejected via this function after use since there
would otherwise be a risk of losing data.
Language selection This button can be used to set the language of
KUKA.Recovery.
Screen resolution The screen resolution can be adapted here.
Utilities Several programs are stored here for quick ac-
cess:
 Editor
 Paint
 Registry editor
 Command prompt
 Check data storage medium
It is possible to add further programs
(>>> 5.3.7 "Utilities" Page 38).
System information Information regarding the following categories is
displayed here:
 General
 BIOS
 Logical drives
 USB devices
(>>> 5.3.6 "System information" Page 35)
Tips and tricks This button can be used to display tips and tricks
for KUKA.Recovery. Further tips and tricks can
be added by the user via RecoveryTips.kxr.
About This button can be used to display information
about the software.

5.3.3 Creating and restoring an image

Overview Various destinations are available for archiving the hard drive images of the
robot controller.
 KUKA.RecoveryUSB stick
 Hidden partition of the hard drive
 Network drive
 External USB hard drive

The hidden partition of the hard drive is not immediately available in


all cases; it might not become available until after the hard drive im-
age has been restored once with KUKA.Recovery.

Separate images are created in WIM format for partition C:\ and partition D:\
and saved with the same name.
 Default name: Image

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 The images for partitions C:\ and D:\ are differentiated by the suffixes C
and D in the name:
 ImageC.WIM
 ImageD.WIM
Both image files (ImageC.WIM and ImageD.WIM) are always used.

5.3.3.1 Restoring an image to a disk

Description The Restore image to disk button opens a window.


The path where the image file is located must be specified here. The corre-
sponding images are loaded onto the disk of the robot controller.

If the image is loaded onto the hard drive, the hard drive
of the robot controller will be permanently overwritten!

Restoration of a hard drive image


 From:
 A network drive
 A KUKA.RecoveryUSB stick
 A hidden hard drive partition
 An external USB hard drive
 To:
 A local controller drive

Precondition  Configuration of the partitions has been completed.


(>>> 5.2.3 "Expert settings" Page 23)

Procedure 1. Click on the Restore image to disk button. A window opens.


2. Select the image file and the drive.
3. Click on OK.
4. A message stating that the hard drive will be overwritten appears. Ac-
knowledge the message with OK.

Overview

Fig. 5-12: Restoring an image to a disk – robot controller

If the check box Connect to network is activated, the previously con-


figured network drives are connected using the log-on data.

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If partition C:/ and partition D:/ are selected individually in the config-
uration, the procedure must be performed twice since the image is
created individually for each partition.

5.3.3.2 Creating an image of a disk

Description The Create image of disk button opens a window.


Creation of a hard drive image
 From:
 A local controller drive
 To:
 A network drive
 A KUKA.RecoveryUSB stick
 A hidden hard drive partition
 An external USB hard drive
The storage location of the image file is entered here. By default: ./Image on
the KUKA.RecoveryUSB stick.
Separate images are created in WIM format for partitions C:/ and D:/ and
saved with the same name.
 Default name: Image
 The images for partitions C:\ and D:\ are differentiated by the suffixes C
and D in the name:
 ImageC.WIM
 ImageD.WIM

Precondition  Configuration of the partitions has been completed.


(>>> 5.2.3 "Expert settings" Page 23)

Procedure 1. In the menu, click on Create image of disk.


2. Select a path for saving the image.
3. Click on OK.

If partition C:/ and partition D:/ are selected individually in the config-
uration, the procedure must be performed twice since the image is
created individually for each partition.

Overview

Fig. 5-13: Creating an image of a disk – robot controller

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5.3.4 Network configuration

Description The Network configuration button opens a window. The configuration win-
dow of the KUKA.RecoveryUSB stick is subdivided into 3 tabs.
 Log-on
(>>> 5.3.4.1 "Configuration – “Log-on” tab" Page 31)
 TCP/IP addresses
(>>> 5.3.4.2 "Configuration – “TCP/IP addresses“ tab" Page 31)
 Network drives
(>>> 5.3.4.3 "Configuration – “Network drives” tab" Page 33)

The settings made here are not saved and are only valid
for the current session. Afterwards, the settings must be
made again.

5.3.4.1 Configuration – “Log-on” tab

Description The log-on data, domain, user and password are entered on this tab. These
are required for connection of the network drives.

Fig. 5-14: “Log-on” tab – robot controller

Parameter Description
Domain The name of the domain is entered here.
User The user name for the network log-on is entered
here.
Password The password is entered here.
The password can be displayed in plain text by
using the magnifying glass.
Retype password For security, the password must be entered a
second time.

5.3.4.2 Configuration – “TCP/IP addresses“ tab

Description The TCP/IP address settings used by the system for establishing a network
connection are defined on this tab.

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Fig. 5-15: “TCP/IP addresses” tab – robot controller

Item Description
1 Static IP address:
Here, a selection is made as to whether to use a static IP address.
If so, the following parameters must be configured:
 IP address
The static IP address for the network connection is specified
here.
 Subnet mask
The subnet mask for the network connection is specified here.
 Standard gateway
The standard gateway for the network connection is entered
here.
Note: If Static IP address is not activated, a dynamic IP address
is automatically used.

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Item Description
2 Static DNS and WINS servers
Here, a selection is made as to whether to use a static configura-
tion for the DNS and WINS servers. If so, the following parameters
must be configured:
 Preferred DNS server
Here, the preferred DNS server is specified.
 Alternative DNS server
Here, the alternative DNS server is specified.
 Preferred WINS server
Here, the preferred WINS server is specified.
 Alternative WINS server
Here, the alternative WINS server is specified.
 DNS suffix
Here, the alternative DNS suffix is specified.
Note: If static DNS and WINS servers are not activated, a dynamic
IP address is automatically used.
3 Activate Windows firewall
Here, a selection is made as to whether the Windows firewall
should be active or inactive when the network connection is active.

5.3.4.3 Configuration – “Network drives” tab

Description On this tab, the network paths are defined in UNC format. These network
paths are available as the target and source drives for the image file.

Fig. 5-16: “Network drives” tab – robot controller

5.3.5 Expert settings

Description The Expert settings button opens a window for advanced configuration.

The settings made here are not saved and are only valid
for the current session. Afterwards, the settings must be
made again.

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Overview

Fig. 5-17: “Expert settings” tab – robot controller

Item Description
1 Automatic size of partitions
If automatic partition size is selected, the following partitions are
created depending on the target operating system:
For XP:
 Partition 1 (KUKA_DISK): drive C:\ = 15 GB
 Partition 2 (KUKA_DATA): drive D:\ = 5 GB
 Partition 3 (KUKA_RECOVERY): hidden partition with the re-
maining space
For WES7:
 Partition 1 (KUKA_DISK): drive C:\ contains 10/16 of the avail-
able space (hard drive size).
 Partition 2 (KUKA_DATA): drive D:\ contains 3/16 of the avail-
able space (hard drive size).
 Partition 3 (KUKA_RECOVERY): the hidden partition contains
3/16 of the available space (hard drive size).
If automatic partition size is not selected, the values must be en-
tered manually:
 Partition C:
In the example, 15360 MByte has been entered.
 Partition D:
In the example, 5120 MByte has been entered.
Note: Partition C and partition D must be included. Otherwise, au-
tomatic partition size cannot be activated.
2 If Include partition C: is activated, partition C is taken into account
when creating or restoring images.

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5 Operation

Item Description
3 If Include partition D: is activated, partition D is taken into
account when creating or restoring images.
4 Copy image to hidden partition
The image files used for restoration can be saved in the 3rd parti-
tion.
Note: If this option is not set, later restoration from the hidden par-
tition is not possible.
Note: With older versions of the control software, it is possible
that the hidden partition of the hard drive will not become available
until the image has been restored once with KUKA.Recovery.
5 Check data storage medium before image creation
If this option is selected, an error check and debugging is carried
out for the individual partitions prior to image creation using
CHKDSK.exe /R.
6 Remove hibernate file
If this option is selected, the file hiberfil.sys is deleted before an
image is created.
Note: If this option is not selected, a check is carried out to see if
the system of which an image is to be created has been shut
down in hibernate mode. If the system was shut down in hibernate
mode, the system must be terminated in cold start mode before
an image is created.
7 Support only KUKA controllers
A configuration setting can be made here, allowing KUKA.Recov-
ery also to be operated using unknown hardware. If this is not
done, KUKA.Recovery can only be operated using known KUKA
hardware.
Note: If the check box is not activated and, for example, the
KUKA.RecoveryUSB stick is connected to a laptop, the entire
hard drive will be overwritten.
8 Time Zone
The time zone of the location where KUKA.Recovery is currently
in operation is configured here. This setting is essential for ensur-
ing that created images receive the correct time stamp. The
WinPE time zone is immediately set in the graphic operating
mode (robot controller user interface).

5.3.6 System information

Description The System informationbutton opens the “System information” window. The
system information is subdivided into 4 tabs.
 General
(>>> 5.3.6.1 "System information – “General” tab" Page 36)
 BIOS
(>>> 5.3.6.2 "System information – “BIOS” tab" Page 36)
 Logical drives
(>>> 5.3.6.3 "System information – “Logical drives” tab" Page 37)
 USB devices
(>>> 5.3.6.4 "System information – “USB devices” tab" Page 37)

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5.3.6.1 System information – “General” tab

Description General information is displayed on this tab.

Overview

Fig. 5-18: System information – “General” tab

Parameter Description
CPU type The CPU type used is displayed here.
Processor(s) The number of process locations used is dis-
played here.
Core(s) The number of cores used is displayed here.
RAM The RAM is displayed here.
Hard drive(s) The hard drive and its capacity are displayed
here.
Current time The time according to the time zone set in the
“Expert settings” is displayed here.

5.3.6.2 System information – “BIOS” tab

Description This tab displays all the information about BIOS.

Overview

Fig. 5-19: System information – “BIOS” tab

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5 Operation

Parameter Description
BIOS date The date of the BIOS is displayed here.
BIOS version The BIOS version is displayed here.
Major version The main version being used is displayed here.
Minor version The minor version being used is displayed here.

5.3.6.3 System information – “Logical drives” tab

Description This tab displays all the information about the logical drives that are available.

Overview

Fig. 5-20: System information – “Logical drives” tab

5.3.6.4 System information – “USB devices” tab

Description This tab displays all the information about the USB devices that are available.

Overview

Fig. 5-21: System information – “USB devices” tab

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5.3.7 Utilities

Description This button can be used to access individual programs. Further programs that
may be helpful for the user can be added (>>> 5.2.2.5 "Configuration – “Util-
ities” tab" Page 22).
The following programs are saved by default:
 Editor
 Paint
 Registry editor
 Command prompt
 Check data storage medium

5.3.7.1 Checking the hard drive or USB devices

Procedure 1. In the graphic operating mode (robot controller user interface), click on the
Utilities button.
2. Click on the Check data storage medium program.
All hard drives and connected USB devices are displayed in the list of
drives.
3. Select the desired drive and click OK.
The program is executed.

5.3.8 Executing Automatic mode

Description Depending on the configuration, an image is created or restored in Automatic


mode.

If the KUKA.RecoveryUSB stick is used more than once to create


hard drive images on the KUKA.RecoveryUSB stick in Automatic
mode, the most recently saved image will be overwritten.

Precondition  The KUKA.RecoveryUSB stick is configured for Automatic mode.

Procedure For KR C2
1. Connect the KUKA.RecoveryUSB stick.
2. Boot the robot controller and press the F10 key.
The image is automatically created in the configured target directory or re-
stored from the source directory.
3. Once the image has been completely created or restored, the KUKA.Re-
coveryUSB stick is automatically deactivated and the robot controller is
automatically rebooted.
4. Before it can be used again, the KUKA.RecoveryUSB stick must be re-
moved and plugged back in.
For KR C4, Sunrise Cabinet
1. Connect the KUKA.RecoveryUSB stick.
2. Boot the robot controller.
The image is automatically created in the configured target directory or re-
stored from the source directory.
3. Once the image has been completely created or restored, the controller is
shut down.
4. Switch off the controller via the main switch.
5. Remove the KUKA.RecoveryUSB stick.

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5 Operation

6. Switch on the controller via the main switch.

5.3.8.1 Creating a KR C4 image in Automatic mode

Precondition  The robot controller is switched off.


 There is sufficient memory space available in the target directory.

Procedure 1. Connect the KUKA.RecoveryUSB stick to the PC of the robot controller.


2. Boot the robot controller.
3. CSP LED 1 flashes: KUKA.RecoveryUSB is booting the controller.
4. CSP LED 1 lights up: The boot procedure has been completed.
5. CSP LED 2 flashes: Image of the C:\ partition is being created.
6. CSP LED 2 lights up: Image creation of the C:\ partition has been complet-
ed.
7. CSP LED 3 flashes: Image of the D:\ partition is being created.
8. CSP LED 3 lights up: Image creation of the D:\ partition has been complet-
ed.
9. CSP LED 1-6 lights up for 1 second: The complete image has been creat-
ed.
10. CSP LED 2 flashes: The controller has been shut down.
11. Switch off the controller via the main switch.
12. Remove the KUKA.RecoveryUSB stick.
13. Switch on the controller via the main switch.

5.3.8.2 Restoring a KR C4 or Sunrise Cabinet image in Automatic mode

Precondition  The robot controller is switched off.

Procedure 1. Connect the KUKA.RecoveryUSB stick to the PC of the robot controller.


2. Boot the robot controller.
3. CSP LED 1 flashes: KUKA.RecoveryUSB stick is booting the controller.
4. CSP LED 1 lights up: The boot procedure has been completed.
5. CSP LED 2 flashes: Image of the C partition is being restored and copied
to the hidden partition.
6. CSP LED 2 lights up: Restoration of the C partition has been completed.
7. CSP LED 2 flashes: Image of the D partition is being restored and copied
to the hidden partition.
8. CSP LED 2 lights up: Restoration of the D partition has been completed.
9. CSP LED 1-6 lights up for 1 second: The complete image has been re-
stored.
10. CSP LED 2 flashes: The controller has been shut down.
11. Switch off the controller via the main switch.
12. Remove the KUKA.RecoveryUSB stick.
13. Switch on the controller via the main switch.

5.3.8.3 KR C4 CSP operating state indicator

Description The LEDs of the Controller System Panel (CSP) indicate the operating state
of the controller.

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Fig. 5-22: KR C4 operating state indicator

Item Description
1 LED 1 (green): Operation
2 LED 2 (white): Sleep
3 LED 3 (white): Automatic
4 LED 4 (red): Error LED 1
5 LED 5 (red): Error LED 2
6 LED 6 (red): Error LED 3

The LEDs 4 - 6 are not controlled by RecoveryUSB during cre-


ation/restoration of the image.

5.3.9 Exiting KUKA.Recovery

Procedure For KR C2
 Click on the Exit button.
The KUKA.RecoveryUSB stick is deactivated and the robot controller is re-
booted.
For KR C4, Sunrise Cabinet
1. Click on the Exit button.
The KUKA.RecoveryUSB stick is deactivated and the robot controller is
shut down. CSP LED 2 flashes.
2. Turn the main switch to OFF.
3. Remove the KUKA.RecoveryUSB stick.
4. Turn the main switch to ON.
The controller is rebooted.

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6 KUKA Service

6 KUKA Service
A

6.1 Requesting support


v

Introduction This documentation provides information on operation and operator control,


and provides assistance with troubleshooting. For further assistance, please
contact your local KUKA subsidiary.

Information The following information is required for processing a support request:


 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 Model and serial number of the controller
 Model and serial number of the energy supply system
 Designation and version of the system software
 Designations and versions of other software components or modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the
software (KRCDiag is not yet available here.)
 Application used
 External axes used

6.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)


Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

Australia KUKA Robotics Australia Pty Ltd


45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
info@kuka-robotics.com.au
www.kuka-robotics.com.au

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Belgium KUKA Automatisering + Robots N.V.


Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.


Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
info@kuka-roboter.com.br
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)


Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl

China KUKA Robotics China Co., Ltd.


No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
info@kuka-robotics.cn
www.kuka-robotics.com

Germany KUKA Roboter GmbH


Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka-roboter.de

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6 KUKA Service

France KUKA Automatisme + Robotique SAS


Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.


Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in

Italy KUKA Roboter Italia S.p.A.


Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

Japan KUKA Robotics Japan K.K.


YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
info@kuka.co.jp

Canada KUKA Robotics Canada Ltd.


6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
info@kukarobotics.com
www.kuka-robotics.com/canada

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Korea KUKA Robotics Korea Co. Ltd.


RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com

Malaysia KUKA Robot Automation (M) Sdn Bhd


South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
info@kuka.com.my

Mexico KUKA de México S. de R.L. de C.V.


Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
www.kuka-robotics.com/mexico

Norway KUKA Sveiseanlegg + Roboter


Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no

Austria KUKA Roboter CEE GmbH


Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
office@kuka-roboter.at
www.kuka.at

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6 KUKA Service

Poland KUKA Roboter CEE GmbH Poland


Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de

Portugal KUKA Robots IBÉRICA, S.A.


Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
info.portugal@kukapt.com
www.kuka.com

Russia KUKA Robotics RUS


Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
info@kuka-robotics.ru
www.kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB


A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se

Switzerland KUKA Roboter Schweiz AG


Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

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Spain KUKA Robots IBÉRICA, S.A.


Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
comercial@kukarob.es
www.kuka.es

South Africa Jendamark Automation LTD (Agency)


76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Robot Automation Taiwan Co., Ltd.


No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
info@kuka.com.tw
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd


Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH


Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz

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6 KUKA Service

Hungary KUKA Robotics Hungaria Kft.


Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

USA KUKA Robotics Corporation


51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
info@kukarobotics.com
www.kukarobotics.com

UK KUKA Robotics UK Ltd


Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk

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Index

Index
Symbols L
“Network drives” tab 21 LEDs 39
Licenses 15
A
Automatic mode, executing 38 M
Multicast 6
B
BIOS 15 N
Network configuration 31
C Non-finalized (master) image 6
Configuration – “Execution mode” tab 18
Configuration – “Log-on” tab 19, 31 O
Configuration – “Network drives” tab 33 Operating system 15
Configuration – “TCP/IP addresses” tab 20, 31 Operation 15
Configuration – “Utilities” tab 22 Operator control, PC/laptop 15
CSP 6, 39 Operator control, robot controller 26
Overview, KUKA.RecoveryUSB 11
D
DHCP 6 P
Documentation, industrial robot 5 Partition, hidden 28
Product description 11
E Purpose 9
Expert settings 23, 33
R
F RAM 15
Finalized image 6
Functions 11 S
Safety 13
G Safety instructions 5
Graphic operating mode, starting 26 Service, KUKA Roboter GmbH 41
Graphics card 6 SID 6
Software 15
H Sunrise Cabinet image, restoring (Automatic mo-
Hard drive or USB devices, checking 38 de) 39
Hard drive space 15 Support request 41
Hardware 15 System information 35
System information – “BIOS” tab 36
I System information – “General” tab 36
Image of disk, creating 30 System information – “Logical drives” tab 37
Image of external disk, creating 25 System information – “USB devices” tab 37
Image, creating 28 System requirements 15
Image, restoring 28
Image, restoring to external disk 26, 29 T
Introduction 5 Target group 9
IPv4 6 Terms used 6
Terms, used 6
K Trademarks 6
KCB 6 Training 9
KLI 6
Knowledge, required 9 U
KPC 6 UNC 6
KR C4 image, creating in Automatic mode 39 Utilities 38
KR C4 image, restoring (Automatic mode) 39
KSB 6 V
KUKA Customer Support 41 VGA 6
KUKA.Recovery, exiting 40 VxWorks 6

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W
Warnings 5
WIM 6
WinPE 6

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