KUKA System Technology KUKA Roboter GmbH

KUKA.RecoveryUSB 1.0

For KR C2 edition2005, KR C2 sr and KR C4

Issued: 04.04.2011

Version: KST RecoveryUSB 1.0 V2 en

 KUKA.RecoveryUSB 1.0

© Copyright 2011
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 1.0 en

Bookstructure: KST RecoveryUSB 1.0 V2.1
Label: KST RecoveryUSB 1.0 V2 en

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 Contents

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

2 Product description ..................................................................................... 9

2.1 Overview of KUKA.RecoveryUSB .............................................................................. 9

3 Safety ............................................................................................................ 11
4 Configuration ............................................................................................... 13
4.1 System requirements ................................................................................................. 13
4.2 Modifying partition sizes ............................................................................................. 13
4.3 Configuring network settings ...................................................................................... 14
4.3.1 Ethernet interfaces of the KR C4 .......................................................................... 15
4.3.2 Ethernet interface of the KR C2 edition2005/sr .................................................... 15
4.4 Configuring silent mode ............................................................................................. 16

5 Operation ...................................................................................................... 17
5.1 Starting KUKA.Recovery in GUI mode (KR C4) ........................................................ 17
5.2 Starting KUKA.Recovery in GUI mode (KR C2 edition2005, KR C2 sr) .................... 17
5.3 Overview of graphical user interface .......................................................................... 18
5.3.1 Changing the user interface language .................................................................. 18
5.3.2 Refreshing the system information ....................................................................... 19
5.3.3 Changing the screen resolution ............................................................................ 19
5.3.4 Establishing a remote desktop connection ........................................................... 19
5.3.5 Calling utilities ....................................................................................................... 20
5.3.5.1 Checking the hard drive or USB devices (Check Disk) ........................................ 20
5.3.6 Calling online help ................................................................................................ 21
5.3.7 Displaying information about KUKA.Recovery ..................................................... 21
5.3.8 Exiting KUKA.Recovery ........................................................................................ 21
5.4 Activating a network connection ................................................................................ 21
5.4.1 Configuring network settings online ...................................................................... 21
5.4.2 Activating the IP address ...................................................................................... 21
5.4.3 Disabling and enabling the firewall ....................................................................... 22
5.5 Creating and archiving a hard drive image ................................................................ 22
5.5.1 Archiving a hard drive image on the RecoveryUSBStick ...................................... 22
5.5.2 Archiving a hard drive image on a network drive .................................................. 23
5.5.3 Archiving a hard drive image on a hidden partition ............................................... 24
5.6 Restoring a hard drive image ..................................................................................... 25
5.6.1 Modifying partition sizes online ............................................................................. 25
5.6.2 Restoring a hard drive image from the RecoveryUSBStick .................................. 25
5.6.3 Restoring a hard drive image from a network drive .............................................. 26
5.6.4 Restoring a hard drive image from a hidden partition ........................................... 26
5.7 Safely removing USB devices .................................................................................... 27
5.8 Executing silent mode ................................................................................................ 28

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5.8.1 Controller System Panel ....................................................................................... 29

5.8.2 Silent mode process sequence with KR C4 ......................................................... 29

6 KUKA Service ............................................................................................... 31

6.1 Requesting support ................................................................................................... 31
6.2 KUKA Customer Support ........................................................................................... 31

Index ............................................................................................................. 39

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 1 Introduction

1 Introduction

1.1 Target group

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.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

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

1.3 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 physical injury will occur, if no pre-
cautions are taken.

These warnings mean that death or severe physical inju-

ry may occur, if no precautions are taken.

These warnings mean that minor physical 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 precautionary measures.

Hints These hints 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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1.4 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.
GUI Graphical User Interface
GUI mode Installation mode for a robot controller with graphical
user interface.
IPv4 Internet Protocol Version 4
ISO image File that contains an image of the contents of a CD
or DVD, structured with the ISO 9660 format.
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.
Silent mode Installation mode for a robot controller without
graphical user interface (no operator action
required)
(>>> 4.4 "Configuring silent mode" Page 16)
UFD USB Flash Drive (USB memory stick)
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
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.

1.5 Trademarks

VxWorks is a trademark of Wind River Systems Inc.

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 1 Introduction

Windows is a trademark of Microsoft Corporation.

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 2 Product description

2 Product description

2.1 Overview of KUKA.RecoveryUSB

Functions KUKA.Recovery is a WinPE-based archiving software package with the fol-

lowing functions:
 Creation and restoration of an image of the hard drive of the robot control-
ler
 Archiving of the image on a KUKA.RecoveryUSBStick, external USB hard
drive, local drive or network drive and on the hidden partition of the hard
drive
 Restoration of the image from a KUKA.RecoveryUSBStick, external USB
hard drive, local drive or network drive and from the hidden partition of the
hard drive
 Configuration of the KUKA.RecoveryUSBStick for silent mode

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 3 Safety

3 Safety
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

must be observed. Death to persons, severe physical injuries or con-
siderable damage to property may otherwise result.

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 4 Configuration

4 Configuration

4.1 System requirements

Hardware  KUKA.RecoveryUSBStick
 KR C2 edition2005, KR C2 sr or KR C4
 At least 512 MB RAM
 Recommended hard drive size: min. 20 GB

Software Minimum requirements:

 BIOS V4.06 R1.05-08.1688.01 for booting with the F10 key
(KR C2 edition2005 or KR C2 sr)
 Operating system Windows XP embedded 2.0

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

4.2 Modifying partition sizes

Description There are 3 partitions on the hard drive of the robot controller:
 Partition 1: Drive C:\KUKA_DISK
 Partition 2: Drive D:\KUKA_DATA
 Partition 3: Hidden partition KUKA_RECOVERY
The hidden partition contains the master image ImageC.WIM and Im-
ageD.WIM of partitions C:\ and D:\ (= factory settings of the KUKA System
Software).
The size of the first and second partitions can be modified in the configuration
file Mode\Controller.INI on the RecoveryUSBStick. The first and second parti-
tions must both be at least 3,000 MB in size and may jointly occupy up to the
entire capacity of the hard drive.
KUKA.Recovery determines the total capacity of the hard drive. If one partition
has been allocated too little capacity or if the sum of both partitions exceeds
the total capacity of the hard drive, the partition sizes are assigned automati-
cally:
 Partition 1: 10 GB (default)
 Partition 2: 10 GB (default)
 Partition 3: Remainder
The size of the first and second partitions in the configuration file Mode\Con-
troller.INI can also be modified online. Partition sizes that are changed online
are only valid for the current WinPE session. The configuration is not perma-
nently saved.
(>>> 5.6.1 "Modifying partition sizes online" Page 25)

Controller.INI ...
[HDDSize]
Partition_1=10000
Partition_2=10000

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Parameter Description
Partition_1 Size of the first partition
Default value: 10,000 MB
Minimum value: 3,000 MB
Partition_2 Size of the second partition
Default value: 10,000 MB
Minimum value: 3,000 MB

Example The default value entered for the first and second partitions is 10,000 MB.
These partition sizes have been retained. How the hard drive of the robot con-
troller is partitioned when an image is restored depends on the capacity of the
hard drive.

Hard drive capacity Silent mode GUI mode

20 GB (» actually less than The partition sizes are The user is prompted by a mes-
20 GB) assigned automatically. sage to modify the partition
sizes.
30 GB (» actually less than The partition sizes are The partition sizes are retained.
30 GB) retained.

4.3 Configuring network settings

Description Hard drive images of the robot controller can be created on a network drive
and restored from a network drive.
The following files are available for the network configuration:
 NetCon.INI: Up to 20 UNC network paths can be configured.
 SetIPAddress.INI:
 IP address
 Subnet mask
 Gateway (optional)
Network settings that are to remain permanently valid must be configured di-
rectly in the INI files in the NET directory on the RecoveryUSBStick.
Network settings that are defined on the user interface are only valid for the
current WinPE session. The configuration is not permanently saved.
(>>> 5.4.1 "Configuring network settings online" Page 21)

NetCon.INI [NetUNC]
1=\\ronts001\transfer

Only UNC network paths may be used. The drive letter is automatically as-
signed by the system.
The format of a UNC network path in Windows is:
 \\ServerName\ShareName

SetIPAddress.INI [StaticIPAddress]
IPAddress=xxx.xxx.xxx.xxx
Subnetmask=xxx.xxx.xxx.xxx
;Gateway=xxx.xxx.xxx.xxx

The default prefix lengths for the router and subnet masks for IPv4 addresses
must be observed. No plausibility check is carried out.
Default values in the file Net\IpAddress.RTF:

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 4 Configuration

Class Start End Prefix length Subnet mask

A 0.0.0.0 127.255.255.255 8 bits 255.0.0.0
B 128.0.0.0 191.255.255.255 16 bits 255.255.0.0
C 192.0.0.0 223.255.255.255 24 bits 255.255.255.0
D 224.0.0.0 239.255.255.255 Multicast Multicast
E 240.0.0.0 255.255.255.254 Reserved Reserved

4.3.1 Ethernet interfaces of the KR C4

Description The KUKA PC in the control cabinet (KPC) has 3 Ethernet interfaces:
 KSB (KUKA System Bus)
 KCB (KUKA Controller Bus)
 KLI (KUKA Line Interface)

When booting with WinPE, only the KLI interface is activated. In order
to establish a link to the network drive, the network cable must be con-
nected to the KLI.

Fig. 4-1: Interfaces on the KPC

1 KSB 3 KCB
2 KLI

4.3.2 Ethernet interface of the KR C2 edition2005/sr

Description When booting with WinPE, only the on-board Ethernet interface is activated.
In order to establish a link to the network drive, the network cable must be con-
nected to this interface.
The illustration (>>> Fig. 4-2 ) shows the position of the on-board Ethernet in-
terface on the control PC, taking the KR C2 edition2005 as an example.

Further information about the on-board Ethernet interface is con-

tained in the assembly or operating instructions for the robot control-
ler.

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Fig. 4-2: Control PC interfaces, KR C2 edition2005 (excerpt)

1 USB (2x) 5 Keyboard connection

2 COM 1 serial interface 6 Mouse connection
3 COM 2 serial interface 7 LPT1 parallel interface
4 USB (2x) 8 Ethernet interface

4.4 Configuring silent mode

Description The RecoveryUSBStick can be configured in such a way that no operator ac-
tion is required when a robot controller hard drive image is created or restored.
Examples of use of silent mode:
 No graphical user interface is available.
 During initial start-up of several identical robots, multiple restorations of
the hard drive image are carried out.
Silent mode is set in the configuration file Mode\Controller.INI on the Recov-
eryUSBStick.

Controller.INI ...
[KRCType]
;Version=silent
Mode=0
Persistent=0
...

Parameter Description
Version  GUI mode is executed if the program line is com-
mented out.
 Silent mode is executed if the program line is acti-
vated.
Default: GUI mode
Mode Program functions
 0: Create hard drive image on RecoveryUSBStick.
 1: Restore hard drive image from RecoveryUSB-
Stick.
 2: Restore master image from the hidden partition.
Default value: 0
Persistent  0: Following program execution, the value set for
Mode is reset to the default value.
 1: Following program execution, the value set for
Mode is retained, e.g. Mode=1.
Default value: 0

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 5 Operation

5 Operation

5.1 Starting KUKA.Recovery in GUI mode (KR C4)

KUKA.Recovery can also be started in silent mode.

(>>> 5.8 "Executing silent mode" Page 28)

Precondition  Robot controller with VGA card

 External monitor
 External keyboard

Procedure 1. Connect the RecoveryUSBStick.

2. Boot the robot controller.
The user interface is opened.

5.2 Starting KUKA.Recovery in GUI mode (KR C2 edition2005, KR C2 sr)

KUKA.Recovery can also be started in silent mode.

(>>> 5.8 "Executing silent mode" Page 28)

Precondition  External keyboard

Procedure 1. Connect external keyboard to the robot controller.

2. Connect the RecoveryUSBStick.
3. Boot the robot controller.
4. Press F10 during the boot procedure.
The user interface is opened.

If KUKA.Recovery is not started after the F10 key has been pressed,
the BIOS settings must be checked and altered if necessary:
1.Press F2 during the boot procedure.
2. Select Advanced > Advanced System Configuration in the BIOS
menu and set USB Legacy Support to Enabled.
It may be necessary for this setting to be altered before every start of KU-
KA.Recovery.

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5.3 Overview of graphical user interface

Fig. 5-1: KUKA.Recovery user interface

Item Description
1 Indication of the logical drive from which KUKA.Recovery was
started
2 System information display
 Computer
 Name: Name of the computer
 Processor(s): Number of processors
 Core(s): Number of processor cores
 RAM: Size of the main memory
 CPU: Name of the main processor
 BIOS: BIOS version numbers
 Logical drive: Partitions and size of the partitions on the hard
drive
 Hard drive disk: Name of the hard drive, number of partitions
on the hard drive and the overall capacity of the hard drive
 System: Version of the WinPE software
 USB Device: Connected USB devices with indication of the
drive letter and the available capacity

5.3.1 Changing the user interface language

Description The user interface is available in the following languages:

 German
 English

Procedure  Select the desired language under Language in the menu.

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5.3.2 Refreshing the system information

Procedure  Select the menu sequence Start > Refresh System Info.
The displayed system information is refreshed.

5.3.3 Changing the screen resolution

Procedure 1. Select the menu sequence Start > Display resolution.

The Display resolution window is opened.
2. Deactivate the KR C2 Ed05/sr resolution check box.
3. Select the desired screen resolution from the list.
4. Press the Display button. The displayed screen resolution is applied.
5. If the set screen resolution is in order, answer the request for confirmation
in the Monitor Settings window with Yes within 15 seconds.
The screen resolution is reset to the default setting if the request for con-
firmation is answered with No or if no answer is given within this time.
6. Close the Display resolution window with Exit.

Description

Fig. 5-2: Display resolution window

Item Description
1 KR C2 Ed05/sr resolution check box
 Check box active: By default, the screen resolution for
KR C2 edition2005/sr is active.
 Check box not active: Additional screen resolutions can be se-
lected.
2 List of available screen resolutions
The list is only available if the KR C2 Ed05/sr resolution check
box is deactivated.
3 Display button
The screen resolution selected in the list is displayed on the button.
4 Display of the screen resolution currently set

5.3.4 Establishing a remote desktop connection

Description It is possible to establish a remote desktop connection to another computer.

The connection corresponds to the client variant, i.e. the connection can only
be established from WinPE. The server variant is not supported by WinPE.

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Procedure 1. Select the menu sequence RemoteDesktop > Client.

The Remote Desktop Connection window is opened.
2. Select remote computer then press Connect.

5.3.5 Calling utilities

Procedure  Select the menu sequence Start > Utilities and the desired menu item.

Description The following utilities are available:

 Notepad: Text editor
 Command prompt: Windows shell (input prompt)
 Registry: Registry editor
 Task manager: Task manager
 Paint: MS Paint for graphics processing
 Check Disk: MS ChkDsk for checking the hard drive and USB devices for
file system errors

5.3.5.1 Checking the hard drive or USB devices (Check Disk)

Procedure 1. Select the menu sequence Start > Utilities > Check Disk.
All hard drives and connected USB devices are displayed in the list of
drives.
2. Select the desired drive and click on the Check button.
The program chkdsk.exe is executed.

Description

Fig. 5-3: Check Disk

1 List of drives 3 Check button

2 Close button

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 5 Operation

5.3.6 Calling online help

Procedure 1. Select the menu sequence ? > Tips and Tricks.

The first help text is displayed.
2. Click on Next Tip to display the next help text.

5.3.7 Displaying information about KUKA.Recovery

Procedure  Select the menu sequence ? > About….

Description The information is required, for example, when requesting help from KUKA
Customer Support.
The following information is displayed:
 Version of the Recovery software
 Version of the basic WinPE software
 Main functionality of the Recovery software

5.3.8 Exiting KUKA.Recovery

Procedure  Select the menu sequence Start > System > Reboot.
The RecoveryUSBStick is deactivated and the robot controller is rebooted.

5.4 Activating a network connection

5.4.1 Configuring network settings online

Description Network settings that are defined on the user interface are only valid for the
current WinPE session. The configuration is not permanently saved.
DHCP is active by default. WinPE issues a new computer name every time the
Recovery software is started. The IP address is automatically allocated by the
DHCP server.
If necessary, a static IP address can be configured. The UNC network path
must always be configured.

Procedure 1. Select the menu sequence Start > Network > Edit ini file > NetCon.ini.
2. Enter the network path in the file NetCon.INI and save it.
(>>> "NetCon.INI" Page 14)
3. Select the menu sequence Start > Network > Edit ini file > SetIPAd-
dress.ini.
4. Enter the IP address, subnet mask and gateway (optional) in the file SetI-
PAddress.INI and save them.
(>>> "SetIPAddress.INI" Page 14)

5.4.2 Activating the IP address

Description The static IP address, i.e. the IP address on the RecoveryUSBStick or config-
ured for the current WinPE session can be activated.

Procedure  Select the menu sequence Start > Network > Set IP address and the de-
sired menu item.
 Static IP: Activates the static IP address
 DHCP: Activates DHCP

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5.4.3 Disabling and enabling the firewall

The firewall is enabled by default and can be disabled.

Procedure  Select the menu sequence Start > Network > Firewall and the desired
menu item.
 Enable: Enables the firewall
 Disable: Disables the firewall

5.5 Creating and archiving a hard drive image

Overview Various destinations are available for archiving the hard drive images of the
robot controller.
 RecoveryUSBStick
 Local drive
 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: Custom
 The images for partitions C:\ and D:\ are differentiated by the suffixes C
and D in the name:
 CustomC.WIM
 CustomD.WIM

5.5.1 Archiving a hard drive image on the RecoveryUSBStick

Procedure Recommended procedure:

1. Select the menu sequence Start > Image hard drive disk > Create.
2. Select the Browse… button.
The HDD Creation window is opened. By default, the Image folder on the
RecoveryUSBStick is selected as the target directory.
3. Click on Next and enter a name for the hard drive image. Click OK to con-
firm.
Separate images are created for partition C:\ and partition D:\ and saved
in the Image folder.
4. A message indicates completion of the archiving process or the occur-
rence of an error.
 Click on Yes to open the LOG file for archiving.
 Click on No to terminate archiving.
Alternative procedure:
1. Select the menu sequence Start > Image hard drive disk > Create.
2. Select the BootStick button.
3. Enter a name for the hard drive image and confirm with OK.
Separate images are created for partition C:\ and partition D:\ and saved
in the Image folder on the RecoveryUSBStick.

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 5 Operation

4. A message indicates completion of the archiving process or the occur-

rence of an error.
 Click on Yes to open the LOG file for archiving.
 Click on No to terminate archiving.

Description

Fig. 5-4: Archiving on RecoveryUSBStick

5.5.2 Archiving a hard drive image on a network drive

Precondition  Network connection is activated.

Procedure 1. Select the menu sequence Start > Image hard drive disk > Create.
2. Select the Browse… button.
The HDD Creation window is opened.
3. Click on the Network check box.
4. Enter the access data in the Network Login window to connect to the net-
work drive:
 Domain (if present)
 User name
 Password
Click OK to confirm.
5. Select the network drive and if necessary navigate to the folder in which
the hard drive image is to be saved.
6. Click on Next and enter a name for the hard drive image. Click OK to con-
firm.
Separate images are created and saved for partition C:\ and partition D:\.
7. A message indicates completion of the archiving process or the occur-
rence of an error.
 Click on Yes to open the LOG file for archiving.
 Click on No to terminate archiving.

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Description

Fig. 5-5: Archiving to network drive

5.5.3 Archiving a hard drive image on a hidden partition

Procedure 1. Select the menu sequence Start > Image hard drive disk > Create.
2. Select the Browse… button.
The HDD Creation window is opened.
3. Select the KUKA_RECOVERY drive.
4. Click on Next and enter a name for the hard drive image. Click OK to con-
firm.
Separate images are created and saved for partition C:\ and partition D:\.
5. A message indicates completion of the archiving process or the occur-
rence of an error.
 Click on Yes to open the LOG file for archiving.
 Click on No to terminate archiving.

Description

Fig. 5-6: Archiving on hidden partition

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 5 Operation

5.6 Restoring a hard drive image

5.6.1 Modifying partition sizes online

Description The partition sizes can be modified online using the text editor. Partition sizes
that are changed online are only valid for the current WinPE session. The con-
figuration is not permanently saved.

Procedure 1. Select the menu sequence Start > Utilities > Notepad.
2. Select File > Open in the menu of the text editor and navigate to the file
Controller.INI.
The file is located in the directory Boot (X:)\Windows\System32\mode.
3. Open the file Controller.INI, change and save the partition sizes.
(>>> "Controller.INI" Page 13)

5.6.2 Restoring a hard drive image from the RecoveryUSBStick

Procedure 1. Select the menu sequence Start > Image hard drive disk > Restore.
The HDD Restoration window is opened. By default, the Image folder on
the RecoveryUSBStick is selected as the directory.
2. Select the image C.WIM for partition C:\ or the image D.WIM for parti-
tion D:\. Click on Next.

Only one WIM file can be selected, e.g. Custom15C.WIM for parti-
tion C:\. Both partitions are automatically restored if a complementary
WIM file with the same name has been saved, e.g. Custom15D.WIM
for partition D:\.

3. A message indicates completion of the restoration process or the occur-

rence of an error.
 Click on Yes to open the LOG file for restoration.
 Click on No to terminate restoration.

Description As can be seen in the screenshot, only an image of partition C:\ has been
saved on the RecoveryUSBStick. The complementary image of partition D:\
has not been created. Only partition C:\ will therefore be restored.

Fig. 5-7: Restoration from RecoveryUSBStick

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 KUKA.RecoveryUSB 1.0

5.6.3 Restoring a hard drive image from a network drive

Precondition  Network connection is activated.

Procedure 1. Select the menu sequence Start > Image hard drive disk > Restore.
The HDD Restoration window is opened.
2. Click on the Network check box.
3. Enter the access data in the Network Login window to connect to the net-
work drive:
 Domain (if present)
 User name
 Password
Click OK to confirm.
4. Select the network drive and if necessary navigate to the folder with the
hard drive image.
5. Select the image C.WIM for partition C:\ or the image D.WIM for parti-
tion D:\. Click on Next.

Only one WIM file can be selected, e.g. Custom15C.WIM for parti-
tion C:\. Both partitions are automatically restored if a complementary
WIM file with the same name has been saved, e.g. Custom15D.WIM
for partition D:\.

6. A message indicates completion of the restoration process or the occur-

rence of an error.
 Click on Yes to open the LOG file for restoration.
 Click on No to terminate restoration.

Description

Fig. 5-8: Restoration from network drive

5.6.4 Restoring a hard drive image from a hidden partition

Procedure 1. Select the menu sequence Start > Image hard drive disk > Restore.
The HDD Restoration window is opened.
2. Select the KUKA_RECOVERY drive.
3. Select the image C.WIM for partition C:\ or the image D.WIM for parti-
tion D:\. Click on Next.

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Only one WIM file can be selected, e.g. Custom15C.WIM for parti-
tion C:\. Both partitions are automatically restored if a complementary
WIM file with the same name has been saved, e.g. Custom15D.WIM
for partition D:\.

4. A message indicates completion of the restoration process or the occur-

rence of an error.
 Click on Yes to open the LOG file for restoration.
 Click on No to terminate restoration.

Description

Fig. 5-9: Restoration from hidden partition

5.7 Safely removing USB devices

Procedure 1. Select the menu sequence Start > USB flash drive > Eject.
All connected USB devices are displayed in the UFD list.
2. In the list, select the USB device that is to be removed. Activate the check
box with the corresponding drive letter.
3. Click on the Remove button.
The connections to all selected USB devices are terminated and deener-
gized. If several USB sticks are plugged into a hub and the connection to
all sticks is terminated, the hub is also deenergized.
4. Once the selected USB devices are no longer displayed in the list, the pro-
cess has been completed. Remove the selected USB devices.

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Description

Fig. 5-10: Safely removing USB devices

1 UFD list 2 Remove button

5.8 Executing silent mode

Description A hard drive image is created or restored in silent mode if configured in Con-
troller.INI (Mode parameter).
(>>> 4.4 "Configuring silent mode" Page 16)
The target directory and name of hard drive images created in silent mode are
predefined.
 Target directory: RecoveryUSBStick\Image
 Image name for partition C:\ and D:\: ImageC.WIM and ImageD.WIM

If the RecoveryUSBStick is used more than once to create hard drive

images in silent mode, the most recently saved image is overwritten.

Precondition  Silent mode is configured.

Procedure 1. Connect the RecoveryUSBStick.

2. Boot the robot controller.
The hard drive image is automatically created or restored.

In the case of a KR C4, the progress of the started process can be

monitored by means of the LEDs on the Controller System Panel.
(>>> 5.8.1 "Controller System Panel" Page 29)
(>>> 5.8.2 "Silent mode process sequence with KR C4" Page 29)

3. Once the hard drive image has been completely created or restored, re-
move the RecoveryUSBStick.
The robot controller is automatically restarted.

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 5 Operation

5.8.1 Controller System Panel

Description The Controller System Panel (CSP) is a display element for the operating state
and has the following connections:
 USB1
 USB2
 KLI from the Cu switch

Overview

Fig. 5-11: Arrangement of LEDs and connectors on CSP

Item Component Color Meaning

1 LED 1 Green Operating LED
2 LED 2 White Sleep LED
3 LED 3 White Automatic LED
4 USB 1 - -
5 USB 2 - -
6 RJ45 - KLI
7 LED 6 Red Error LED 3
8 LED 5 Red Error LED 2
9 LED 4 Red Error LED 1

5.8.2 Silent mode process sequence with KR C4

Description The process sequence for the restoration of a hard drive image of the KR C4
in silent mode is described here.
1. Start WinPE
2. Run start file
a. Search for RecoveryUSBStick
b. Connection to power management board (controls the LEDs on the
CSP)
c. Creation of 1st partition
d. Operating LED flashes (= LED1 on CSP)
e. Creation of 2nd partition
f. Creation of 3rd partition
g. Creation of boot sector on 1st partition
h. Sleep LED lights up (= LED2 on CSP)
i. Installation of image of partition C

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 KUKA.RecoveryUSB 1.0

j. Installation of image of partition D

k. Automatic LED lights up (= LED3 on CSP)
l. Copying of ImageC.WIM and ImageD.WIM to 3rd partition
m. Hiding of 3rd partition
n. LEDs on CSP light up briefly (6 LEDs including error LEDs)
o. Automatic ejection of the RecoveryUSBStick
3. Terminate WinPE
4. Reboot robot controller

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 6 KUKA Service

6 KUKA Service

6.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

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

 Model and serial number of the robot
 Model and serial number of the controller
 Model and serial number of the linear unit (if applicable)
 Version of the KUKA System Software
 Optional software or modifications
 Archive of the software
 Application used
 Any external axes used
 Description of the problem, duration and frequency of the fault

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
[email protected]

Australia Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
[email protected]
www.headland.com.au

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 KUKA.RecoveryUSB 1.0

Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
[email protected]

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Automation Equipment (Shanghai) Co., Ltd.

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1808
Fax +86 21 6787-1805
[email protected]
www.kuka.cn

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
[email protected]
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
[email protected]
www.kuka.fr

India KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
Indien
Tel. +91 124 4148574
[email protected]
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
[email protected]
www.kuka.it

Japan KUKA Robotics Japan K.K.

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
[email protected]

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
[email protected]

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 KUKA.RecoveryUSB 1.0

Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
[email protected]

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

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]

Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
[email protected]

Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
[email protected]
www.kuka-roboter.at

Poland KUKA Roboter Austria GmbH

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
[email protected]

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 6 KUKA Service

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
[email protected]

Russia OOO KUKA Robotics Rus

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
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
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

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
[email protected]
www.kuka-e.com

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 KUKA.RecoveryUSB 1.0

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
[email protected]
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
[email protected]
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
[email protected]

Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

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 6 KUKA Service

USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036
Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
[email protected]
www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
[email protected]

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 Index

Index
A KUKA.Recovery, starting (KR C2) 17
About… (menu item) 21 KUKA.Recovery, starting (KR C4) 17
Archiving, overview 22
L
B Language, changing 18
BIOS 13 Licenses 13

C M
Client (menu item) 20 Master image, hidden partition 13, 16
Configuration 13 Multicast 6
Controller System Panel 29
Controller.INI 13, 16, 25 N
Create (menu item) 22, 23, 24 NetCon.INI 14, 21
CSP 6, 29 Network settings, configuring 14, 21
CSP overview 29 Network, activating a connection 21

D O
DHCP 6, 21 Online help 21
Display resolution (menu item) 19 Operating system 13
Documentation, industrial robot 5 Operation 17
Overview, graphical user interface 18
E Overview, KUKA.RecoveryUSB 9
Edit ini file (menu item) 21
Ethernet, KR C4 interfaces 15 P
Partition, hidden 13, 16, 22
F Partitions, modifying size 13, 25
Firewall 22 Product description 9
Firewall (menu item) 22
Functions 9 R
RAM 13
G Reboot (menu item) 21
Graphics card 6, 17 Refresh System Info (menu item) 19
GUI 6 Remote desktop, establishing a connection 19
GUI mode 6, 16 Restore (menu item) 25, 26

H S
Hard drive image, creating 22 Safety 11
Hard drive image, restoring 25 Safety instructions 5
Hard drive space 13 Screen resolution, changing 19
Hardware 13 Service, KUKA Roboter 31
Help 21 Set IP address (menu item) 21
SetIPAddress.INI 14, 21
I Silent mode 6, 16, 29
Introduction 5 Silent mode, configuring 16
IP address, activating 21 Silent mode, executing 28
IpAddress.RTF 14 Software 13
IPv4 6 Support request 31
ISO image 6 System information, refreshing 19
System requirements 13
K
KCB 6 T
KLI 6, 15 Target group 5
Knowledge, required 5 Terms used 6
KPC 6 Terms, used 6
KSB 6 Tips and Tricks (menu item) 21
KUKA Customer Support 21, 31 Trademarks 6
KUKA.Recovery, exiting 21 Training 5
KUKA.Recovery, information about 21

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 KUKA.RecoveryUSB 1.0

U
UFD 6
UNC 6
USB devices, safely removing 27
Utilities (menu item) 20
Utilities, calling 20

V
Version, KUKA.Recovery 21
Version, WinPE 21
VGA 6
VxWorks 6

W
Warnings 5
WIM 6
WinPE 6

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