How To Backup And Restore A Fanuc R-30iB

• How To Make An IMG Backup

1. Obtain a thumb drive with plenty of room available:

• A typical IMG is around 64 or 128 MB, depending on your robot model
2. Insert the thumb drive into either the USB port on the controller (UD1:) or the USB
port on the right side of the teach pendant (UT1:)
3. On the TP, press the MENU button then select File -> File
4. On the FILE menu, press F5 [UTIL]. If [UTIL] is not shown above F5, press NEXT until
[UTIL] is shown and then press F5
5. Select Set Device
6. Select either USB Disk (UD1:) or USB on TP (UT1:), depending on where you inserted
your thumb drive
7. Press F5 [UTIL] again and select Make DIR
8. Enter a new directory name that will help you remember which robot you’ve backed
up.
9. Once you have made your new directory, you should be taken there. The directory
listed on the top line should be UT1:\ (or UD1:\) {YOUR-NEW-DIR}\*.*
10. Place the robot in Teach
11. Once in Teach, press F4 [BACKUP]. Hit the right arrow button to go to the second
menu page and select Image backup
12. On the Destination device menu that pops up, select Current Directory
13. You will be prompted to “Cycle power?”. Press F4 OK
14. The robot will restart and the image backup will begin
15. The Fanuc image backup process takes about 4-5 minutes and then the robot will
start back up
 How To Restore An IMG Backup
1. Obtain a thumb drive with a previous IMG backup for the robot you’re working on
2. Insert the thumb drive into either the USB port on the controller (UD1:) or the USB
port on the right side of the teach pendant (UT1:)
3. Restart the robot and load the Boot Monitor:
• Cycle power to the controller
• As soon as the robot starts to power back up, hold F1 and F5 on the teach pendant to enter the Boot
Monitor menu
4. Type 4 and press ENTER to go to the Controller backup/restore menu
5. On the Controller backup/restore menu, type 3 and press ENTER to select Restore
Controller Images
6. Type the appropriate number to select your device (UD1: or UT1:) and press ENTER
7. Type the appropriate number to select the directory in which your IMG backups are
stored, or type 0 for the next listing of directories or -1 for the previous listing of
directories, and press ENTER
8. Once you are in the appropriate directory, type 1 for OK (Current Directory) and press
ENTER
9. The restore process will begin. Once initiated, the Fanuc image restore process takes about
5 minutes
10. You will get a message about “update DCS parameters” choose NO
11. When the restore is complete, you will be prompted with “Press ENTER to return >”. Press
ENTER
12. Type 1 for Configuration menu and press ENTER
13. Once the Configuration menu loads, type 3 for Controlled start and press ENTER
14. Once the teach pendant boots back up, press the MENU button then select File -> File
15. On the FILE menu, press F5 [UTIL]. If [UTIL] is not shown above F5, press NEXT until [UTIL]
is shown and then press F5
16. Select Set Device
17. Select either USB Disk (UD1:) or USB on TP (UT1:), depending on where you inserted your
thumb drive
18. Navigate to the directory in which your MD or All of Above backup is stored. If no files or
directories are shown, you will have to press ENTER on (* * (all files)) to see the thumb
drive’s contents
19. If [RESTOR] is not shown above F4, press FCTN, then select RESTORE/BACKUP to
toggle between restore and backup
20. Press F4 [RESTOR]
21. Select the type of restore action that you want:
• Choose “All of above”
22. You will be prompted with “Restore from UT1: (or UD1:\) (OVERWRT)?”. Press F4 YES
23. The TP will show “Accessing device. PREV to exit.” for about 30-60 seconds, then the
restore will commence. Once it begins, typical restore time is ~2-6 minutes,
depending on the contents of your robot
24. As many files as possible will be restored. Once the restore is complete, you will need
to perform a Cold Start:
• Press FCTN
• Select START (COLD)
25. You should get warning "SYST-212 Need to apply DCS parameter“
26. Press Menu -> Next -> System -> DCS
27. Scroll down to Mastering parameter: CHGD
28. Click Apply (F2) -> Enter Code 1111 (Should show Mastering parameter: PEND)
29. Cycle Power
 Pulse Mismatch Recovery procedure
* This should only be used, if the robot has not been recalibrated since you
Image was taken.

1. Press MENU -> 0 “NEXT PAGE” -> 6 “SYSTEM”

2. Press F1 Type -> “MASTER CALL” , If Master Cal option is not there, see instructions
below:
1. Press MENU -> 0 “NEXT PAGE” -> 6 “SYSTEM” -> “VARIABLES”
2. Change $MASTER_ENB = 0 to 1
3. Press ENTER
4. Type F1 (MASTER CAL should now be there)
3. Press F3 RES_PCA
4. Answer yes F4
5. Cycle power on the Robot
6. Type MENU -> 0 “NEXT PAGE” -> 6 “SYSTEM” -> “VARIABLES”
7. $DMR_GROUP, press enter twice
8. First variable should say “Master done = False”. Change it to true.
9. Repeat step 8 for all the external axis in the robot (if they are available)
10. Press F1 “type”-> “Master Call”
11. Select option 6 “Calibrate” -> answer YES (message should say Robot Calibrated)
12. Repeat step 11 for all the external axis in the robot (if they are available)
13. If a message pops up “"MOTN-049 Attempt to move without Calibrated“ ->Recalibrate
14. Repeat step 13 for all the external axis in the robot (if they are available)
15. Run the Zero Master Position routine to double check the robot zero marks position.
16. Run any routine to check (in some rare cases points needs to be re-teach).
 THICKNESS CHECK ROUTINE
This routine is setup to check the thickness in any weld Spot position during production.
• The routine is called R1_THCK it has been declared as a macro routine.
• Inside the routine there’s the following logic:
1: !-------------------------------- ;
2: ! Thickness check ;
3: !-------------------------------- ;
4: ! Preset thickness ;
5: R[5:Specified thick]=$SGSCH1[1].$THICKNESS ;
6: ;
7: R[6:Observed thicns]=$SGTHKRPT1.$THK_OBSV ;
8: ;
9: IF ((R[6:Observed thicns])<=(R[5:Specified thick]-.5)),CALL DO_R1_THCK ;
10: ;

• The thickness value set by design is stored in the variable $SGSCH1[1].$THICKNESS this
value is recorded in the register 5 available in this robot (check availability of registers before
loading this macro in another robot)
• The thickness value observed by the robot during production is stored in the variable
$SGTHKRPT1.$THK_OBSV, this value is recorded in the register 6 available in this robot
(check availability of registers before loading this macro in another robot)
• The IF statement compares the value observed and value set by design, if the observe
thickness is 0.5 less than the set by design it will call a macro called CALL DO_R1_THCK
• The macro CALL DO_R1_THCK is used to communicate with PLC:
1: !-------------------------------- ;
2: ! Thickness check ;
3: !-------------------------------- ;
4: ! Set DO to PLC ;
5: DO[166:Thickness failed]=ON ;
6: WAIT DI[166:Thickness failed]=ON ;
7: ;
8: ! Set DO to PLC ;
9: DO[166:Thickness failed]=OFF ;
10: ;

• If the thickness check failed it will send a Digital Output to the PLC DO:166 (check
availability of digital outputs before loading this macro in another robot)
• It will wait until a Digital input is received by the PLC
• The routine R1_THCK must to be placed after the SPOT instruction in the weld
routine:
175:L P[41] 3000mm/sec CNT100 ;
176: ;
177: ! GM WeldNr: f02_509a806 ;
178: CALL R1_WELD_PRE(5091806,51,1.9,2200) ;
179:L P[42] 1000mm/sec CNT100
: SPOT[SD=1,P=1,S=1,ED=1] ;
180: CALL R1_THCK ; -------------------------------- THICKNESS MACRO
181: CALL R1_WELD_END ;
182: ;
183:L P[43] 3000mm/sec CNT100 ;