I am trying to use the Clean Disk function in RobotStudio’s Installation Manager (RW6) to completely reset a 2GB internal SD card from an IRC5 Compact controller. (due to a failed upgrade and stuck in disk full and cannot create nor delete any of the systems etc.)
I am following the standard recovery disk procedure, but after I click “Write Disk” and select “No” for the product defect report, I never get the prompt to insert the SD card.
Instead, I get the message: “One or more products were not found. Please browse for product directory!” (what file is it looking for?`).
I have the RobotWare files saved locally on my PC and navigated to the folder containing RobotWare_RPK_6.16.3007 in the browser panel, but not sure if this is right file to select or if it should be a ‘boot’ file etc.
Which exact folder, package, or file type do I need to select in this window so RobotStudio can find the necessary files, and ‘clean’ the SD card?
I managed to resolve this issue with some help. In RobotStudio 2024/2026, the directory structure for RobotWare distribution packages has changed, causing the tool to fail to auto-locate the paths.
How to fix it:
Open the Robot Recovery Disk Creator and look at the upper panel.
Select the BootServer line item and completely remove the default path that is currently filled in.
Keeping the BootServer line highlighted, use the lower file browser panel to manually navigate to the new DistributionPackages2 directory path: C:\Users\....\AppData\Local\ABB\DistributionPackages2\ABB.RobotWare-6.xx.xxxx\RobotPackages\RobotWare_RPK_6.xx.xxxx
Once you target this specific RobotWare_RPK folder, the tool will recognize it, unlock the button, and allow you to successfully run the “Clean Disk” procedure.
Now that the SD card has been successfully cleaned, I want to make sure I follow the exact required procedure for reinstallation and avoid skipping any critical steps.
Are the following steps correct to get the system back up and running?
Hardware Reinstallation: Leave the IRC5 controller powered off, insert the “cleaned” SD card back into its original slot in the controller, and then turn the controller power back on.
Connection: Connect my laptop directly to the IRC5 controller cabinet using an Ethernet cable plugged into the Service Port (X2).
System Deployment: Open RobotStudio, navigate to the Controller tab → Installation Manager, select Create New, and choose Create a New System (or create from an existing Virtual Controller layout) to deploy the software back to the robot.
Is it safe to proceed with this sequence, or are there any specific pre-requisites or calibration steps I need to watch out for during this initial boot?
I appreciate any guidance or verification on this process!
Have you already created this system with installation manager? If so, you should just need to download it. Otherwise, with create new, you need the keystrings.
Does that mean I will just need to upload the license file during the ‘create a new system’ process?
UPDATE: I just reinserted the SD card back into the robot controller, physically connected to controller → opened installation manager RW6 → Created a new system → Added my old license file that I found within ‘backinfo’ from an old backup that I had.
It seems to be a fresh system now and have to update the rev counters etc!
