Service Manual UR10 En 3.1.3

Service Manual

Revision UR10_en_3.1.3

"Original instructions"

Robot:

UR10 with CB3.0/3.1-controller

CB3.0 valid from robot s/n 2014300001 to 2016301178

CB3.1 valid from robot s/n 2016301179

 
 
 
All rights reserved  2  Servicemanual_UR10_en_3.1.3 
 
 
Contents 
 General information ................................................................................................................................ 4 
1 Purpose.............................................................................................................................................. 4 
2 Company details ................................................................................................................................ 5 
3 Disclaimer .......................................................................................................................................... 5 
Preventive Maintenance ................................................................................................................................ 6 
1 Controller .......................................................................................................................................... 6 
1.1 Inspection plan, Safety Functions ........................................................................................ 6 
1.2 Visual inspection .................................................................................................................. 8 
1.3 Cleaning and replacement of filters ..................................................................................... 8 
2 Robot arm .......................................................................................................................................... 9 
2.1 Visual inspection .................................................................................................................. 9 
Service and Replacement of parts ............................................................................................................... 10 
1 Robot arm ........................................................................................................................................ 10 
1.1 Before returning any part to Universal Robots .................................................................. 10 
1.2  Robot arm configuration ................................................................................................... 11 
1.3 Brake release ...................................................................................................................... 12 
1.4 General guidance to separate joint from counterpart ...................................................... 13 
1.5 Torque values ..................................................................................................................... 17 
1.6 Base joint – Base mounting bracket .................................................................................. 18 
1.7 Shoulder joint – Base joint ................................................................................................. 20 
1.8 Upper arm – Shoulder joint ............................................................................................... 22 
1.9 Elbow joint – Upper arm .................................................................................................... 24 
1.11 Wrist 1 joint – Lower arm ................................................................................................ 26 
1.12 Wrist 2 joint – Wrist 1 joint .............................................................................................. 28 
1.13 Wrist 3 joint – Wrist 2 joint .............................................................................................. 30 
1.14 Tool flange – Wrist 3 joint ................................................................................................ 30 
1.15 Instructions for calibrating a joint .................................................................................... 32 
1.16 Dual Robot calibration ..................................................................................................... 40 
1.17 Change joint ID ................................................................................................................. 41 
1.18 Joint spare part adaptation .............................................................................................. 42 
2 Controller ........................................................................................................................................ 44 

 
 
 
All rights reserved  3  Servicemanual_UR10_en_3.1.3 
 
2.1 Handling ESD-sensitive parts ............................................................................................. 44 
2.2 Replacement of motherboard 3.0 ..................................................................................... 48 
2.3 Replacement of motherboard 3.1 ..................................................................................... 51 
2.4 Replacement of Safety Control Board ............................................................................... 54 
2.5 Replacement of teach pendant.......................................................................................... 57 
2.6 Replacement of 48V power supply .................................................................................... 59 
2.7 Replacement of 12V power supply .................................................................................... 62 
2.8 Replacement of current distributor ................................................................................... 63 
Software ...................................................................................................................................................... 64 
1 Update software .............................................................................................................................. 64 
2 Update joint firmware ..................................................................................................................... 66 
3 Using Magic files .............................................................................................................................. 69 
Troubleshooting .......................................................................................................................................... 70 
1 Error codes ...................................................................................................................................... 70 
2 LED indicators and Fuses on Safety Control Board ......................................................................... 92 
3 Error phenomena ............................................................................................................................ 94 
3.1 ControlBox: NO CONTROLLER displayed in Initializing ...................................................... 94 
3.2 NO CABLE displayed during power up ............................................................................... 95 
3.3 Protective stop ................................................................................................................... 96 
3.4 Power on failure in Initializing ........................................................................................... 97 
3.5 Checklist after a collision ................................................................................................. 100 
4 Electrical documentation .............................................................................................................. 101 
4.1 Schematic overview ......................................................................................................... 101 
4.2 E-Plan diagrams ................................................................................................................ 107 
 Spare parts ................................................................................................................................................ 120 
1 Spare part list ................................................................................................................................ 120 
2 Service kit ...................................................................................................................................... 121 
Packing of robot ......................................................................................................................................... 122 
Change log ................................................................................................................................................. 123 
 
 
   

1. General information

1.1 Purpose

The main purpose of this manual is to help the user safely perform service related operations and

troubleshooting.

Universal Robots industrial robots are designed using high quality components designed for long lifetime.

However any improper use of robot can potentially cause failures. For example, the robot may have been

overloaded or have been dropped on the floor when relocating or have run with a load not recommended

by Universal Robots. Any improper use of the robot will invalidate the guarantee.

Universal Robots recommends that you do not attempt repair, adjustment or other intervention in the

mechanical or electrical systems of the robot unless a problem has arisen. Any unauthorized intervention

will invalidate the guarantee. Service related operations and troubleshooting should only be performed by

qualified personnel.

Before performing service related operations, always make sure to stop the robot program and disconnect

power supply to any potential dangerous tool on the robot or in the work cell.

In the event of a defect, Universal Robots recommends ordering new parts from the Universal

Robot distributor from where the robot has been purchased.

Alternatively, you can order parts from your nearest distributor, whose details you can obtain from

Universal Robots official website at www.universal-robots.com

1.2 Company details

Universal Robots A/S

Energivej 25

DK-5260 Odense Denmark

Tel.: +45 89 93 89 89

Fax +45 38 79 89 89

1.3 Disclaimer

The information contained herein is the property of Universal Robots A/S and shall not be reproduced in

whole or in part without prior written approval of Universal Robots A/S. The information herein is subject

to change without notice and should not be construed as a commitment by Universal Robots A/S. This

Manual is periodically reviewed and revised.

Universal Robots A/S assumes no responsibility for any errors or omissions in this document.

The Universal Robots logo is a registered trademark of Universal Robots A/S.

2 Preventive Maintenance

2.1 Controller

2.1.1 Inspection plan, Safety Functions

The safety functions of the robots must be tested at least once a year to ensure correct function. The

following tests must be performed.

 Test that the Emergency Stop button on the Teach Pendant functions:

o Press the Emergency Stop button on the Teach Pendant

o Observe that the robot stops and turns off the power to the joints

o Power on robot again

 Test Free drive mode:

o Unmount attachment or set TCP/Payload/CoG according to tool specifications

o Set the robot in Free drive mode by pressing the Free drive button on the Teach Pendant

o Move the robot to a position where it is stretched out horizontally

o Monitor that the robot maintains its position when not holding the robot and the Free

drive button still pressed.

 Test Back drive mode:

If robot is close to collision, the BACKDRIVE function can be used to move robot arm to safe

position before initializing.

o Press ON to enable power, state will change to Idle.

o Press and hold Freedrive -> status will change to BACKDRIVE

o Move the robot as done in Freedrive, brakes will be released on the joints where it’s

needed but only as long as the Freedrive button is activated. Robot will be “heavy” to move

around.

o Be sure to test this so that all joints have been tested.

 Verify safety settings:

o Verify that the safety settings of the robot comply with the Risk Assessment of the robot

installation

 Test that additional safety inputs and outputs are still functioning:

o Check which safety inputs and outputs are active and test that they can be triggered.

2.1.2 Visual inspection

 Disconnect power cable from controller

 Check terminals are properly inserted on Safety Control Board

 Check all connections on Motherboard and connection between Safety Control Board and

Motherboard

 Check for any dirt/dust inside of controller, clean with vacuum cleaner if needed

» Use a soft cloth. You can add: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha

2.1.3 Cleaning and replacement of filters

 Controller box contains two filters, one on each side of controller

 Remove filters from controller box and clean them thoroughly using compressed air

o Replace filters if necessary

o Gently remove the outer plastic frame and maintain the filter

2.2 Robot arm

2.2.1 Visual inspection

 If you observe dirt/oil on the robot arm you simply clean it with a soft cloth.

Cleaning agent: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha

In very rare cases the grease is from the inside of the joint. There is still enough grease in the gear

for life time you just clean the joint with a cloth.

 Move robot arm to HOME position (if possible)

 Turn off and disconnect power cable from controller

 Inspect cable between controller and robot arm for any damage

 Inspect flat rings for wear and damage

» Replace flat rings if worn out or damaged

 Inspect blue lids on all joints for any cracks or damage

» Replace blue lids if cracked or damaged.

 Inspect that screws for blue lids are in place and properly tightened

» Replace screws, tighten properly if necessary

Correct torque value for screws on blue lids are 0.4Nm

If any damage is observed on a robot within the warranty period, contact the distributor from which the

robot has been purchased.

3. Service and Replacement of parts

3.1 Robot arm

3.1.1 Before returning any part to Universal Robots

 Remove all external non-UR equipment such as grippers, hoses, cables and so on.

Universal Robots cannot be held responsible for damage caused to non-UR equipment mounted on

the robot.

 Backup all relevant files before sending the robot/part to UR. Universal Robots cannot be held

responsible for loss of programs, data or files stored in the robot.

Safety notice:

If the robot/part has been in contact with, or working in environments, where dangerous chemicals

or materials are present, the robot must be cleaned before shipment.

If this is not possible, the shipment must be accompanied by an MSDA (Material Safety Data Sheet)

in English and instructions for cleaning the chemicals.

The amount of labor hours needed for cleaning will be billed at the standard rate.

If UR finds the robot/part unsafe to service, UR reserve the right to get the robot/part cleaned or

decline the case and send the part back, at customer’s expense.

Note: Please note that the robot will be updated to newest software/firmware when repaired. New parts

will also be updated to newest version (hardware/software). Therefore, updating PolyScope may be

necessary when new parts are mounted.

3.1.2 Robot arm configuration

3.1.8 Upper arm – Shoulder joint

3.1.7 Shoulder joint – Base joint

3.1.6 Base joint – Base mounting bracket

3.1.9 Elbow joint – Upper arm

Error! Reference source not found.

3.1.14 Tool flange – Wrist 3 joint

3.1.13 Wrist 3 joint – Wrist 2 joint

3.1.12 Wrist 2 joint – Wrist 1 joint

3.1.11 Wrist 1 joint – Lower arm

3.1.3 Brake release

If required, the brake on a joint can be released without power connected.

IMPORTANT NOTICE:

 Before releasing a brake, it is extremely important to dismount any dangerous parts to avoid any

hazardous situations.

 If releasing the brake on Base joint, Shoulder joint or Elbow joint, it is important to make proper

mechanical support prior to releasing the brake.

 Always make sure personnel are in no risk when releasing the brake.

 Do not move the joint more than necessary.

No more than about 160 degrees in order for the robot to find its original physical position.

Procedure for releasing the joint

1. Shut down Controller.

2. Remove blue lid on joint.

3. Push brake pin down to release, joint can then be rotated.

Brake on Base and Shoulder joints, Brake on Elbow joint, Brake on Wrist joints

4. Make sure to mount blue lid properly on joint before turning on Controller.

5. Correct torque value for screws on blue lids are 0.4Nm

3.1.4 General guidance to separate joint from counterpart

Disassemble:

1. Check if the necessary tools and documentation are available before starting a repair.

a. Service kit with torque tools, ESD Wristband, etc.

b. Thoroughly read and understand this guide.

2. Move the robot to a comfortable position for disassembly or if necessary dismount entire robot

arm from work cell and place on a solid surface.

3. Shut down the controller.

4. Remove blue lid.

5. Reattach one of the screws from the blue lids, in order to connect an alligator Clip on the ESD

wristband as shown below.

6. Gently unplug the cable connectors without bending the printed circuit board.

The power supply connector for the size 1 has a lock that has to be engaged before it is pulled out

of the printed circuit board.

7. Disconnect wires

8. Remove alignment screw.

9. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the

joint housing.

10. Slide the grey Teflon ring back.

10 screws become visible, 5 on each side of joint.

Loosen the screws with an open-ended spanner approximately two full turns each.

11. Pull the two parts apart and gently twist them in opposite directions around 10 mm, until a

mechanical stop is met (holes are keyhole-type). They can then be completely separated.

Assemble:

1. After replacing a joint etc. do as follows to assemble the robot arm.

2. Gently insert one part with screws and washers into the other part.

3. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

4. Gently tighten the 10 screws, tighten in cross order with the correct torque. When shorter bolts are

used (marked with red) drawing on the right shows where they are mounted.

See 3.1.5 Torque values

Tighten in numeric order.

5. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring.

6. Mount the alignment screw and tighten with 0.4Nm.

7. Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

8. Mount the blue lid on the joint and tighten with 0.4Nm.

9. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.5 Torque values

UR10 torque values

CONNECTION

TORQUE

HEAD SIZE

Base mounting bracket

J0 BASE

8.0Nm

10 mm.

[J0] Base

[J1] Shoulder

8.0Nm

10 mm.

[J1] Shoulder

Upper arm

8.0Nm

10 mm.

Upper arm

[J2] Elbow

2.6-3.0Nm

7 mm.

[J2] Elbow

Elbow counter part

2.6-3.0Nm

7 mm.

Elbow counter part

Lower arm

2.6-3.0Nm

7 mm.

Lower arm

[J3] Wrist 1

1.3Nm

5.5 mm.

[J3] Wrist 1

[J4] Wrist 2

1.3Nm

5.5 mm.

[J4] Wrist 2

[J5] Wrist 3

1.3Nm

5.5 mm.

[J5] Wrist 3

Tool mounting bracket

1.3Nm

5.5 mm.

Alignment screw

0.4Nm

Torx T10

Blue lid

0.4Nm

Torx T10

Attention: Click the torque tools 3 times before used to get the correct calibrated torque.

8.0Nm

2.6-3.0Nm

1.3Nm

2.6-3.0Nm

3.1.6 Base joint – Base mounting bracket

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Shut down the controller.

2. Remove alignment screw.

3. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint

housing.

4. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws

with a 7 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.

5. Pull the base mounting bracket and Base joint apart and gently twist the two parts in opposite

directions around 10 mm. until a mechanical stop is met (holes are keyhole-type).

6. Pull away the base mounting bracket from Base joint.

7. Disconnect wires between base mounting bracket and Base joint.

2 x red wire = 48V DC

2 x black wire = GND

Black connector = bus cable

Base joint – Base mounting bracket: Assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Replace base mounting bracket and reconnect wires according to illustration:

2. Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

3. Gently insert base mounting bracket with screws and washers into the Base joint.

4. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

5. Gently tighten the 10 screws, and then tighten in cross order with 8.0Nm.

6. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring.

7. Mount the alignment screw and tighten with 0.4Nm.

8. Mount blue lid on Base joint and tighten with 0.4Nm.

9. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.7 Shoulder joint – Base joint

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Shut down the controller.

2. Remove blue lid on Base joint.

3. Connect ESD wristband

4. Disconnect wires between Base joint and Shoulder joint

2 x red wire = 48V DC

2 x black wire = GND

Black connector = bus cable (NB: polarized)

5. Remove alignment screw

6. Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or similar tool

and twist it around the joint housing.

7. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws

with a 7 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.

8. Pull the Base joint and Shoulder joint apart and gently twist the two parts in opposite directions around

10 mm. until a mechanical stop is met (holes are keyhole-type).

9. Pull away the Base joint from Shoulder joint.

Shoulder joint – Base joint: Assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Gently insert Base joint with screws and washers into the Shoulder joint.

2. Make sure the washers are fully inserted and located on the correct side (this is important) before

gently twisting the Base joint and Shoulder joint in opposite directions until a mechanical stop is met.

3. Tighten the 10 screws lightly, and then tighten in cross order with 8.0Nm.

4. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

5. Mount the alignment screw and tighten with 0.4Nm.

6. Reconnect connectors as illustrated.

7. Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

8. Mount blue lid on Base joint and tighten with 0.4Nm.

10. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.8 Upper arm – Shoulder joint

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Shut down the controller.

2. Remove blue lid on Shoulder joint.

3. Connect ESD wristband

4. Disconnect wires between Upper arm and Shoulder joint

1 x red wire = 48V DC

1 x black wire = GND

Black connector = bus cable (NB: polarized)

5. Remove alignment screw.

6. Gently remove black flexible gasket between Upper arm and Shoulder with a tiny screwdriver or similar

tool and twist it around the upper arm.

7. 10 screws become visible, 5 on each side of joint.

Untighten gently the screw with a 10 mm. open-ended spanner about two full rounds, approximately 3

mm. for each screw.

8. Pull the Shoulder joint and upper arm apart and gently twist the two parts in opposite directions

around 10 mm. until a mechanical stop is met (holes are keyhole-type).

9. Pull away the Shoulder joint from upper arm.

Upper arm – Shoulder joint: Assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Gently insert Shoulder joint with screws and washers into the upper arm.

2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

3. Tighten the 10 screws lightly, and then tighten in cross order with 8.0Nm.

4. Gently put back the gasket.

5. Mount the alignment screw and tighten with 0.4Nm.

6. Connect ESD wristband

7. Reconnect wires correctly.

Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

8. Mount blue lid on Shoulder joint and tighten with 0.4Nm.

11. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.9 Elbow joint – Upper arm

Disassemble and assemble

Procedure for separating Elbow joint from Upper arm is similar to separation of Upper arm and Shoulder

joint, consult chapter 3.1.8 Upper arm – Shoulder joint

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Shut down the controller.

2. Remove blue lid on Elbow counterpart.

3. Disconnect wires between Elbow joint and Elbow counterpart

1 x red wire = 48V DC

1 x black wire = GND

Black connector = bus cable (NB: polarized)

4. Remove alignment screw.

5. Gently remove black flexible flat ring between Elbow and Elbow counterpart with a tiny screwdriver or

similar tool and twist it around the joint housing.

6. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws

with a 7 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.

7. Pull Elbow joint and Elbow counterpart apart and gently twist the two parts in opposite directions

around 10 mm. until a mechanical stop is met (holes are keyhole-type).

8. Pull away the Elbow joint from Elbow counterpart.

Elbow counterpart – Elbow joint: assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Gently insert Elbow joint with screws and washers into the Elbow counterpart.

2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

3. Tighten the 10 screws lightly, and then tighten in cross order with 2.6-3.0Nm.

4. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

5. Mount the alignment screw and tighten with 0.4Nm.

6. Reconnect connectors as illustrated.

7. Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

8. Mount blue lid on Elbow joint and tighten with 0.4Nm.

9. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.11 Wrist 1 joint – Lower arm

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart Shut down

the controller.

1. Remove blue lid on Wrist 1 joint.

2. Connect ESD wristband

3. Disconnect wires between lower arm and Wrist 1 joint.

1 x red wire = 48V DC

1 x black wire = GND

Black connector = bus cable (NB: polarized)

4. Remove alignment screw.

5. Gently remove black flexible gasket between lower arm and Wrist 1 joint with a tiny screwdriver or

similar tool and twist it around the lower arm.

6. 10 screws become visible, 5 on each side of joint. Loosen the screws with a 5.5 mm. open-ended

spanner about two full turns, approximately 3 mm. for each screw.

7. Pull the lower arm and Wrist 1 joint apart and gently twist the two parts in opposite directions around

8 mm. until a mechanical stop is met (holes are keyhole-type).

8. Pull away the lower arm from Wrist 1 joint.

Wrist 1 joint – Lower arm: Assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Gently insert Wrist 1 joint with screws and washers into the lower arm.

2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

3. Tighten the 10 screws lightly, and then tighten in cross order with 1.3Nm.

4. Gently put back the gasket.

5. Mount the alignment screw and tighten with 0.4Nm.

6. Connect ESD wristband

7. Reconnect wires between lower arm and Wrist 1 joint correctly.

8. Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

9. Mount blue lid on Wrist 1 joint and tighten 2 pc M3x6 and 1 pc M3x10 with 0.4Nm.

10. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.12 Wrist 2 joint – Wrist 1 joint

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart Shut down

the controller.

1. Remove blue lid on Wrist 1 joint.

2. Connect ESD wristband

3. Disconnect wires between Wrist 1 joint and Wrist 2 joint

1 x red wire = 48V DC

1 x black wire = GND

Black connector = bus cable (NB: polarized)

4. Remove alignment screw.

5. Gently remove black flexible flat ring between Wrist 1 and Wrist 2 with a tiny screwdriver or similar tool

and twist it around the joint housing.

6. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws

with a 5.5 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.

7. Pull Wrist 1 joint and Wrist 2 joint apart and gently twist the two parts in opposite directions around 8

mm. until a mechanical stop is met (holes are keyhole-type).

8. Pull away Wrist 1 joint from Wrist 2 joint.

Wrist 2 joint – Wrist 1 joint: Assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Gently insert Wrist 1 joint with screws and washers into Wrist 2 joint.

2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

3. Tighten the 10 screws lightly, and then tighten in cross order with 1.3Nm.

4. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

5. Mount the alignment screw and tighten with 0.4Nm.

6. Connect ESD wristband

7. Replace Wrist 1 and reconnect connectors as illustrated into Wrist 2.

8. Twist the communication cable 1.5 to 2 full rounds before it is connected.

(To reduce electrical noise in the system)

9. Mount blue lid on Wrist 1 joint and tighten 2 pc M3x6 and 1 pc M3x10 with 0.4Nm.

10. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.13 Wrist 3 joint – Wrist 2 joint

Disassemble and assemble

Procedure for separating Wrist 3 joint from Wrist 2 is similar to separation of Wrist 2 joint and Wrist 1 joint,

consult chapter 3.1.12 Wrist 2 joint – Wrist 1 joint

3.1.14 Tool flange – Wrist 3 joint

Disassemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Shut down the controller.

2. Remove alignment screw.

3. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint

housing.

4. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws

with a 5.5 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.

5. Pull the tool flange and Wrist 3 joint apart and gently twist the two parts in opposite directions around

8 mm. until a mechanical stop is met (holes are keyhole-type).

6. Pull away the tool flange from Wrist 3 joint.

7. Connect ESD wristband.

8. Disconnect the two connectors.

Tool flange – Wrist 3 joint: Assemble

For details and photos please see: 3.1.4 General guidance to separate joint from counterpart

1. Connect ESD wristband

2. Replace tool flange and reconnect connectors as illustrated.

3. Twist the communication cable 1.5 to 2 full rounds before it is

connected (To reduce electrical noise in the system)

4. Gently insert tool flange with screws and washers into the Wrist 3 joint.

5. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)

before gently twisting the parts in opposite directions until a mechanical stop is met.

6. Tighten the 10 screws lightly, and then tighten in cross order with 1.3Nm.

7. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

8. Mount the alignment screw and tighten with 0.4Nm.

9. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

3.1.15 Instructions for calibrating a joint

After replacement calibration of the new joint is required in order to find the correct zero position.

If it is possible and necessary, perform the 3.1.16 Dual Robot calibration alternative perform a joint

calibration.

Instructions for calibrating a joint:

1. Jog robot to HOME position

Illustration shows the HOME position, which is defined as zero position of all joints.

2. Drag a finger from left to right across the UNIVERSAL-sign on main screen of PolyScope.

3. Enter password lightbot and press OK.

4. You are now in Expert Mode, press Low Level Control.

lightbot

5. Press Turn power on for enabling power to joints.

6. Press Go to Idle for enabling the joints ready mode.

7. Select the desired joint by directly clicking the status line for that joint.

8. Press Arm current joint to release the brake on the selected joint.

Use the Up and Down buttons in the Move window to navigate the joint to the correct zero position

according to the following illustrations.

Press STOP when the joint is in the correct position.

9. Zero position illustrations

Base: Shoulder, Elbow, Wrist 1:

Base zero position is aligned so that the Shoulder, Elbow and Wrist 1 zero output flange is

output flange is offset 180 degrees from vertical aligned (if Base if horizontal).

the cable in back of robot base. Make sure that base of robot is horizontal, use

spirit level to align joints.

Wrist 2: Wrist 3:

Wrist 2 zero position is aligned similar Wrist 3 zero position is aligned so tool connector

to Base joint, with tool flange parallel is pointing upward.

with wrist Mount two bolts in tool holes and use spirit level

to align joint.

10. Select Calibration tab and press Zero current joint position to calibrate the joint.

11. Press Back to exit Low Level Control.

12. Press Return to Normal.

13. Verify zero position by moving the robot to HOME.

If not satisfied with the zero position, perform the procedure once again.

3.1.16 Dual Robot calibration

Dual Robot Calibration kit (Part no: 185500)

Dual Robot Calibration is a calibration that calibrates the robot in the full work space. All robots are Dual

Robot Calibrated when they are produced.

If a joint has been replaced on a calibrated robot the calibration is not correct anymore.

There are 2 options:

- Performing a Dual Robot Calibration after replacement of a joint will let the robot continue in the

production line without modifying waypoints in the robot program. To perform a Dual Robot

Calibration, you need: 2 robots (same size and same generation), calibration Horse and calibration

tool connector.

Go to http://www.universal-robots.com/support/ for downloading CalibrationManual.pdf.

- Joint calibration described in this section: After replacing a joint a zero position of the joint can be

adjusted but the calibration level form the Dual Robot Calibration cannot be achieved. Adjustments

of waypoints in the program should be expected.

3.1.17 Change joint ID

Each joint has a unique ID no. It is NOT possible to have two joints with the same ID no. on the same robot.

ID

Joint

J0

Base

J1

Shoulder

J2

Elbow

J3

Wrist 1

J4

Wrist 2

J5

Wrist 3

Example:

Wrist 1 (J3) has to be replaced. Spare joint is a Wrist 3 (J5)

1. Disconnect the joint with correct ID no.

2. Enter Low Level Control

3. Press Turn power on and the connected joints turn into BOOTLOADER

4. Press Go to Idle and the connected joints turn into READY

5. Select Joint ID

6. Select J5 (The one to be changed)

7. Uncheck “Exchange IDs” box

8. In dropdown box, select ID no. 3

9. Press Set it

10. Confirm Change ID

11. After you have turned power on you can see the joint J5 has changed to J3.

+

3.1.18 Joint spare part adaptation

The UR5 and UR10 are constructed of 4 joint sizes and have to be setup on the robot:

Recommended spare joints for UR5 and UR10 are marked with:

Robot: UR5 UR10

Wrist 3: ID =5 Size 1* Size 2

Alignment screw or new wire bundle

Wrist 2: ID =4 Size 1 Size 2

Wrist 1: ID =3 Size 1 Size 2

Elbow: ID =2 Size 3* Size 3

Wires under/over bracket

Shoulder: ID =1 Size 3 Size 4

Base: ID =0 Size 3* Size 4

* Using a joint size in a different location i.e. UR5 base as UR5 Elbow, it may be necessary to change ID,

connect all joints electrically, turn the joint 180 degrees in low level control by using the Move tap's

Up/Down function, before mechanical assemble the robot. The robot then needs to be zero positioned or

dual robot calibrated - 3.1.15 Instructions for calibrating a joint

3.2 Controller

3.2.1 Handling ESD-sensitive parts

To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the

usual precautions, such as turning off power before removing logic cards:

.

Put the ESD wrist strap on your

wrist. Connect the wrist band to

the system ground point.

This discharges any static electricity in your

body to ground.

Keep the ESD-sensitive part in its

original shipping container.

(a special "ESD bag") until the part is ready to

be installed

Hold the ESD-sensitive part by its edges;

do not touch its pins.

If a pluggable module is being removed, then

use the correct tool.

Step 1:

Put OLD board into spare ESD bag.

Step 2:

Take NEW board out of ESD bag.

Do not place the ESD-sensitive part on

nonconductive material or on a metal table.

If the ESD-sensitive part needs to be put

down for any reason, then first put it into its

special ESD bag

Machine covers and metal tables

are electrical grounds. They

increase the risk of damage

because they make a discharge path from

your body through the ESD-sensitive part.

(Large metal objects can be discharge paths

without being grounded.)

Prevent ESD-sensitive parts from being accidentally touched by other personnel and do not put

unprotected ESD-sensitive parts on a table.

Be extra careful in working with ESD-sensitive parts when cold-weather and

heating is used, because low humidity increases static electricity.

3.2.2 Replacement of motherboard 3.0

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

Motherboard 3.0 uses flash memory card.

Motherboard 3.1 uses USB memory stick.

1. Shut down the controller and disconnect the power cable, open the controller cabinet and loosen

the 3 Torx screws

2. Remove the aluminum cover plate

3. Disconnect cable connections from motherboard:

1. White plug with white, brown, yellow and green wires. 12 V Power

2. Black USB cable for TP USB connector

3. Ethernet cable to external connector

4. Ethernet cable to Safety control board SCB

5. DVI-cable for TP screen

6. Black cable for RS232-connection for TP touch

1

2

3

4

5

6

12. Remove the 4 screws from the 2 holding brackets

NB! Ethernet cable to Safety Control Board

13. Replace Motherboard with new one

14. If controller is equipped with long-hole brackets, make sure to replace them with circular-hole

brackets. Tighten the 4 screws gently

15. Insert the 6 cables in correct positions. Special attention on the Ethernet cable to the Safety

Control Board. It must be connected to the right connector on the mother board

16. Re-install Flash card and RAM block

17. Carefully put back the grey aluminum cover plate, make sure to mount it correct and fix it with the

3 screws

18. Connect power and verify that teach pendant works properly

3.2.3 Replacement of motherboard 3.1

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

Motherboard 3.0 uses flash memory card.

Motherboard 3.1 uses USB memory stick.

1. Shut down the controller and disconnect the power cable, open the controller cabinet and loosen

the 3 Torx screws

2. Remove the aluminum cover plate

3. Disconnect cable connections from motherboard:

1. White plug with white, brown, yellow and green wires. 12 V Power

2. DVI-cable for TP screen

3. Ethernet cable to Safety control board SCB

4. Ethernet cable to external connector

5. Black USB cable for TP USB connector

6. Grey flat cable for RS232-connection for TP touch

4. Remove the 4 screws from the 2 holding brackets

1

2

3

4

5

6

5. Replace Motherboard.

6. Insert the 6 cables in correct connectors.

7. Re-install USB stick for UR system SW.

8. Carefully put back the aluminum cover plate, make sure to mount it correct and fix it with the 3

screws

1

3

4

6

2

5

3.2.4 Replacement of Safety Control Board

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace Safety Control Board in Controller box

1. Check that the software on the robot is as new as the firmware version on the SCB.

If the software on the robot is too old, then you get an error C203A0.

Find the SCB firmware ver. on the Ethernet connector.

Find the firmware versions in the “About” menu.

Shortcut to “About” is available from software version 3.2.18642

2. Shut down the controller and disconnect the power cable, open the controller cabinet

Carefully remove all plugs and connectors

3. Loosen the 5 Torx screws and remove the aluminum cover.

4. Carefully remove all plugs and connectors

5. Remove 14 screws holding the Safety Control Board.

6. Replace Safety Control Board with new one and tighten the 14 screws to hold the board

7. Insert all connectors and plugs in correct positions.

Eventually see section 5.4.1 Schematic overview

8. Carefully attach the aluminum cover, make sure to mount it correct and fix it with the 5 screws.

3.2.5 Replacement of teach pendant

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

Note: use the same procedure for power down and removing the aluminum cover

plates as in chapter 3.2.2 Replacement of motherboard 3.0 or

3.2.3 Replacement of motherboard 3.1 and 3.2.4 Replacement of Safety Control Board

1. Disconnect 4 cables:

1. Red plug with black cable

2. Black DVI cable

3. Black USB cable

4. Black cable for RS232-connection to touchscreen

1

3

2

4

1

2

3

4

Motherboard 3.0

Motherboard 3.1

2. Remove the bracket (foot of the controller box) that holds the cable inlet and pull out the cables and

plugs through this hole.

3. Replace teach pendant with new, insert cable in cable inlet and perform reconnection of all plugs and

mounting of aluminum cover in reverse order to the above description.

4. Connect power and verify that teach pendant works properly.

3.2.6 Replacement of 48V power supply

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace 48V power supply in Controller box

Note: use the same procedure for power down and removing the aluminum cover plates as in

chapter 3.2.2 Replacement of motherboard 3.0 or 3.2.3 Replacement of motherboard 3.1

and 3.2.4 Replacement of Safety Control Board

1. Remove the handle on Controller box by loosen the 2 screws holding it.

2. Removes the 2 wires for the energy eater/fan.

Black wire

Orange wire

3. Remove the 2 nuts (M6) in the bottom of Controller module.

4. Gently take out the controller module from the Controller box without disconnecting the robot

cable and power cable.

5. Power supplies are located in the rack under the controller module, the two 48V power supplies

are the lower ones in the rack. (UR5 have one and the UR10 have two 48V power supplies)

Before dismounting the 48V power supply, mark and disconnect the cables from that supply.

6. Remove the screws respectively of the defective 48V power supply from the side of the rack.

7. Replace 48V power supply with new one.

8. Reconnect the wires for the 48V power supply.

9. Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the

teach pendant.

10. Carefully put back the grey aluminum cover plate, make sure to mount it correct and fix it with the

screws.

11. Connect power and verify that teach pendant works properly.

3.2.7 Replacement of 12V power supply

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace 12V power supply in Controller box

Note: use the same procedure for power down and removing the aluminum cover plate

and cables for teach pendant as in chapter 3.2.5 Replacement of teach pendant

To replace the 12V power supply follow exactly the same steps as for the procedure in

chapter 3.2.6 Replacement of 48V power supply

1. The 12V power supply is placed in top of rack. The screws holding it in the frame are placed on the

sides.

2. Replace 12V power supply with new one.

3. Reconnect the wires for the 12V power supply.

4. Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the

teach pendant.

5. Carefully put back the grey aluminum cover plate, make sure to mount it correct and fix it with the

5 screws.

6. Connect power and verify that teach pendant works properly.

3.2.8 Replacement of current distributor

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace current distributor in Controller box

Note: use the same procedure for power down and removing the aluminum cover plate

and cables for teach pendant as in chapter 3.2.5 Replacement of teach pendant

1. Current distributor is placed on top of rack.

2. Before dismounting the current distributor, mark and disconnect the cables from the circuit board.

3. Replace current distributor with new one.

4. Reconnect the wires for the current distributor.

5. Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the

teach pendant.

6. Carefully put back the grey aluminum cover plate, make sure to mount it correct and fix it with the

5 screws.

7. Connect power and verify that teach pendant works properly.

4. Software

4.1 Update software

Universal Robots software is named PolyScope.

Read This Prior to Updating Your Software:

Updating the software may cause changes or restrictions to functionality.

1. Do not downgrade the software to earlier version than the version the robot was produced with.

2. We advise you only to update, if you can benefit from the new features or the fixed issues.

3. We advise you to thoroughly read the release notes before doing an update, in order to avoid surprises,

caused by changed or added functionality.

4. In case of concerns related to your actual or planned applications, please contact your supplier for

advice and assistance.

5. Follow the instructions in the guide in the download section of the support web site.

Find it under http://universal-robots.com/support

Instructions to update software:

1. Download software update. Carefully read requirements on support site relating to which software

must be installed on robot prior to updating to the downloaded version.

2. Save it in the root folder on a USB-stick.

3. Insert USB-stick into USB-connector on right-hand side of teach pendant.

4. Go to main screen of PolyScope.

5. Press button SETUP Robot.

6. In left side menu, select Update Robot.

7. Press button Search for searching after software update on USB-stick.

8. Select the desired software update and press UPDATE.

9. Press YES to update the software.

10. Wait for update to complete, after successful update controller will automatically reboot.

11. Remove USB-stick and power on.

4.2 Update joint firmware

Each joint on the robot contains firmware to control the joint.

Software version 3.1.16828 and newer:

When the software is updated on a robot the firmware is automatically updated.

After replacement of a joint on a robot the firmware is automatically updated.

Software version before 3.1.16828:

IMPORTANT NOTICE:

19. When updating firmware controller power MUST NOT be turned off during update.

20. Universal Robots can by no means be held responsible for any failed update caused by improper

operation.

Instructions for updating firmware:

Prior to updating firmware, robot software must be updated.

Please refer to chapter 4.1 Update software. When updating robot software, the firmware will

automatically be copied to a folder on the controller.

1. Drag a finger from left to right across the UNIVERSAL-sign on main screen of PolyScope.

2. Enter password lightbot and press OK.

lightbot

3. You are now in Expert Mode, press Low Level Control.

4. Press Turn power on to go into BOOTLOADER

5. Select the Firmware tab, mark All joints and press UPDATE Firmware.

6. Firmware update is being processed, await message that robot firmware updated successfully.

Controller MUST NOT be powered off during this update.

7. After successful update, press Back.

8. Back in Expert Mode, press Return to Normal.

Firmware has now been updated.

4.3 Using Magic files

For easy backup, Universal Robots provides Magic files to automatically copy data from controller to USB-

stick.

These files are available: Function:

 URmagic log file copies the entire log history file to USB-stick

 URmagic backup programs copies all programs and installation files to USB-stick

 URmagic configuration files copies all configuration files to USB-stick

 URmagic upload programs copies all programs and installation files from USB-stick

 URmagic screenshot generates a screenshot of GUI when USB-stick is inserted

Go to http://www.universal-robots.com/support/ to download Magic files.

Instruction for using Magic files.

1. Download Magic file.

2. Save it in the root folder on a USB-stick.

If more than one Magic file is on USB-stick, they will be run in sequence; the warnings will then

appear for each file. Do not remove the USB-stick until after the last file has been run. Multiple

folders will be created and named with serial number plus a sequential no, like 201430xxxx_0,

201430xxxx_1etc.

3. Insert USB-stick into USB-connector on right-hand side of teach pendant.

4. After a few seconds a red ! USB ! -sign will appear on the screen, this is a warning not to remove

the USB-stick, while the file will do its magic.

5. Await a green <- USB -sign appears on the screen, if there is more than one Magic file on the USB-

stick then go to 4.

6. After the last Magic file is completed the USB-stick can be safely removed.

7. Remove USB-stick and the process is complete.

The Magic file creates a folder on USB-stick named with the serial number of the robot.

5. Troubleshooting

In the error codes different words have been used for the same thing:

 On the Safety Control Board: Processor A = A uP = SafetySys1

 On the Safety Control Board: Processor B = B uP = SafetySys2

PSU = Power Supply

PC = Controller

Open log files with Support Log Reader.

Go to http://www.universal-robots.com/support/ to download Support Log Reader

5.1 Error codes

Code

Error description

Explanation

How to fix

C0

No error

C1

Outbuffer overflow error

C1A1

Buffer of stored warnings

overflowed

C1A2

Outbuffer to RS485

overflowed (problem with PCs

message)

C2

Inbuffer overflow error

C3

Processor overloaded error

Processor in any part could

give this error.

C4

Broken communication

C4A1

Communication with PC lost.

Between Safety Control Board

and Motherboard

C4A2

Communication with Safety

Control Board A uP lost

If either processor A or

processer B is communicating,

the Safety Control Board or

cable between the

Motherboard and Safety

Control Board is defect

a) Check TCP/IP connection

between Motherboard and

Safety Control Board. B)

Exchange Safety Control

Board

C4A3

Communication with Safety

Control Board B uP lost

If either processor A or

processer B is communicating,

the Safety Control Board or

cable between the

Motherboard and Safety

Control Board is defect

a) Check TCP/IP connection

between Motherboard and

Safety Control Board. B)

Exchange Safety Control

Board

C4A4

Communication with primary

Teach Pendant uP lost

If either processor A or

processer B is communicating,

the Teach Pendant or cable

between the Motherboard and

Teach Pendant is defect

a) Check RS485-12V

connection between

Motherboard and Teach

Pendant. B) Exchange

Teach Pendant

C4A5

Communication with

secondary Teach Pendant uP

lost

If either processor A or

processer B is communicating,

the Teach Pendant or cable

between the Motherboard and

Teach Pendant is defect

a) Check RS485-12V

connection between

Motherboard and Teach

Pendant. B) Exchange

Teach Pendant

C4A6

Communication with primary

EUROMAP67 uP lost

If either processor A or

processer B is communicating,

Euromap67 or cable between

the Motherboard and

Euromap is defect

a) Check Euromap67

connection between

Motherboard and

Euromap67. B) Exchange

Euromap67

C4A7

Communication with

secondary EUROMAP67 uP

lost

If either processor A or

processer B is communicating,

Euromap67 or cable between

the Motherboard and

Euromap is defect

a) Check Euromap67

connection between

Motherboard and

Euromap67. B) Exchange

Euromap67

C4A8

Primary EUROMAP67 uP

present, but euromap67 is

disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

C4A9

Secondary EUROMAP67 uP

present, but euromap67 is

disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

C4A10

Primary Teach Pendant

present, but Teach Pendant

safety is disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

C4A11

Secondary Teach Pendant uP

present, Teach Pendant safety

is disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

C4A12

Communication with joint 0

lost

More than 1 package lost

C4A13

Communication with joint 1

lost

More than 1 package lost

C4A14

Communication with joint 2

lost

More than 1 package lost

C4A15

Communication with joint 3

lost

More than 1 package lost

C4A16

Communication with joint 4

lost

More than 1 package lost

C4A17

Communication with joint 5

lost

More than 1 package lost

C4A18

Communication with tool lost

More than 1 package lost

C4A65

Lost package from Primary

Teach Pendant

1 package lost – warning

C4A66

Lost package from Secondary

Teach Pendant

1 package lost – warning

C4A67

Lost package from Primary

Euromap67

1 package lost – warning

C4A68

Lost package from Secondary

Euromap67

1 package lost – warning

C4A69

Lost package from Secondary

Masterboard

1 package lost – warning

C4A70

Lost package from joint 0

1 package lost – warning

C4A71

Lost package from joint 1

1 package lost – warning

C4A72

Lost package from joint 2

1 package lost – warning

C4A73

Lost package from joint 3

1 package lost – warning

C4A74

Lost package from joint 4

1 package lost – warning

C4A75

Lost package from joint 5

1 package lost – warning

C4A76

Lost package from tool

1 package lost – warning

C4A77

Lost package from uPA to

joints

1 package lost – warning

C4A78

Lost package from uPA to

teach pendant

1 package lost – warning

C4A79

Lost package from uPA to uPB

1 package lost – warning

C4A80

Lost package from uPB

1 package lost – warning

C4A81

Packet counter disagreement

in packet from Primary

Screen

Safety processor 1 in Teach

pendant has a packet

disagreement

C4A82

Packet counter disagreement

in packet from Secondary

Screen

Safety processor 2 in Teach

pendant has a packet

disagreement

C4A83

Packet counter disagreement

in packet from Primary

Euromap67

C4A84

Packet counter disagreement

in packet from Secondary

Euromap67

C4A85

Packet counter disagreement

in packet from Safety Control

Board B

C4A86

Packet counter disagreement

in packet from joint 0

C4A87

Packet counter disagreement

in packet from joint 1

C4A88

Packet counter disagreement

in packet from joint 2

C4A89

Packet counter disagreement

in packet from joint 3

C4A90

Packet counter disagreement

in packet from joint 4

C4A91

Packet counter disagreement

in packet from joint 5

C4A92

Packet counter disagreement

in packet from tool

C4A93

Packet counter disagreement

in packet from processor A to

joints

C4A94

Packet counter disagreement

in packet from processor A to

B

C4A95

Packet counter disagreement

in packet from processor A to

Teach Pendant and EUROMAP

C5

Heavy processor load warning

C5A1

Heavy processor load

warning:1

C5A2

Heavy processor load

warning:2

C10

Broken PC communication

error

Eventually update the

software

C10A1

Lost packet from PC

Eventually update the

software

C10A101

PC packet received too early

Eventually update the

software

C10A102

Packet counter does not

match

Eventually update the

software

C10A103

PC is sending packets too often

Eventually update the

software

C11

Bad CRC error

Serial communication problem

with joint

Check black 2-wire

connectors and wires in

joints. Eventually 2 joints

with the same ID.

C12

Unknown message error

C14

Debug message

C14A1

{float}

Should not occur in the field

Do you see this error on a

robot report it to Universal

Robots.

C14A2

{signed}

Should not occur in the field

Do you see this error on a

robot report it to Universal

Robots.

C14A3

{unsigned}

Should not occur in the field

Do you see this error on a

robot report it to Universal

Robots.

C17

Inbuffer overflow in package

from PC

Communication error between

Safety Control Board and

Motherboard

Check Ethernet connection

between circuit boards.

Eventually update the

software

C26

Motor Encoder index drift

detected

Joint mechanical problem

Replace joint

C27

Calibration data is invalid or

does not exist, selftest is

needed!

C29

Online Calibration data

checksum failed

Calibration data is not in the

joint

a) Power OFF and Power

ON. B) replace joint

C30

Master received data from too

many joints

C31

Caught wrong message (not

from master)

Serial communication problem

with joint

Check black 2-wire

connectors and wires in

joints

C32

Flash write verify failed

Debug message

Ignor

C33

Calibration flash checksum

failed

C34

Program flash checksum failed

Update Firmware

C34A0

Program flash checksum failed

during bootloading

Update Firmware

C34A1

Program flash checksum failed

at runtime

Update Firmware

C35

Joint ID is undefined

C36

Illegal bootloader command

Debug message

Ignore

C37

Inbuffer parse error

Serial communication problem

with joint

Check black 2-wire

connectors and wires in

joints

C38

Online RAM test failed

Replace Item

C38A1

Data-bus test failed

Replace Item

C38A2

Address-bus stuck-high test

failed

Replace Item

C38A3

Address-bus stuck-low test

failed

Replace Item

C38A4

Address-bus shorted test failed

Replace Item

C38A5

Memory-cell test failed

Replace Item

C39

Logic and Temporal

Monitoring Fault

C39A1

Max current deviation failure

The joint is broken; it must

be replaced

C39A2

Max joint-encoder speed

exceeded

The joint is broken; it must

be replaced

C39A3

Max motor-encoder speed

exceeded

The joint is broken; it must

be replaced

C39A4

Illegal state change in joint

detected

If this error occurs several

times, report it as a bug

C39A5

Too fast state change in joint

detected

If this error occurs several

times, report it as a bug

C39A6

5V regulator voltage too low

Replace joint

C39A7

5V regulator voltage too high

Replace joint

C39A100

Watchpoint fault: ADC task

timeout

C39A101

Watchpoint fault: Motor-

Control task timeout

C39A102

Watchpoint fault: Motor-

encoder task timeout

C39A103

Watchpoint fault: Joint-

encoder task timeout

C39A104

Watchpoint fault:

Communication task timeout

C39A105

Watchpoint fault: RAM-test

task timeout

C39A106

Watchpoint fault: CalVal-test

task timeout

C39A107

Watchpoint fault: ROM-test

task timeout

C40

AD-Converter hit high limit

joint

EMC issue external or

electronics internal

Check grounding and

shielding for EMC problems

C44

CRC check failure on primary

bus

Serial communication problem

with joint or secondary bus

node

Check black 2-wire

connectors and wires in

joints

C44A0

Joint 0 CRC check failure on

primary bus

Serial communication problem

with joint or secondary bus

node

Replace joint 0

C44A1

Joint 1 CRC check failure on

primary bus

Serial communication problem

with joint or secondary bus

node

Replace joint 1

C44A2

Joint 2 CRC check failure on

primary bus

Serial communication problem

with joint or secondary bus

node

Replace joint 2

C44A3

Joint 3 CRC check failure on

primary bus

Serial communication problem

with joint or secondary bus

node

Replace joint 3

C44A4

Joint 4 CRC check failure on

primary bus

Serial communication problem

with joint or secondary bus

node

Replace joint 4

C44A5

Joint 5 CRC check failure on

primary bus

Serial communication problem

with joint or secondary bus

node

Replace joint 5

C44A6

Tool CRC check failure on

primary bus

Serial communication problem

with tool or secondary bus

node

Replace Tool mounting

bracket

C44A80

CRC Check failure on primary

bus

Most likely an interference on

the communication bus

a) Check green 2-wire

connectors and wires in

joints, b) If the error

reappears contact your

local service provider for

assistance.

C45

AD-Converter error

Replace Item

C46

Loose gearbox or bad encoder

mounting

Mechanical problem in gear

related to encoder mounting

Replace joint

C47

AD-Converter hit low limit

EMC issue external or

electronics internal

a) Check grounding and

shielding for EMC

problems. B) Replace Item

C48

Powerbus voltage drop

detected.

Error on 48V powerbus to

robot arm

Check 48V output from

PSU. Check current-

distributor PCB.

Replacement of 48V PSU or

current-distributor is

necessary

C49

RS485 receive warning

C49A200

Secondary RS485 bus is down

Bus for: Teach Pendant,

Processor A and Processor B

on the Safety Control Board.

Check TCP/IP-12V cable to

Teach Pendant

C50

Robot powerup failure

Electrical error control box

Remove all external

connections to I/O-

interface of Safety Control

Board. Check for short

circuit. Argument of error

code specifies in detail

what causes the error.

C50A1

Voltage detected at 24V rail

before startup

C50A2

Voltage present at unpowered

robot

C50A5

Powersupply voltage too low

C50A6

Powersupply voltage too high

C50A11

Voltage not detected at 24V

rail after startup

24 V to the I/O interface in the

controller

C50A15

Warning, waiting for

SafetySYS2

SafetySYS2 = Processor B on

Safety Control Board

C50A16

The Teach Pendant does not

respond

Loose wire or incorrect safety

configuration. Message comes

from Safety Control Board

Check the cable or change

in the Safety Configuration

of the Installation the

miscellaneous settings

C50A17

The Euromap67 interface does

not respond

Loose wire or incorrect safety

configuration

Check the cable or change

in the Safety Configuration

of the Installation the

miscellaneous settings

C50A18

Warning, waiting for

SafetySYS1

SafetySYS1 = Processor A on

Safety Control Board

C50A20

5V, 3V3 or ADC error (5V too

high)

C50A21

5V, 3V3 or ADC error (5V too

low)

C50A22

Robot current sensor reading

too high

C50A23

Robot current sensor reading

too low

C50A24

48V not present (Check

internal connection)

This error can have several root causes and you have to measure the voltage some places.

There are 3 different components that could be the root cause and you have to measure the

voltage to determine which one of them that is the faulty one.

- 48 V power supply

- Current distributor

- Safety Control Board.

Find the schematic drawing in this service manual

C50A25

Robot voltage present at 48V

PSU powereup

C50A26

Voltage present on unpowered

48V power supply

C50A27

12V, 3V3 or ADC error (12V

too high)

C50A28

12V, 3V3 or ADC error (12V

too low)

C50A29

Analog I/O error (-12V too

high)

C50A30

Analog I/O error (-12V too

low)

C50A31

The other safetySYS do not

initialize

C50A40

Wrong voltage from PSU1

C50A41

Wrong voltage from PSU2

C50A42

Voltage will not disappear

from PSU

C50A43

Warning, waiting for CB2 type

answer from primary

processor

C50A50

Processor A 3.3V supply voltage

out of bounds

C50A51

Robot voltage below threshold

C50A52

Robot voltage above threshold

C50A53

58V generator deviation error

C50A54

5V regulator too low

C50A55

5V regulator too high

C50A56

-4V generator too low

C50A57

-4V generator too high

C50A80

Last CPU reset caused by Low-

Power-Reset

C50A81

Last CPU reset caused by

Window-Watchdog-Reset

C50A82

Last CPU reset caused by

Independent-Watchdog-Reset

C50A83

Last CPU reset caused by

Software-Reset

C50A84

Last CPU reset caused by

External-Pin-Reset

C50A85

Last CPU reset caused by

Brown-Out-Reset

C50A99

Wrong software on PCB

C50A100

Cable not connected

Robot Problem: Robot Cable is

not detected

C50A101

Short circuit in robot detected

or wrong robot connected to

control box

Robot Problem: 48V or wrong

robot type

Check robot type. Look for

short circuit in cable and in

robot arm.

C50A102

Voltage rising too slowly

Robot Problem: 48V

C50A103

Voltage failed to reach

acceptable level

Robot Problem: 48V

C51

CRC check failure on

secondary bus

C51A0

Processor B

C51A1

Primary screen processor

CRC check failure on Safety

processor 1 in Teach pendant

C51A2

Secondary screen processor

CRC check failure on Safety

processor 2 in Teach pendant

C51A3

Primary E67

C51A4

Secondary E67

C53

IO overcurrent detected

Safety Control Board error

Remove all external

connections to I/O-

interface of Safety Control

Board. Check for short

circuit

C53A1

IO overcurrent detected, max

is 800mA

Safety Control Board error

Remove all external

connections to I/O-

interface of Safety Control

Board. Check for short

circuit

C53A2

IO overcurrent detected, max

is 600mA

Tool error

Remove tool connector.

Check for short circuit

C55

Safety system error

Safety system malfunction

Check Motherboard, Safety

Control Board,

Screenboard, Current

distributor (Euromap, if

installed). Bypass safety

connections to I/O-

interface of Safety Control

Board

C55A23

Safety relay error (minus

connection)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

C55A24

Safety relay error (plus

connection)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

C55A33

Safety relay error (a relay is

stuck)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

C55A34

Safety relay error (relays are

not on)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

C55A50

Voltage present at unpowered

robot

SCB hardware fault

Replace Safety Control

Board (SCB)

C55A51

Voltage will not disappear

from robot

SCB hardware fault

Replace Safety Control

Board (SCB)

C55A52

5V, 3V3 or ADC error (5V too

low)

SCB hardware fault

Replace Safety Control

Board (SCB)

C55A53

5V, 3V3 or ADC error (5V too

high)

SCB hardware fault

Replace Safety Control

Board (SCB)

C55A90

Bootloader error, robot

voltage too low or current too

high

C55A91

Bootloader error, robot

voltage too high

C55A100

Safety violation

C55A101

Safety Channel Error In Safety

Control Board

C55A102

Safety Channel Error In Screen

C55A103

Safety Channel Error In

Euromap67 Interface

C55A109

Received fault message from

PC

C55A110

Safety State is changing too

often

C55A111

On/Off State is changing too

often

C55A112

Robot current sensors

readings differ

C55A120

Robot current is too high while

emergency stopped

C55A121

Robot current is too high while

safeguard stopped

C56

Overvoltage shutdown

Voltage exceeded 55V

Check Energy Eater. Cable

to Energy eater, Replace

Energy Eater

C57

Brake release failure

Check Brake, solenoid,

Payload, TCP and Mount

C57A1

Joint did not move or motor

encoder is not functioning

Check Brake, solenoid,

Payload, TCP and Mount

C57A2

Large movement detected

during brake release

Check Brake, solenoid,

Payload, TCP and Mount

C57A3

Robot was not able to brake

release, see log for details

Check Brake, solenoid,

Payload, TCP and Mount

C58

Motor encoder not calibrated

Calibrate joint

C59

Overcurrent shutdown

Overcurrent in joint. Argument

= Current in Amps.

Check for short circuit.

Check program for

singularity issues. Replace

joint if necessary

C62

Joint temperature

C62A1

High (80 C)

Warning

C62A3

Static load too high warning

Warning

C62A11

Shut down (85 C)

Stop

C62A13

Static load too high

Stop

Check Payload

C63

Selftest failed

C68

SPI error

Joint: Absolut encoder on joint

communication error

Replace joint

C70

Close to gearbox shear limit

Acceleration / deceleration to

high. Mechanical problem in

gear related to encoder

mounting

Reduce acceleration in user

program. Replace joint if

necessary

C71

Startup check error

Fault: Firmware in joint

C71A1

Hardware is size1, software is

not

Fault: Firmware in joint

C71A2

Hardware is size2, software is

not

Fault: Firmware in joint

C71A3

Hardware is size3, software is

not

Fault: Firmware in joint

C71A4

Hardware is size4, software is

not

Fault: Firmware in joint

C71A5

Invalid hardware size read

C71A6

Motor indication signal not

working

C71A7

Phase 1 and phase 2 not

working

The motor wires are damaged,

bad connection in screw

terminals or defect PCB

Replace joint (Replace PCB)

C71A8

Phase 2 not working

The motor wires are damaged,

bad connection in screw

terminals or defect PCB

Replace joint (Replace PCB)

C71A9

Phase 1 not working

The motor wires are damaged,

bad connection in screw

terminals or defect PCB

Replace joint (Replace PCB)

C71A10

Invalid motor test result

C71A11

ADC calibration failed

Only in joint

C71A12

Phase 3 not working in joint

failed

The wire is (1) damaged or (2)

has been disconnected from

the PCB (not likely) or (3)

defect PCB

Replace the joint

C71A50

Current sensor test failed

Sensor reported wrong current

when probed

Replace the joint. Defect

Printed circuit board

C71A51

Current sensor test failed

Sensor reported wrong current

when probed

Replace the joint. Defect

Printed circuit board

C71A52

Current sensor test failed

Sensors reported different

currents when probed

Replace the joint. Defect

Printed circuit board

C72

Power Supply Unit failure

48 V Power problem

C72A1

0 PSUs are active

PSU was not able to deliver

48V (In UR10: No 48V)

Check power connection

between power supply and

Safety Control Board

C72A2

1 PSU active, but we expect 2

(UR10)

PSU was not able to deliver

48V or UR10 flash card in UR5

robot

Check power connection

between power supply and

Safety Control Board and

check that the flash card

and robot match

C72A3

2 PSUs active, but we expect 1

(UR5)

UR5 flash card in UR10 robot

Check that the flash card

and robot match

C73

Brake test failed during

selftest, check brakepin

C74

Joint encoder warning

Magnetic encoder error

(Absolut encoder)

C74A1

Invalid decode: Readhead

misalignment, ring damaged

or external magnetic field

present.

Warning: The argument is the

sum of C74 errors

C74A2

Speed reading is not valid

Warning: The argument is the

sum of C74 errors

C74A4

System error=malfunction or

inconsistent calibration

detected

Warning: The argument is the

sum of C74 errors

C74A8

Supply voltage is out of range

Warning: The argument is the

sum of C74 errors

C74A16

Temperature is out of range

Warning: The argument is the

sum of C74 errors

C74A64

Signal low =Too far from

magnetic ring

Warning: The argument is the

sum of C74 errors

C74A128

Signal saturation =Too close to

magnetic ring

Warning: The argument is the

sum of C74 errors

C74A207

Joint encoder error

Example: Argument 207 is the

sum of 128,64,8,4,2,1 which

means that all the errors in

connection to argument 1, 2,

4, 8, 64 and 128 have been

reported.

Example.

C75

Joint encoder error

Magnetic encoder error

(Absolut encoder)

C75A1

Invalid decode: Readhead

misalignment, ring damaged

or external magnetic field

present.

Error: The argument is the sum

of C75 errors

Replace joint

C75A2

Speed reading is not valid

Error: The argument is the sum

of C75 errors

Replace joint

C75A4

System error=malfunction or

inconsistent calibration

detected

Error: The argument is the sum

of C75 errors

Replace joint

C75A8

Supply voltage is out of range

Error: The argument is the sum

of C75 errors

Check previous error

C75A16

Temperature is out of range

Error: The argument is the sum

of C75 errors

Check previous error

C75A32

Signal lost =Misaligned

readhead or damaged ring

Error: The argument is the sum

of C75 errors

Replace joint

C75A64

Signal low =Too far from

magnetic ring

Error: The argument is the sum

of C75 errors

Replace joint

C75A128

Signal saturation =Too close to

magnetic ring

Error: The argument is the sum

of C75 errors

Replace joint

C75A207

Joint encoder error

Example: Argument 207 is the

sum of 128,64,8,4,2,1 which

means that all the errors in

connection to argument 1, 2,

4, 8, 64 and 128 have been

reported.

Example

C76

Joint encoder communication

CRC error

Error between sensor and joint

circuit

Check connections or very

heavy electrical noise

C77

Sudden position change

detected on the joint-encoder

The position reading from the

encoder was different than

expected

C78

Large sudden position change

detected on the joint-encoder

The position reading from the

encoder was severely different

than expected, the latest

measurement was discarded

Contact your local service

provider for assistance

C78A255

Large sudden position change

detected on the joint-encoder

The argument 255 is a number

that relates to the size of the

position change. In other

words this can be treated as a

C78 error.

Example.

C80A51

Window watchdog reset

C100

Robot changed mode

Status warning, general modus

change

Check preceding errors in

log history

C101

Real Robot Connected

C102

Real Robot not connected –

Simulating Robot

C103

UR Ethernet Error

Comm. Prob. Between Mother

Board and Safety Control

Board

Check cable

C103A1

Connection to Safety Control

Board lost

PC did not receive 3 packets in

a row

Check that the Ethernet

cable between PC board

and Safety Control Board is

connected and restart

system

C103A2

Package lost from Safety

Control Board

C104

Error=Empty command sent to

robot

C111

Something is pulling the robot

Check Payload setting

C115

Unknown robot type

The robot type specified in the

configuration is unknown

C116

Realtime part warning

Possible CPU-overload due to

structure of user program

Restructure user program

C117

Restart SCB failed

The Safety Control Board

couldn’t be rebooted from the

controller.

Reboot the robot

C150

Protective Stop: Position close

to joint limits

C151

Protective Stop: Tool

orientation close to limits

C152

Protective Stop: Position close

to safety plane limits

C153

Protective Stop: Position

deviates from path

C154

Protective Stop: Position in

singularity

Robot cannot move linear in a

singularity

Use jointspace movement

or change the motion

C155

Protective Stop: Robot cannot

maintain its position, check if

payload is correct

C156

Protective Stop: Wrong

payload or mounting detected,

or something is pushing the

robot when entering Freedrive

mode

The robot may move

unexpected due to wrong

settings

Verify that the TCP

configuration and mounting

in the used installation is

correct

C160

Protective stop: The robot was

powered off last time due to a

joint position disagreement

1. Verify that the robot

position in the 3D graphics

matches the real robot, to

ensure that the encoders

function before releasing the

brakes. Stand back and

monitor the robot performing

its first program cycle as

expected.

2. If the position is not correct,

the robot must be repaired. In

this case, click “Power Off

Robot”.

3. If the position is correct,

please tick the check box

below the 3D graphics and

click “Robot Position Verified”

C161

Protective stop: Large

movement of the robot

detected while it was powered

off. The joints were moved

while it was powered off, or

the encoders do not function.

1. Verify that the robot

position in the 3D graphics

matches the real robot, to

ensure that the encoders

function before releasing the

brakes. Stand back and

monitor the robot performing

its first program cycle as

expected.

2. If the position is not correct,

the robot must be repaired. In

this case, click “Power Off

Robot”.

3. If the position is correct,

please tick the check box

below the 3D graphics and

click “Robot Position Verified”

C171

Issue with blends

C171A0

A MoveC-waypoint were

skipped due to a blend.

The value for the blend radius

is too large compared to the

distance between the

waypoints.

Decrease the blend radius

or choose waypoints that

are further apart.

C171A1

Blend radius too small in a

MoveC

C171A3

A ServoC-waypoint were

skipped due to a blend.

The value for the blend radius

is too large compared to the

distance between the

waypoints.

Decrease the blend radius

or choose waypoints that

are further apart.

C171A4

Overlapping Blends in a

MoveJ, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A5

Overlapping Blends in a

MoveJ, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A6

Overlapping Blends in a

MoveJ, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A7

Overlapping Blends in a

MoveJ, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A9

A MoveP-waypoint were

skipped due to a blend.

The value for the blend radius

is too large compared to the

distance between the

waypoints.

Decrease the blend radius

or choose waypoints that

are further apart.

C171A10

Blend radius too small error in

a MoveP

C171A11

Overlapping Blends in a

MoveL, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A12

Overlapping Blends in a

MoveL, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A13

Overlapping Blends in a

MoveL, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C171A14

Overlapping Blends in a

MoveL, a waypoint was

skipped

Decrease the blend radius

or choose waypoints that

are further apart.

C172

Illegal control mode

C184

Joint self test not received by

controller

C185A1

START_NORMAL_OPERATION

is not allowed on selftest

firmware

C185A2

GOTO_BACKDRIVE_COMMAN

D is not allowed on selftest

firmware

C186A1

joint_mode ==

JOINT_RUNNING_MODE is not

allowed on selftest firmware

C191

Safety system violation

C191A1

Joint position limit violated

C191A2

Joint speed limit violated

Reduce acceleration or

speed for joint

C191A3

TCP speed limit violated

Reduce acceleration or

speed for joint

C191A4

TCP position limit violated

C191A5

TCP orientation limit violated

C191A6

Power limit violated

Reduce acceleration or

speed for joint

C191A7

Joint torque window violated

C191A8

Joint torque window too large

C191A9

Reduced mode output

violation

C191A10

Safeguard stop output

violation

C191A11

Emergency stop output

violation

C191A12

Momentum limit violation

C191A13

Robot moving output violation

C191A14

Robot is not braking in stop

mode

During the braking process,

the safety system monitors if

the robot brakes as expected.

If this is not the case, this error

is generated

Check payload settings and

mounting

C191A15

Robot is moving in stop mode

When the robot is stopped

due to a safety violation or a

safeguard stop, the safety

system generates this error, if

the robot moves while in this

mode

Is the robot physically

pushed while safeguard

stopped?

C191A16

Robot did not stop in time

C191A17

Received a null vector for TCP

orientation

Fault in config file, when no

GUI is used

C191A18

Robot not stopping output

violation

C191A19

Invalid safety IO configuration

Fault in config file, when no

GUI is used

C191A20

Configuration information or

limit sets not received

C191A21

The other safety processor

detected a violation

C191A22

Received unknown command

from Controller

Check Firmware

C191A23

Invalid setup of safety limits

Check Firmware

C191A24

Reduced Mode Output set,

while it should not be

Check Firmware

C191A25

Reduced Mode Output not set,

while it should be

Check Firmware

C191A26

Not Reduced Mode Output

set, while it should not be

Check Firmware

C191A27

Not Reduced Mode Output not

set, while it should be

Check Firmware

C191A28

Robot Emergency Stop

exceeded maximum stop time

Too high payload

C191A29

System Emergency Stop

exceeded maximum stop time

Too high payload

C191A30

Safeguard Stop exceeded

maximum stop time

Too high payload

C191A31

Operation mode switch is

present while the three

position switch is missing

C192

Safety system fault

C192A1

Robot still powered in

emergency stop

When emergency stop is

active, the robot arm powers

off. The controller is

responsible for sending the

power off command. This

error is generated, if the safety

system detects that the robot

arm still has power.

C192A2

Robot emergency stop

disagreement

E-stop in teach pendant or in

Robot E-stop circuit problem

Check cables or replace

Safety Control Board (SCB)

C192A3

System emergency stop

disagreement

System E-stop circuit problem

Check cables or replace

Safety Control Board (SCB)

C192A4

Safeguard stop disagreement

Safeguard circuit problem

Check cables or replace

Safety Control Board (SCB)

C192A5

Euromap safeguard stop

disagreement

Euromap circuit problem

Check cables from Safety

Control Board to Euromap

to external machine

C192A6

Joint position disagreement

Reduce payload, check for

encoder problems

C192A7

Joint speed disagreement

Reduce payload, check for

encoder problems

C192A8

Joint torque disagreement

Reduce payload, check for

encoder problems

C192A9

TCP speed disagreement

Reduce payload, check for

encoder problems

C192A10

TCP position disagreement

Reduce payload, check for

encoder problems

C192A11

TCP orientation disagreement

Reduce payload, check for

encoder problems

C192A12

Power disagreement

Power calculation: uP-A and

uP-B disagreement

Joint error: Check previous

error codes from the same

joint and evaluate

C192A13

Joint torque window

disagreement

C192A14

Reduced mode input

disagreement

Safety I/O uP-A and uP-B

disagreement

Check cables

C192A15

Reduced mode output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A16

Safety output failed

C192A17

Safeguard stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A18

The other safety processor is

in fault

C192A19

Emergency stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A20

SPI output error detected

Safety Control Board

Check 24 V supply

C192A21

Momentum disagreement

C192A22

Robot moving output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A23

Wrong processor ID

C192A24

Wrong processor revision

C192A25

Potential brownout detected

Voltage drop on Safety Control

Board(SCB) or defect SCB

C192A26

Emergency stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A27

Safeguard stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A28

Robot not stopping output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A29

Safeguard reset input

disagreement

Safety I/O uP-A and uP-B

disagreement

Check cables

C192A30

Safety processor booted up in

fault mode

C192A31

Reduced Mode Output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A32

Not Reduced Mode Output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

C192A33

Checksum disagreement

between uA and uB

C192A34

User safety config checksum

disagreement between uA and

GUI

C192A35

Robot config checksum

disagreement between uA and

GUI

C192A36

Online RAM test failed

C192A37

Not all safety related

functionalities are running

C192A38

Package too short for CRC

calculation

C192A39

Three position switch input

disagreement

C192A40

Operation mode switch input

disagreement

C193

One of the nodes is in fault

mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A0

Joint 0 is in fault mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A1

Joint 1 is in fault mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A2

Joint 2 is in fault mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A3

Joint 3 is in fault mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A4

Joint 4 is in fault mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A5

Joint 5 is in fault mode

SCB has detected an error

See previous error or

update the firmware on the

joint or reboot system

C193A6

Tool is in fault mode

SCB has detected an error

See previous error or

reboot system

C193A7

Screen 1 is in fault mode

SCB has detected an error on

Safety processor 1 in Teach

pendant

See previous error or

reboot system

C193A8

Screen 2 is in fault mode

SCB has detected an error on

Safety processor 2 in Teach

pendant

See previous error or

reboot system

C193A9

Euromap 1 is in fault mode

SCB has detected an error

See previous error or

reboot system

C193A10

Euromap 2 is in fault mode

SCB has detected an error

See previous error or

reboot system

C194

One of the nodes is not booted

or not present

C194A0

Joint 0 is not booted or not

present

SCB has detected an error

C194A1

Joint 1 is not booted or not

present

SCB has detected an error

C194A2

Joint 2 is not booted or not

present

SCB has detected an error

C194A3

Joint 3 is not booted or not

present

SCB has detected an error

C194A4

Joint 4 is not booted or not

present

SCB has detected an error

C194A5

Joint 5 is not booted or not

present

SCB has detected an error

C194A6

Tool is not booted or not

present

SCB has detected an error

C194A7

Screen 1 is not booted or not

present

SCB has detected an error on

Safety processor 1 in Teach

pendant

C194A8

Screen 2 is not booted or not

present

SCB has detected an error on

Safety processor 2 in Teach

pendant

C194A9

Euromap 1 is not booted or

not present

SCB has detected an error

C194A10

Euromap 2 is not booted or

not present

SCB has detected an error

C194A128

Joint 0 not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace base

C194A129

Joint 1 not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace shoulder

C194A130

Joint 2 not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace elbow

C194A131

Joint 3 not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace Wrist 1

C194A132

Joint 4 not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace Wrist 2

C194A133

Joint 5 not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace Wrist 3

C194A134

Tool not ready while brake

release requested

Must be at least in IDLE mode

when the brake release is

requested

1. Check for loose

communication cable. 2.

Replace Tool

C195

Conveyor speed too high

Conveyor speed higher than

robot is able to run

Make sure that conveyor

tracking is set correct up

C195A1

Conveyor speed too high for

joint speed safety limit

Make sure that conveyor

tracking is set correct up

C195A2

Conveyor speed too high for

TCP speed safety limit

Make sure that conveyor

tracking is set correct up

C195A3

Conveyor speed too high for

momentum safety limit

Make sure that conveyor

tracking is set correct up

C196

MoveP speed too high

Too high speed in relation to

blend radius

Reduce speed or increase

blend radius in user

program

C197

Blend overlap warning

C200

Safety Control Board hardware

error

SCB: uP-A has detected an

error

C200A1

Hardware ID is wrong

SCB: uP-A has detected an

error: Wrong SCB

C200A2

MCU type is wrong

SCB: uP-A has detected an

error

C200A3

Part ID is wrong

SCB: uP-A has detected an

error

C200A4

RAM test failed

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A5

Register test failed

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A6

pRom Crc test failed

SCB: uP-A has detected an

error: firmware error

Replace Safety Control

Board (SCB)

C200A7

Watchdog reset the processor

SCB: uP-A has detected an

error

C200A8

OVG signal test not passed

SCB: uP-A has detected an

error: over voltage generator

Replace Safety Control

Board (SCB)

C200A9

3V3A power good pin is low

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A10

3V3B power good pin is low

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A11

5V power good is low

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A12

3V3 voltage too low

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A13

3v3 voltage too high

SCB: uP-A has detected an

error

Replace Safety Control

Board (SCB)

C200A14

48V input is too low

Check: 48 V power supply,

current distributer energy

eater or replace SCB

C200A15

48V input is too high

Check: 48 V power supply,

current distributer energy

eater or replace SCB

C200A16

24V IO short circuited

Too high current

Disconnect external

connections

C200A17

PC current is too high

Motherboard takes too high

current

C200A18

Robot voltage is too low

Check: Short circuit in robot

arm, 48 V power supply,

current distributer energy

eater or replace SCB

C200A19

Robot voltage is too high

Check: 48 V power supply,

current distributer energy

eater or replace SCB

C200A20

24V IO voltage is too low

Disconnect I/O or replace

SCB

C200A21

12V voltage is too high

Check 12 V power supply,

cables or replace SCB

C200A22

12V voltage is too low

Check 12 V power supply,

cables or replace SCB

C200A23

It took too long to stabilize

24V

Safety Control Board

error(SCB)

External 24 V problem or

replace SCB

C200A24

It took too long to stabilize

24V IO

Safety Control Board

error(SCB)

External 24 V problem or

replace SCB

C200A25

24V voltage is too high

Safety Control Board

error(SCB)

Replace Safety Control

Board (SCB)

C200A26

24V IO voltage is too high

Disconnect I/O or replace

SCB

C201

Setup of safety board failed

Invalid safety parameters have

been received

Verify that the setup of the

Safety Configuration is

valid. Check the Ethernet

connection between

Motherboard and Safety

Control Board.

C202

SCE configuration was illegal,

after applying tolerances

C203A0

PolyScope detected a

mismatch between the shown

and (to be) applied safety

parameters

The PolyScope continuously

verifies that the shown safety

parameters are equal to the

running parameters

Check that the software

version is the same or

newer than the firmware

on the safety control board.

Reload the installation and

re boot the robot

C204A0

Protective Stop: Invalid

setpoint

C204A1

Sudden change in target

position

C204A2

Inconsistency between target

position and speed

C204A3

Sudden stop

The program contains motions

that are not ramped correctly

down

To abort a motion, use

“stopj(a)” or “stopl(a)”

script commands to

generate a smooth

deceleration.”

C204A4

Robot is not braking in stop or

pause mode

If this happens, report it as

a bug

C204A5

Robot program resulted in

invalid setpoint

C204A6

Blending failed and resulted in

an invalid setpoint

Try changing the blend

radius or contact technical

support

C205

Target speed does not match

target position

C205A0

Inconsistency between target

position and speed

C206

Sanity check failed

The software version on

the robot must be the same

or later than the version

the robot had from the

factory.

C206A0

Target joint speed does not

match target joint position –

Joint 0 (Base)

C206A1

Target joint speed does not

match target joint position –

Joint 1 (Shoulder)

C206A2

Target joint speed does not

match target joint position –

Joint 2 (Elbow)

C206A3

Target joint speed does not

match target joint position –

Joint 3 (Wrist 1)

C206A4

Target joint speed does not

match target joint position –

Joint 4 (Wrist 2)

C206A5

Target joint speed does not

match target joint position –

Joint 5 (Wrist 3)

C207

Fieldbus input disconnected

Check fieldbus connections

or disable the fieldbus in

the installation

5.2 LED indicators and Fuses on Safety Control Board

Safety Control Board (SCB)

Fuse 48 V:

The 5 A fuse “48 V” protects all 48 V for over current in the system inclusive Euromap.

This information is only for troubleshooting. Do NOT replace the fuse on any circumstances.

Do ONLY replace the SCB with a new tested board.

Fuse 24 V:

2 fuses 5 Amp in parallel for the DI/DO 24 V supply on the safety control board no matter if the 24 V is from

the controller or external power supply. Do NOT replace the fuse on any circumstances. Do ONLY replace

the SCB with a new tested board

LED indicators:

 12V-PSU On when the power plug is connected.

 12V System: On when the power on has been activated

 5V On when “12 V System” is on and indicate that 5 V is ok.

 -4V On when “12 V System” is on and indicate that – 4 V to analog I/O is ok.

 3V3A On when 5V is on and indicate 3.3 V for logic Safety circuit A

 3V3B On when 5V is on and indicate 3.3 V for logic Safety circuit B

 48V 48 V is present on the safety control board

 24V 48 V is detected and ok, indicate that internal 24 V is present for I/O’s

 R 48 V on robot arm

 A Status for Logic A: a blink sequence

 B Status for Logic B: a blink sequence

LED

Normal startup sequence for a CB3.x UR10:

1. The 12V-PSU LED is on when the power plug is connected to a working power supply.

2. When the power button on the teach pendant is pressed, all LED indicators are turned on except for

the 48V, 24V and R LEDs. The A and B LEDs also exhibit a special behavior by intermittently turning off

and on ("blinking") once triggered.

3. The final phase of the startup sequence occurs (immediately) after the Polyscope software is done

loading. At this stage, the 48V and 24V LED indicators become active (are switched on).

If the 48V LED indicator is off all the time in the startup sequence you should measure the voltage:

See the E-Plan diagram: 5.4.1 Schematic overview

3.1. Measure the 48V on the Safety Control Board (SCB) where the 48V comes from the Current

distributor. And check this 1 second pulse.

3.1.1. The voltage is measured on the Safety Control Board. That means the Safety Control Board is

defect.

3.1.2. No voltage is measured on the Safety Control Board. Then measure the 230 V on the input

side of the 48V power supply. If the voltage pulse of 1 second is present, the Power supply is

defect.

3.1.3. No voltage is measured on the input of the power supply. Then measure the 230 V on the

input side of the Current distributor. If the voltage is present, the current distributor is defect.

5.3 Error phenomena

5.3.1 ControlBox: NO CONTROLLER displayed in Initializing

ControlBox = NO

CONTROLLER displayed at

INITIALIZING screen

Defective Safety Control

Board

Replace Safety Control Board and verify problem

is solved

Replace Ethernet cable between motherboard

and Safety Control Board and verify problem is

solved

Replace motherboard and verify problem is solved

Defective motherboard

YES

NO

Defective Ethernet cable

YES

5.3.2 NO CABLE displayed during power up

NO CABLE displayed during

power up > controller shuts

off after few seconds

Replace 12V power supply

Check that 12V PSU LED is lid. The top LED in the

row in the right side of the Safety Control Board.

See.: 5.2 LED indicators and Fuses on Safety

Control Board

Measure that 230V AC is present on power input

connector on 12V power supply

During power up (within first few seconds) check

that the 48 V LED and R LED are lid before they

turns off again. The no. 3 and no 5 LED from the

bottom on the Safety Control Board.

Replace Safety Control

Board

Replace motherboard

NO

YES

Replace current distributor

NO

5.3.3 Protective stop

Protective Stop

Is center of mass very different from tcp point?

Payload and tcp settings in Installation\TCP

Configuration must correspond with actual tool.

Are settings incorrect?

Are waypoints positioned very close to cylindrical

area around base of robot where robot can not

operate?

Adjust waypoints away

from this area or reduce

speed/acceleration

YES

NO

Adjust payload and tcp

settings

YES

Adjust center of mass in the

TCP tap or using script code

set_payload()

YES

NO

Is robot moving with excessive speed or

accelerating very hard?

Reduce speed or

acceleration

YES

NO

Press free drive button on back of TP and check

the free drive function of all joints > observe any

abnormal friction or behavior observed?

NO

Inspect joint with abnormal

behavior, joint might have

mechanical failure

YES

Contact distributor from where robot has been

purchased

NO

Read also article 18939 on the support site

www.universal-robots.com/support

5.3.4 Power on failure in Initializing

If power turns off a few seconds after Robot Power is turned On in the Initializing window, there are

many possible causes for this phenomenon.

Most likely it is a control box failure or a communication failure with a joint or the tool.

Control box failure

Replace 48V power supply

During power up (within the first three seconds of

power up) measure that 230V AC is present on

48V_PSU1 connector on current distributor PCB

Power controller OFF/ON

Measure that 12V DC is present in the red

connector/flatcable on the current distributor

Replace current distributor

Check log history for error messages and consult

the section Error Codes for detailed explanation

Replace Safety Control

Board

YES

NO

Communication failure with

a joint or the tool connector

Go to tab General and press “TURN POWER ON”

and “Go to Idle” and “Arm robot” Does state of

tool switch from “OFF” to “ON”?

Go to LOW LEVEL CONTROL in EXPERT MODE

(consult chapter 4.2 for how to access EXPERT

MODE)

Does state of tool switch to

READY?

Replace tool

Check log history for error messages and consult

the section Error Codes for detailed explanation

NO

YES

Unmount tool/joint and

check black comm.

connector is fully inserted in

printed circuit board

YES

NO

Continue to

www.universal-robots.com/support

Go to tab General and press “TURN POWER ON”

and “Go to Idle” and “Arm robot”. Does state of

all joints J0-J5 switch from “Power OFF” to

READY?

Does state of joint switch to

READY?

Replace joint

NO

YES

Remove blue lid of joint and

check black comm.

connector is fully inserted

Continued

NO

Communication ok to joints and tool

5.3.5 Checklist after a collision

Checklist after a collision

Remove lid and inspect

parts inside of joint

Visually inspect robot arm.

Are any parts visually damaged, like damages on

one of the blue lids?

Stop robot program and eventually press the

Emergency button prior to entering the work cell

Press free drive button on back of TP and check

the free drive function of all joints > any abnormal

friction or behavior observed?

Inspect joint with abnormal

behavior

Check log history for error messages and consult

the section Error Codes for detailed explanation

YES

NO

Press free drive button on back of TP and check

the free drive function of all joints > any excessive

noise observed?

YES

NO

Inspect joint with abnormal

noise. If click noises appear,

check brake pin

Start the robot program in reduced speed and

verify robot is running as intended

NO

5.4 Electrical documentation

5.4.1 Schematic overview

Diagrams in pdf or in E-plan format, can be found on the Support site:

http://www.universal-robots.com/support/

5.4.2 E-Plan diagrams

Diagrams in pdf or in E-plan format, can be found on the Support site:

http://www.universal-robots.com/support/

6. Spare parts

6.1 Spare part list

Item no.

Item designation

Controller:

122950

Controller excl. Teach Pendant UR10

124910

Controller OEM CB3 UR10 (Excl. Teach Pendant and cabinet)

122091

Teach Pendant incl. Touch Screen & power cable UR5 & UR10

180001

Stylus Pen

171022

Flash card CB3.0

171010

USB Flash 2 GB for UR system SW CB3.1

122600

Motherboard kit CB3.0

122650

Motherboard kit CB3.1

172290

Safety Control board kit

177002

Power Supply Unit 12V

177003

Power Supply Unit 48V

172080

Current Distributor PCB

122745

Energy-eater incl. fan CB3

164229

Connector Epic w. cable UR10 CB3 (Controller output connector to robot arm)

171030

RAM module for Motherboard 3.0

171031

RAM module DDR3L for Motherboard 3.1

177503

Filter kit for controller

106800

Euromap E67 kit CB3

122671

Euromap E67 Bypass Plug

122673

Euromap E67 module CB3

123670

Euromap E67 cable 6 m

Robot arm:

111110

UR10 robotarm stand-alone CB3

164231

Cable: Base to Controller UR10

122071

Base Mounting Bracket UR10

122124

Joint Size 4 Base UR10

122224

Joint Size 4 Shoulder UR10

122324

Joint Size 3 Elbow UR10

104001

Elbow counterpart and Lower arm kit UR10

122122

Joint Size 2 Wrist 1 UR10

122222

Joint Size 2 Wrist 2 UR10

122322

Joint Size 2 Wrist 3 UR10

122061

Tool Mounting Bracket UR10

103310

Sealing set UR10, external. Visible flat rings between joints

103410

Lid set complete UR10 incl. seal in the lids

Item no.

Item designation

Accessories:

173101

Cable for tool, angle: external

131095

Lid, For tool connector. Tool protective cap Alu.

139033

Bracket for Mounting Teach Pendant

132407

Bracket for Mounting Controller

107000

Safety Control board Terminal Kit

131510

Bracket for mounting robot arm UR10 (Item & Bosch profile)

6.2 Service kit

Item no.

Item designation

109010

Service kit UR5/UR10 (kit includes all of the below part no.’s)

109101

Spanner Hex 5.5mm

UR5 & UR10

109102

Spanner Hex 7.0mm

UR5 & UR10

109110

Spanner Hex 10.0mm

UR10 only

Screwdriver Flat 2.5

UR3 & UR5 & UR10

109103

Screwdriver torx T10

UR5 & UR10

109105

Torque wrench Hex 5.5mm Size 1 and Size 2 (1.3 Nm)

UR5 & UR10

109106

Torque wrench Hex 7.0mm Size 3 (3.0 Nm)

UR5 & UR10

109107

Torque wrench Hex 10.0mm Size 4 (8.0 Nm)

UR10 only

109104

Torque screwdriver torx T8 + T10 (0.4 Nm)

UR3 & UR5 & UR10

109111

Torque screwdriver torx T10 (1.3 Nm)

UR3

109112

Torque screwdriver torx T20 (3.0 Nm)

UR3

164084

Bypass cable (for setting joint-ID)

UR3 & UR5 & UR10

109180

ESD wrist strap

UR3 & UR5 & UR10

Service kit box

UR3 & UR5 & UR10

7. Packing of robot

Packing of robot and controller box for shipment

 Remove any external tooling and external electrical connections.

 Download the Put_Into_Box program to a USB stick. Download it from:

http://www.universal-robots.com/support/

 Load program Put_into_box_ur10.urp and follow instructions while removing mounting bolts.

While robot folds together, hold a piece of bubble wrap between Shoulder joint and wrists.

Note: If robot cannot run or power is not available, it is possible to manually release the brakes for

each joint individually and pack the robot accordingly. For brake release, see 3.1.3 Brake release

 Power down, disconnect power and disconnect robot arm from controller.

 Pack robot arm and Controller box in designated boxes. Make sure the robot arm is orientated

correct in the box.

8. Change log

Date

Revision

Action

Changes

3. May 2014

UR10_en_3.0

Added

First revision 3.0 released

19. June 2014

UR10_en_3.0.1

Changed

Pictures and illustrations changed to match 3. gen. robot

11. July 2014

UR10_en_3.0.2

Changed

Error codes, Spareparts changed to match 3. Gen robot

and ESD handling added

20. Octo. 2014

UR10_en_3.1.1

Changed

Electrical doc., E-plan , Spare parts update and error code

update. New structure for disassemble/assemble guide.

ESD handling modified.

January 2016

UR10_en_3.1.2

Changed

Update of electrical drawings, Joint spare part adaption,

error codes. Dual robot calibration. Added Motherboard

3.1

December

2016

Added

3.1.4 Bolt length for joints

Added

Error code C71A12

Added

3.1.5 Added tolerance to Size 3 torque

Corrected

5.2 LED startup sequence

Service Manual UR10 En 3.1.3

Navigation menu

Versions of this User Manual:

Views

Navigation