ServiceManual_UR5_en_3.1.1 Service Manual UR5 En 3.1.1

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Service Manual
Revision UR5_en_3.1.1

Robot:
UR5 with CB3-controller

valid from robot s/n 2014350001

Contents


General information .................................................................................................................................. 4
1.1 Purpose .................................................................................................................................................... 4
1.2 Company details ...................................................................................................................................... 5
1.3 Disclaimer ................................................................................................................................................ 5



Preventive Maintenance ........................................................................................................................... 6
2.1 Controller ................................................................................................................................................. 6
2.1.1 Inspection plan, Safety Functions ..................................................................................................... 6
2.1.2 Visual inspection ............................................................................................................................... 7
2.1.3 Cleaning and replacement of filters ................................................................................................. 7
2.2 Robot arm ................................................................................................................................................ 8
2.2.1 Visual inspection ............................................................................................................................... 8



Service and Replacement of parts ............................................................................................................. 9
3.1 Robot arm ................................................................................................................................................ 9
3.1.1 Robot arm configuration .................................................................................................................. 9
3.1.2 Brake release .................................................................................................................................. 10
3.1.3 General guidance to separate joint from counterpart ................................................................... 11
3.1.4 Torque values ................................................................................................................................. 14
3.1.5 Base joint – Base mounting bracket ............................................................................................... 15
3.1.6 Shoulder joint – Base joint.............................................................................................................. 17
3.1.7 Upper arm – Shoulder joint ............................................................................................................ 19
3.1.8 Elbow joint – Upper arm................................................................................................................. 21
3.1.9 Elbow counterpart – Elbow joint .................................................................................................... 21
3.1.10 Wrist 1 joint – Lower arm ............................................................................................................. 23
3.1.11 Wrist 2 joint – Wrist 1 joint .......................................................................................................... 25
3.1.12 Wrist 3 joint – Wrist 2 joint .......................................................................................................... 27
3.1.13 Tool flange – Wrist 3 joint ............................................................................................................ 27
3.1.14 Joint calibration ............................................................................................................................ 29
3.1.15 Change joint ID ............................................................................................................................. 35
3.2 Controller ............................................................................................................................................... 37
3.2.1 Handling ESD-sensitive parts .......................................................................................................... 37
3.2.2 Replacement of motherboard ........................................................................................................ 41

Servicemanual_UR5_en_rev3.1.1

3.2.3 Replacement of Safety Control Board ............................................................................................ 44
3.2.4 Replacement of teach pendant ...................................................................................................... 46
3.2.5 Replacement of 48V power supply................................................................................................. 47
3.2.6 Replacement of 12V power supply................................................................................................. 50
3.2.7 Replacement of current distributor................................................................................................ 51
4.

Software .................................................................................................................................................. 52
4.1 Update software .................................................................................................................................... 52
4.2 Update joint firmware ........................................................................................................................... 54
4.3 Using Magic files .................................................................................................................................... 57

Troubleshooting ...................................................................................................................................... 58
5.1 Error codes............................................................................................................................................. 58
5.2

LED indicators on Safety Control Board .......................................................................................... 73

5.3 Error phenomena .................................................................................................................................. 74
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing ................................................................... 74
5.3.2 NO CABLE displayed during power up ............................................................................................ 75
5.3.3 Force limit protective stop ............................................................................................................. 76
5.3.4 Power on failure in Initializing ........................................................................................................ 77
5.3.5 Checklist after a collision ................................................................................................................ 80
5.4

Electrical drawing ............................................................................................................................ 81

5.4.1 Schematic overview ........................................................................................................................ 81
5.4.2 E-Plan diagrams .............................................................................................................................. 86
6

Spare parts............................................................................................................................................... 99
6.1 Spare part list......................................................................................................................................... 99
6.2 Service kit............................................................................................................................................. 100

Packing of robot..................................................................................................................................... 101

Changelog .............................................................................................................................................. 102
8.1 Changelog ............................................................................................................................................ 102

Servicemanual_UR5_en_rev3.1.1



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

Servicemanual_UR5_en_rev3.1.1

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.
Copyright © 2014 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

Servicemanual_UR5_en_rev3.1.1



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 the robot again
Test Teach mode:
o Set the robot in Teach mode by pressing the Teach 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 teach
button still pressed
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

Servicemanual_UR5_en_rev3.1.1

2.1.2 Visual inspection






Disconnect power cable from controller
Open cabinet door
Check connectors are properly inserted on printed circuit boards
Check for any dirt/dust inside of controller
If any dirt/dust is present:
»
gently use a vacuum cleaner to remove particles

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
»
Replace filters if necessary

Servicemanual_UR5_en_rev3.1.1

2.2 Robot arm

2.2.1 Visual inspection







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.

Servicemanual_UR5_en_rev3.1.1



Service and Replacement of parts

3.1 Robot arm
3.1.1 Robot arm configuration
3.1.13 Tool flange – Wrist 3 joint
J5
Wrist 3
Tool flange

3.1.12 Wrist 3 joint – Wrist 2 joint
3.1.11 Wrist 2 joint– Wrist 1 joint

J4
Wrist 2

J3
Wrist 1

3.1.10 Wrist 1 joint – Lower arm
Lower arm

J2
Elbow

Elbow counter part

3.1.9 Elbow counter part – Elbow joint

Upper arm

3.1.8 Elbow joint – Upper arm
3.1.7 Upper arm – Shoulder joint
3.1.6 Shoulder joint – Base joint

J1
Shoulder

J0
Base

3.1.5 Base joint – Base mounting bracket
Base mounting bracket

Servicemanual_UR5_en_rev3.1.1

3.1.2 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 tooling 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 no personnel are located under the arm when releasing the brake.
 Do not move the joint more than necessary, absolute max. is 180 degrees in order for the robot to
find its original physical position.

Procedure for releasing the joint


Shut down Controller.



Remove blue lid on joint.



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

Brake on Base, Shoulder and Elbow joints,


Brake on Wrist joints

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

Servicemanual_UR5_en_rev3.1.1

3.1.3 General guidance to separate joint from counterpart
Disassemble:
1. Shut down the controller.
2. Move the robot to a comfortable position for disassembly. If necessary dismount entire robot arm
from work cell and place on a solid surface.
3. Remove blue lid.
4. Now screw back one of the lid screws into a pol. Clip on your ESD wristband/alligator clip as shown
below.

5. Disconnect wires.
6. Remove alignment screw.

Servicemanual_UR5_en_rev3.1.1

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

8. 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.
9. 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.

Servicemanual_UR5_en_rev3.1.1

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, and then tighten in cross order with the correct torque.
See Section 3.1.4 Torque value.
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 wires before they are 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 3.1.14 Joint calibration for calibrating the joint.

Servicemanual_UR5_en_rev3.1.1

3.1.4 Torque values
UR5 torque values
CONNECTION
BASE PLATE
J0 BASE
[J0] BASE
J[1] Shoulder
[J1] SHOULDER
LOWER ARM
LOWER ARM
[J2] ELBOW
[J2] ELBOW
HIGHER ARM
HIGHER ARM
[J3] WRIST 1
[J3] WRIST 1
[J4] WRIST 2
[J4] WRIST 2
[J5] WRIST 3
[J5] WRIST 3
TOOL
Alignment screw
Blue lid

TORQUE
3.0Nm
3.0Nm
3.0Nm
3.0Nm
3.0Nm
1.3Nm
1.3Nm
1.3Nm
1.3Nm
0.4Nm
0.4Nm

HEAD SIZE
7 mm.
7 mm.
7 mm.
7 mm.
7 mm.
5.5 mm.
5.5 mm.
5.5 mm.
5.5 mm.
Torx T10
Torx T10

Attention: Click the torque tools 3 times before use to get the correct calibrated torque.
1.3Nm
1.3Nm

1.3Nm

3.0Nm

Servicemanual_UR5_en_rev3.1.1

3.1.5 Base joint – Base mounting bracket
Disassemble
For details and photos please see: 3.1.3 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 plate 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 plate from Base joint.
7. Disconnect wires between base plate and Base joint.
1 x red wire
= 48V DC
1 x black wire
= GND
Black connector
= bus cable

Servicemanual_UR5_en_rev3.1.1

Base joint – Base mounting bracket: Assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Replace base plate and reconnect wires according to illustration:

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)

2. Gently insert base plate with screws and washers into the Base joint.
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, and then tighten in cross order with 3.0Nm.
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. Mount blue lid on Base joint and tighten with 0.4Nm.

Servicemanual_UR5_en_rev3.1.1

3.1.6 Shoulder joint – Base joint
Disassemble
For details and photos please see: 3.1.3 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
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 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.

Servicemanual_UR5_en_rev3.1.1

Shoulder joint – Base joint: Assemble
For details and photos please see: 3.1.3 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 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 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. Connect ESD wristband
7. Reconnect connectors as illustrated.

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)

8. Mount blue lid on Base joint and tighten with 0.4Nm.
9. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

Servicemanual_UR5_en_rev3.1.1

3.1.7 Upper arm – Shoulder joint
Disassemble
For details and photos please see: 3.1.3 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. Unmount screws around the upper arm as indicated on the illustration:

7. Pull away the Shoulder joint from upper arm.

Servicemanual_UR5_en_rev3.1.1

Upper arm – Shoulder joint: Assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Gently assembly the Shoulder joint with upper arm end mount screws into shoulder joint.
2. Tighten the 10 screws lightly, and then tighten in cross order with 3.0Nm.
3. Mount the alignment screw and tighten with 0.4Nm.
4. Connect ESD wristband
5. Reconnect wires correctly.

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)

6. Mount blue lid on Shoulder joint and tighten with 0.4Nm.
7. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

Servicemanual_UR5_en_rev3.1.1

3.1.8 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 3.1.7 Upper arm - Shoulder joint.

3.1.9 Elbow counterpart – Elbow joint
Disassemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Shut down the controller.
2. Remove alignment screw
3. 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.
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 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).
6. Pull away the Elbow joint from Elbow counterpart.
7. 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)

Servicemanual_UR5_en_rev3.1.1

Elbow counterpart – Elbow joint: assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1.

Reconnect connectors.

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)
2. Gently insert Elbow joint with screws and washers into the Elbow counterpart.
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. Tighten the 10 screws lightly, and then tighten in cross order with 3.0Nm.
5. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
6. Mount the alignment screw and tighten with 0.4Nm.
7. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

Servicemanual_UR5_en_rev3.1.1

3.1.10 Wrist 1 joint – Lower arm
Disassemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Shut down the controller.
2. Remove blue lid on Wrist 1 joint.
3. Connect ESD wristband
4. 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)
5. Remove alignment screw
6. 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.
7. 8 screws become visible, 4 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.

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

Servicemanual_UR5_en_rev3.1.1

Wrist 1 joint – Lower arm: Assemble
For details and photos please see: 3.1.3 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 8 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.

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)

8. Mount blue lid on Wrist 1 joint and tighten with 0.4Nm.
9. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

Servicemanual_UR5_en_rev3.1.1

3.1.11 Wrist 2 joint – Wrist 1 joint
Disassemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Shut down the controller.
2. Remove blue lid on Wrist 1 joint.
3. Connect ESD wristband
4. Disconnect wires between Wrist 1 joint and Wrist 2 joint
1 x red wire
1 x black wire
Black connector

= 48V DC
= GND
= bus cable (NB: polarized)

5. Remove alignment screw
6. 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.
7. Slide the grey Teflon ring back. 8 screws become visible, 4 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.
8. 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).
9. Pull away Wrist 1 joint from Wrist 2 joint.

Servicemanual_UR5_en_rev3.1.1

Wrist 2 joint – Wrist 1 joint: Assemble
For details and photos please see: 3.1.3 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 8 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.

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)

8. Mount blue lid on Wrist 1 joint and tighten with 0.4Nm.
9. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

Servicemanual_UR5_en_rev3.1.1

3.1.12 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 3.1.11 Wrist 2 joint – Wrist 1 joint.

3.1.13 Tool flange – Wrist 3 joint
Disassemble
For details and photos please see: 3.1.3 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.
10. Slide the grey Teflon ring back. 8 screws become visible, 4 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.
4. 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).
5. Pull away the tool flange from Wrist 3 joint.
6. Connect ESD wristband
7. Disconnect the two connectors.

Servicemanual_UR5_en_rev3.1.1

Tool flange – Wrist 3 joint: Assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart

1. Connect ESD wristband
2. Replace tool flange and reconnect connectors as illustrated.

Twist the communication wires before they are connected.
(To reduce electrical noise in the system)

3. Gently insert tool flange with screws and washers into the Wrist 3 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. Tighten the 8 screws lightly, and then tighten in cross order with 1.3Nm.
6. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
7. Mount the alignment screw and tighten with 0.4Nm.

Servicemanual_UR5_en_rev3.1.1

3.1.14 Joint calibration
After replacement calibration of the new joint is required in order to find the correct zero position.
Instructions for calibrating a joint:


Jog robot to HOME position

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

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



Enter password lightbot and press OK.

Servicemanual_UR5_en_rev3.1.1

lightbot



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



Press Turn power on for enabling power to joints.



Press Go to Idle for enabling the joints ready mode.

Servicemanual_UR5_en_rev3.1.1



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



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

Servicemanual_UR5_en_rev3.1.1

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.

Servicemanual_UR5_en_rev3.1.1



Zero position illustrations
Base:

Shoulder, Elbow, Wrist 1:

Base zero position is aligned so that the
output flange is offset 180 degree from
the cable in back of robot base.

Shoulder, Elbow and Wrist 1 zero output flange is
vertical aligned (if Base if horizontal).
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
to Base joint, with tool flange parallel
with wrist

Wrist 3 zero position is aligned so tool connector
is pointing upward.
Mount two bolts in tool holes and use spirit level
to align joint.

Servicemanual_UR5_en_rev3.1.1



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



Press Back to exit Low Level Control.



Press Return to Normal.



Verify zero position by moving the robot to HOME.
If not satisfied with the zero position, perform the procedure once again.

Servicemanual_UR5_en_rev3.1.1

3.1.15 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
J0
J1
J2
J3
J4
J5

Joint
Base
Shoulder
Elbow
Wrist 1
Wrist 2
Wrist 3

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

Disconnect the joint with correct ID no.
Enter Low Level Control
Press Turn power on and the connected joints turn into BOOTLOADER



Press Go to Idle and the connected joints turn into READY



Select Joint ID

Servicemanual_UR5_en_rev3.1.1






Select J5 (The one to be changed)
Uncheck “Exchange IDs” box
In dropdown box, select ID no. 3
Press Set it



Confirm Change ID



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

Servicemanual_UR5_en_rev3.1.1

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:

Keep the ESD-sensitive part in its
original shipping container.
(a special "ESD bag") until the part is ready to
be installed

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.

Servicemanual_UR5_en_rev3.1.1

Step 1:

Step 2:

Put OLD board into spare ESD bag.

Take NEW board out of ESD bag.

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.

Servicemanual_UR5_en_rev3.1.1

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.)

Servicemanual_UR5_en_rev3.1.1

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.

Servicemanual_UR5_en_rev3.1.1

3.2.2 Replacement of motherboard
Take care of ESD handling 3.2.1 Handling ESD-sensitive parts
How to replace motherboard in Controller box


Shut down the controller and disconnect the power cable, open the controller cabinet and
loosen the 3 Torx screws



Remove the aluminum cover plate

Servicemanual_UR5_en_rev3.1.1



Disconnect cable connections from motherboard:
2x RJ45 network cables
Black USB cable
DVI-cable
Black cable for RS232-connection
White plug with white, brown, yellow and green wires

Servicemanual_UR5_en_rev3.1.1



Remove the 4 screws from the 2 holding brackets

NB! Ethernet cable to Safety control Board


Replace Motherboard with new one



If controller is equipped with long-hole brackets, make sure to replace them with circular-hole
brackets. Tighten the 4 screws gently



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



Re-install Flash card and RAM block



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



Connect power and verify that teach pendant works properly

Servicemanual_UR5_en_rev3.1.1

3.2.3 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


Shut down the controller and disconnect the power cable, open the controller cabinet and
loosen the 5 Torx screws



Carefully remove all plugs and connectors (it is recommended to mark the cable positions or
take a picture of them).



Remove the aluminum cover plate.

Servicemanual_UR5_en_rev3.1.1



Carefully remove all plugs and connectors (it is recommended to mark the cable positions or
take a picture of them).



Remove 13 screws holding the Safety Control Board.



Replace Safety Control Board with new one and tighten the 13 screws to hold the board



Insert all connectors and plugs in correct positions. Eventually see section 5.4.1 Schematic
overview



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



Connect power and verify that teach pendant works properly.

Servicemanual_UR5_en_rev3.1.1

3.2.4 Replacement of teach pendant
Take care of ESD handling 3.2.1 Handling ESD-sensitive parts
How to replace Teach Pendant on Controller
Note: use the same procedure for power down and removing the aluminum cover plates as in
chapter 3.2.2 Replacement of motherboard and 3.2.3 Replacement of Safety Control Board


Disconnect 4 cables:
Red plug with black cable
Black USB cable
Black DVI cable
Black cable for RS232-connection to touchscreen
Pull Red plug with black cable through rubber gasket.



Remove the bracket (foot of the controller box) that holds the cable inlet and pull out the
cables and plugs through this hole.



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.
Connect power and verify that teach pendant works properly.



Servicemanual_UR5_en_rev3.1.1

3.2.5 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 and 3.2.3 Replacement of Safety Control Board


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



Removes the 2 wires for the fan.

Servicemanual_UR5_en_rev3.1.1



Remove the 2 nuts in the bottom of Controller module.



Gently take out the controller module from the Controller box without disconnecting the robot
cable and power cable.



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.

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

Servicemanual_UR5_en_rev3.1.1



Replace 48V power supply with new one.



Reconnect the wires for the 48V power supply.



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



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



Connect power and verify that teach pendant works properly.

Servicemanual_UR5_en_rev3.1.1

3.2.6 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 3.2.4 Replacement of teach pendant
To replace the 12V power supply follow exactly the same steps as for the procedure in
chapter 3.2.5 Replacement of 48V power supply


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



Replace 12V power supply with new one.



Reconnect the wires for the 12V power supply.



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



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



Connect power and verify that teach pendant works properly.

Servicemanual_UR5_en_rev3.1.1

3.2.7 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 chapter3.2.4 Replacement of teach pendant


Current distributor is placed on top of rack.



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



Replace current distributor with new one.



Reconnect the wires for the current distributor.



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



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



Connect power and verify that teach pendant works properly.

Servicemanual_UR5_en_rev3.1.1

4. Software

4.1 Update software
Universal Robots software is named PolyScope.
This software can be updated, when new releases of software become available.
When updating software from an older version, updates must be installed sequentially.
If it ain’t broke, don’t fix it:
If a robot is operating in an existing application, Universal Robots do not recommend updating software,
unless the use of new functions in a newer software release is required for this application.

IMPORTANT NOTICE:
 Software should only be updated after consulting Distributor from which the robot has been
purchased or after consulting Universal Robots if representing a Distributor.
 Universal Robots do not recommend updating software without proper instruction in how to carry
out updates.
 When updating firmware controller power MUST NOT be turned off during update.
 Universal Robots can by no means be held responsible for any failed update caused by improper
operation.

Go to www.support.universal-robots.com/download for downloading software updates.
A login is required, which is only available to Distributors.
Please note: If representing an end customer, contact the Distributor from which the robot has been
purchased to request software updates.

Instructions to updat software:
 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.
 Save it in the root folder on a USB-stick.
 Insert USB-stick into USB-connector on right-hand side of teach pendant.
 Go to main screen of PolyScope.

Servicemanual_UR5_en_rev3.1.1




Press button SETUP Robot.
In left side menu, select UPDATE Robot.



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






Select the found software update and press UPDATE.
Press YES to update the software.
Wait for update to complete, after successful update controller will automatically power off.
Remove USB-stick and boot robot.

Servicemanual_UR5_en_rev3.1.1

4.2 Update joint firmware
Each joint on the robot contains firmware to control the joint.
For normal operation firmware update is not required. Software can be updated on robot without updating
the firmware.
IMPORTANT NOTICE:
 Firmware should only be updated after consulting Distributor from which the robot has been
purchased or after consulting Universal Robots if representing a Distributor.
 Universal Robots do not recommend updating firmware without proper instruction in how to
update firmware.
 When updating firmware controller power MUST NOT be turned off during update.
 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 for updating software. When updating robot software, the firmware will
automatically be copied to a folder on the controller.


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

Servicemanual_UR5_en_rev3.1.1



Enter password lightbot and press OK.

lightbot



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



Press Turn power on to go into BOOTLOADER



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



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

Servicemanual_UR5_en_rev3.1.1



Controller MUST NOT be powered off during this update.
After successful update, press Back.



Back in Expert Mode, press Return to Normal.

Firmware has now been updated.

Servicemanual_UR5_en_rev3.1.1

4.3 Using Magic files
For easy backup, Universal Robots provides Magic files to automatically copy data from controller to USBstick.
These files are available:
 URmagic log file
 URmagic backup programs
 URmagic configuration files
 URmagic upload programs
 URmagic screenshot

Function:
copies the entire log history file to USB-stick
copies all programs and installation files to USB-stick
copies all configuration files to USB-stick
copies all programs and installation files from USB-stick
generates a screenshot of GUI when USB-stick is inserted

Go to www.support.universal-robots.com/download to download Magic files.
A login is required, which is only available to Distributors.
Please note: If representing an end customer, contact the Distributor from which the robot has been
purchased to request Magic files.

Instruction for using Magic files
 Download Magic file.
 Save it in the root folder on a USB-stick.
 Insert USB-stick into USB-connector on right-hand side of teach pendant.
 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.
 Await a green <- USB -sign appears on the screen, the USB-stick can then be safely removed.
 Remove USB-stick and the process is complete.
The Magic file creates a folder on USB-stick named with the serial number of robot.
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.

Servicemanual_UR5_en_rev3.1.1

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
PC = Motherboard

Open log files with Support Log Reader.
Go to www.support.universal-robots.com/download to download Support Log Reader

5.1 Error codes
Code

Error description

CODE_0
CODE_1
CODE_1A1

CODE_2
CODE_3

No error
Outbuffer overflow error
Buffer of stored warnings
overflowed
Outbuffer to RS485
overflowed (problem with PCs
message)
Inbuffer overflow error
Processor overloaded error

CODE_4
CODE_4A1

Broken communication
Communication with PC lost.

CODE_4A2

Communication with Safety
Control Board A uP lost

CODE_1A2

CODE_4A3

Communication with Safety
Control Board B uP lost

CODE_4A4

Communication with primary
Teach Pendant uP lost

CODE_4A5

Communication with
secondary Teach Pendant uP
lost

Explanation

How to fix

Processor in any part could give
this error.
Between Safety Control Board
and Motherboard
If either processor A or
processer B is communicating,
the Safety Control Board or
cable between the
Motherboard and Safety
Control Board is defect
If either processor A or
processer B is communicating,
the Safety Control Board or
cable between the
Motherboard and Safety
Control Board is defect
If either processor A or
processer B is communicating,
the Teach Pendant or cable
between the Motherboard and
Teach Pendant is defect
If either processor A or
processer B is communicating,
the Teach Pendant or cable
between the Motherboard and
Teach Pendant is defect
58

a) Check TCP/IP connection
between Motherboard and
Safety Control Board. b)
Exchange Safety Control
Board
a) Check TCP/IP connection
between Motherboard and
Safety Control Board. b)
Exchange Safety Control
Board
a) Check TCP/IP-12V
connection between
Motherboard and Teach
Pendant. b) Exchange
Teach Pendant
a) Check TCP/IP-12V
connection between
Motherboard and Teach
Pendant. b) Exchange
Teach Pendant

Servicemanual_UR5_en_rev3.1.1

CODE_4A6

Communication with primary
EUROMAP67 uP lost

CODE_4A7

Communication with
secondary EUROMAP67 uP
lost

CODE_4A8

Primary EUROMAP67 uP
present, but euromap67 is
disabled
Secondary EUROMAP67 uP
present, but euromap67 is
disabled
Primary Teach Pendant
present, but Teach Pendant
safety is disabled
Secondary Teach Pendant uP
present, Teach Pendant safety
is disabled
Communication with joint 0
lost
Communication with joint 1
lost
Communication with joint 2
lost
Communication with joint 3
lost
Communication with joint 4
lost
Communication with joint 5
lost
Communication with tool lost
Lost package from Primary
Teach Pendant
Lost package from Secondary
Teach Pendant
Lost package from Primary
Euromap67
Lost package from Secondary
Euromap67
Lost package from Secondary
Masterboard
Lost package from joint 0
Lost package from joint 1
Lost package from joint 2
Lost package from joint 3
Lost package from joint 4
Lost package from joint 5

CODE_4A9

CODE_4A10

CODE_4A11

CODE_4A12
CODE_4A13
CODE_4A14
CODE_4A15
CODE_4A16
CODE_4A17
CODE_4A18
CODE_4A65
CODE_4A66
CODE_4A67
CODE_4A68
CODE_4A69
CODE_4A70
CODE_4A71
CODE_4A72
CODE_4A73
CODE_4A74
CODE_4A75

If either processor A or
processer B is communicating,
Euromap67 or cable between
the Motherboard and Euromap
is defect
If either processor A or
processer B is communicating,
Euromap67 or cable between
the Motherboard and Euromap
is defect

Incorrect safety configuration

a) Check Euromap67
connection between
Motherboard and
Euromap67. b) Exchange
Euromap67
a) Check Euromap67
connection between
Motherboard and
Euromap67. b) Exchange
Euromap67
Update the miscellaneous
settings in the Safety
Configuration
Update the miscellaneous
settings in the Safety
Configuration
Update the miscellaneous
settings in the Safety
Configuration
Update the miscellaneous
settings in the Safety
Configuration

More than 1 package lost
More than 1 package lost
More than 1 package lost
More than 1 package lost
More than 1 package lost
More than 1 package lost
More than 1 package lost
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
59

Servicemanual_UR5_en_rev3.1.1

CODE_4A76
CODE_4A77

CODE_10A1

Lost package from tool
Lost package from uPA to
joints
Lost package from uPA to
teach pendant
Lost package from uPA to uPB
Lost package from uPB
Packet counter disagreement
in packet from Primary
Screen
Packet counter disagreement
in packet from Secondary
Screen
Packet counter disagreement
in packet from Primary
Euromap67
Packet counter disagreement
in packet from Secondary
Euromap67
Packet counter disagreement
in packet from Safety Control
Board B
Packet counter disagreement
in packet from joint 0
Packet counter disagreement
in packet from joint 1
Packet counter disagreement
in packet from joint 2
Packet counter disagreement
in packet from joint 3
Packet counter disagreement
in packet from joint 4
Packet counter disagreement
in packet from joint 5
Packet counter disagreement
in packet from tool
Packet counter disagreement
in packet from processor A to
joints
Packet counter disagreement
in packet from processor A to
B
Packet counter disagreement
in packet from processor A to
Teach Pendant and EUROMAP
Heavy processor load warning
Broken PC communication
error
Lost packet from PC

CODE_10A101

PC packet received too early

CODE_4A78
CODE_4A79
CODE_4A80
CODE_4A81

CODE_4A82

CODE_4A83

CODE_4A84

CODE_4A85

CODE_4A86
CODE_4A87
CODE_4A88
CODE_4A89
CODE_4A90
CODE_4A91
CODE_4A92
CODE_4A93

CODE_4A94

CODE_4A95

CODE_5
CODE_10

1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning
1 package lost - warning

Eventually update the
software
Eventually update the
software
Eventually update the
60

Servicemanual_UR5_en_rev3.1.1

CODE_10A102
CODE_10A103
CODE_11

CODE_12
CODE_14
CODE_17

CODE_26
CODE_27

CODE_29
CODE_30
CODE_31

CODE_32
CODE_33
CODE_34
CODE_34A0
CODE_34A1
CODE_35
CODE_36
CODE_37

Serial communication problem
with joint

software
Eventually update the
software
Eventually update the
software
Check black 2-wire
connectors and wires in
joints. Eventually 2 joints
with the same ID.

Communication error between
Safety Control Board and
Motherboard

Check ethernet connection
between circuit boards.
Eventually update the
software

Joint mechanical problem

Replace joint

Calibration data is not in the
joint

a) Power OFF and Power
ON. b) replace joint

Serial communication problem
with joint
Debug message

Check black 2-wire
connectors and wires in
joints
Ignor

Packet counter does not
match
PC is sending packets too
often
Bad CRC error

Unknown message error
Debug message
Inbuffer overflow in package
from PC

Motor Encoder index drift
detected
Calibration data is invalid or
does not exist, selftest is
needed!
Online Calibration data
checksum failed
Master received data from too
many joints
Caught wrong message (not
from master)
Flash write verify failed
Calibration flash checksum
failed
Program flash checksum failed
Program flash checksum failed
during bootloading
Program flash checksum failed
at runtime
Joint ID is undefined
Illegal bootloader command
Inbuffer parse error

Update Firmware
Update Firmware
Update Firmware
Debug message
Serial communication problem
with joint

CODE_38
CODE_38A1
CODE_38A2
CODE_38A3
CODE_38A4
CODE_38A5
CODE_39

Online RAM test failed
Data-bus test failed
Address-bus stuck-high test
failed
Address-bus stuck-low test
failed
Address-bus shorted test
failed
Memory-cell test failed
Logic and Temporal

Ignor
Check black 2-wire
connectors and wires in
joints
Replace Item
Replace Item
Replace Item
Replace Item
Replace Item
Replace Item

Servicemanual_UR5_en_rev3.1.1

CODE_39A1
CODE_39A2
CODE_39A3
CODE_39A4
CODE_39A5
CODE_39A6
CODE_39A7
CODE_39A100
CODE_39A101
CODE_39A102
CODE_39A103
CODE_39A104
CODE_39A105
CODE_39A106
CODE_39A107
CODE_40
CODE_44

Monitoring Fault
Max current deviation failure
Max joint-encoder speed
exceeded
Max motor-encoder speed
exceeded
Illegal state change in joint
detected
Too fast state change in joint
detected
5V regulator voltage too low
5V regulator voltage too high
Watchpoint fault: ADC task
timeout
Watchpoint fault: MotorControl task timeout
Watchpoint fault: Motorencoder task timeout
Watchpoint fault: Jointencoder task timeout
Watchpoint fault:
Communication task timeout
Watchpoint fault: RAM-test
task timeout
Watchpoint fault: CalVal-test
task timeout
Watchpoint fault: ROM-test
task timeout
AD-Converter hit high limit
joint
CRC check failure on primary
bus

CODE_44A0
CODE_44A1
CODE_44A2
CODE_44A3
CODE_44A4
CODE_44A5
CODE_44A6

Joint 0
Joint 1
Joint 2
Joint 3
Joint 4
Joint 5
Tool

CODE_45
CODE_46

AD-Converter error
Loose gearbox or bad encoder
mounting
AD-Converter hit low limit

CODE_47

CODE_48

Powerbus voltage drop
detected.

Replace joint
Replace joint

EMC issue external or
electronics internal
Serial communication problem
with joint or secondary bus
node

Mechanical problem in gear
related to encoder mounting

Check grounding and
shielding for EMC problems
Check black 2-wire
connectors and wires in
joints
Replace joint 0
Replace joint 1
Replace joint 2
Replace joint 3
Replace joint 4
Replace joint 5
Replace Tool mounting
bracket
Replace Item

EMC issue external or
electronics internal

Replace joint
a) Check grounding and
shielding for EMC
problems. b) Replace Item

Error on 48V powerbus to robot
arm

Check 48V output from
PSU. Check currentdistributor PCB.

Servicemanual_UR5_en_rev3.1.1

Replacement of 48V PSU or
current-distributor is
necessary
CODE_49
CODE_49A200

RS485 receive warning
Secondary RS485 bus is down

CODE_50

Robot powerup failure

CODE_50A1

Voltage detected at 24V rail
before startup
Voltage present at unpowered
robot
Powersupply voltage too low
Powersupply voltage too high
Voltage not detected at 24V
rail after startup
Warning, waiting for
SafetySYS2
The Teach Pendant does not
respond

Bus for: Teach Pendant,
Processor A and Processor B on
the Safety Control Board.

Electrical error control box

CODE_50A2
CODE_50A5
CODE_50A6
CODE_50A11
CODE_50A15
CODE_50A16

CODE_50A17

CODE_50A18
CODE_50A20
CODE_50A21
CODE_50A22
CODE_50A23
CODE_50A24
CODE_50A25
CODE_50A26
CODE_50A27
CODE_50A28

24 V to the I/O interface in the
controller
SafetySYS2 = Processor B on
Safety Control Board
Loose wire or incorrect safety
configuration. Message comes
from Safety Control Board

The Euromap67 interface does
not respond

Warning, waiting for
SafetySYS1
5V, 3V3 or ADC error (5V too
high)
5V, 3V3 or ADC error (5V too
low)
Robot current sensor reading
too high
Robot current sensor reading
too low
48V not present (Check
internal connection)
Robot voltage present at 48V
PSU powereup
Voltage present on
unpowered 48V power supply
12V, 3V3 or ADC error (12V
too high)
12V, 3V3 or ADC error (12V

Check TCP/IP-12V cable to
Teach Pendant
Remove all external
connections to I/Ointerface of Safty Control
Board. Check for short
circuit. Argument of error
code specifies in details
what causes the error.

Loose wire or incorrect safety
configuration
SafetySYS1 = Processor A on
Safety Control Board

Check the cable or change
in the Safety Configuration
of the Installation the
miscellaneous settings
Check the cable or change
in the Safety Configuration
of the Installation the
miscellaneous settings

Servicemanual_UR5_en_rev3.1.1

CODE_50A29
CODE_50A30
CODE_50A31
CODE_50A80
CODE_50A81
CODE_50A82
CODE_50A83
CODE_50A84
CODE_50A85
CODE_50A99
CODE_50A100
CODE_50A101
CODE_50A102
CODE_50A103

too low)
Analog I/O error (-12V too
high)
Analog I/O error (-12V too
low)
The other safetySYS do not
initialize
Last CPU reset caused by LowPower-Reset
Last CPU reset caused by
Window-Watchdog-Reset
Last CPU reset caused by
Independent-Watchdog-Reset
Last CPU reset caused by
Software-Reset
Last CPU reset caused by
External-Pin-Reset
Last CPU reset caused by
Brown-Out-Reset
Wrong software on PCB
Cable not connected

Robot Problem: Robot Cable is
not detected
Robot Problem: 48V
Robot Problem: 48V

CODE_51A0
CODE_51A1
CODE_51A2
CODE_51A3
CODE_51A4
CODE_53

Short circuit in robot detected
Voltage rising too slowly
Voltage failed to reach
acceptable level
CRC check failure on
secondary bus
Processor B
Primary screen processor
Secondary screen processor
Primary E67
Secondary E67
IO overcurrent detected

CODE_53AMA
STER

IO overcurrent detected, max
is 800mA

Safety Control Board error

CODE_53ATO
OL
CODE_55

IO overcurrent detected, max
is 600mA
Safety system error

Tool error

CODE_51

Robot Problem: 48V

Safety Control Board error

Safety system malfunction

Remove all external
connections to I/Ointerface of Safety Control
Board. Check for short
circuit
Remove all external
connections to I/Ointerface of Safety Control
Board. Check for short
circuit
Remove tool connector.
Check for short circuit
Check Motherboard, Safety
Control Board,
Screenboard, Current
distributor( Euromap, if
installed ). Bypass safety

Servicemanual_UR5_en_rev3.1.1

connections to I/Ointerface of Safety Control
Board
CODE_55A23

Safety relay error (minus
connection)

Current distributor error

CODE_55A24

Safety relay error (plus
connection)

Current distributor error

CODE_55A33

Safety relay error (a relay is
stuck)

Current distributor error

CODE_55A34

Safety relay error (relays are
not on)

Current distributor error

CODE_55A50

Voltage present at unpowered
robot
Voltage will not disappear
from robot
5V, 3V3 or ADC error (5V too
low)
5V, 3V3 or ADC error (5V too
high)
Bootloader error, robot
voltage too low or current too
high
Bootloader error, robot
voltage too high
Safety violation
Safety Channel Error In Safety
Control Board
Safety Channel Error In Screen
Safety Channel Error In
Euromap67 Interface
Received fault message from
PC
Safety State is changing too
often
On/Off State is changing too
often
Robot current sensors
readings differ
Robot current is too high while
emergency stopped
Robot current is too high while
safeguard stopped

SCB hardware fault

CODE_55A51
CODE_55A52
CODE_55A53
CODE_55A90

CODE_55A91
CODE_55A100
CODE_55A101
CODE_55A102
CODE_55A103
CODE_55A109
CODE_55A110
CODE_55A111
CODE_55A112
CODE_55A120
CODE_55A121

SCB hardware fault
SCB hardware fault
SCB hardware fault

Fault: Cable SCB-Current
distributor or 48V Power
supply or Current
distributor.
Fault: Cable SCB-Current
distributor or 48V Power
supply or Current
distributor.
Fault: Cable SCB-Current
distributor or 48V Power
supply or Current
distributor.
Fault: Cable SCB-Current
distributor or 48V Power
supply or Current
distributor.
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)

Servicemanual_UR5_en_rev3.1.1

CODE_56

Overvoltage shutdown

CODE_57

Brake release failure

CODE_57A1

CODE_58
CODE_59

Joint did not move or motor
encoder is not functioning
Large movement detected
during brake release
Robot was not able to brake
release, see log for details
Motor encoder not calibrated
Overcurrent shutdown

CODE_62
CODE_62A1
CODE_62A3
CODE_62A11
CODE_62A13
CODE_63
CODE_68

Joint temperature
High (80 C)
Static load too high warning
Shut down (85 C)
Static load too high
Selftest failed
SPI error

CODE_70

Close to gearbox shear limit

CODE_71
CODE_71A1

Startup check error
Hardware is size1, software is
not
Hardware is size2, software is
not
Hardware is size3, software is
not
Hardware is size4, software is
not
Invalid hardware size read
Motor indication signal not
working
Phase 1 and phase 2 not
working

CODE_57A2
CODE_57A3

CODE_71A2
CODE_71A3
CODE_71A4
CODE_71A5
CODE_71A6
CODE_71A7

CODE_71A8

Phase 2 not working

CODE_71A9

Phase 1 not working

CODE_71A10

Invalid motor test result

Voltage exceeded 55V

Overcurrent in joint. Argument
= Current in Amps.

Warning
Warning
Stop
Stop

Check Energy Eater. Cable
to Energy eater, Replace
Energy Eater
Check Brake, solonoide,
Payload, TCP and Mount
Check Brake, solonoide,
Payload, TCP and Mount
Check Brake, solonoide,
Payload, TCP and Mount
Check Brake, solonoide,
Payload, TCP and Mount
Callibrate joint
Check for short circuit.
Check program for
singularity issues. Replace
joint if necessary

Check Payload

Joint: Absolut encoder on joint
communication error
Acceleration / deceleration to
high. Mechanical problem in
gear related to encoder
mounting
Fault: Firmware in joint
Fault: Firmware in joint

Replace joint
Reduce acceleration in user
program. Replace joint if
necessary

Fault: Firmware in joint
Fault: Firmware in joint
Fault: Firmware in joint

The motor wires are damaged
or bad connection in
screwterminals
The motor wires are damaged
or bad connection in
screwterminals
The motor wires are damaged
or bad connection in
screwterminals

Servicemanual_UR5_en_rev3.1.1

CODE_71A11
CODE_72
CODE_72A1

ADC calibration failed
Power Supply Unit failure
0 PSUs are active

Only in joint
48 V Power problem
PSU was not able to deliver 48V
(In UR10: No 48V)

CODE_72A2

1 PSU active, but we expect 2
(UR10)

PSU was not able to deliver 48V
or UR10 flash card in UR5 robot

CODE_72A3

UR5 flash card in UR10 robot

CODE_74

2 PSUs active, but we expect 1
(UR5)
Brake test failed during
selftest, check brakepin
Joint encoder warning

CODE_74A2

Speed reading is not valid

CODE_74A8

Supply voltage is out of range

CODE_74A16

Temperature is out of range

CODE_74A64

Signal low =Too far from
magnetic ring
Signal saturation =Too close to
magnetic ring
Joint encoder error

CODE_73

CODE_74A128
CODE_75
CODE_75A1

CODE_75A4

CODE_75A32
CODE_75A128
CODE_76
CODE_100
CODE_101
CODE_102
CODE_103
CODE_103A1
CODE_104

Invalid decode: Readhead
misalignment, ring damaged
or external magnetic field
present.
System error=malfunction or
inconsistent calibration
detected
Signal lost =Misaligned
readhead or damaged ring
Signal saturation =Too close to
magnetic ring
Joint encoder communication
CRC error
Robot changed mode
Real Robot Connected
Real Robot not connected Simulating Robot
UR Ethernet Error

Magnetic encoder error
(Absolut encoder)
If more 74 errors on one time
the argument is the sum
If more 74 errors on one time
the argument is the sum
If more 74 errors on one time
the argument is the sum
If more 74 errors on one time
the argument is the sum
If more 74 errors on one time
the argument is the sum
If more 75 errors on one time
the argument is the sum
If more 75 errors on one time
the argument is the sum

Check power connection
between power supply and
Safety Control Board
Check power connection
between power supply and
Safety Control Board and
check that the flash card
and robot match
Check that the flash card
and robot match

Look in the service manual
Look in the service manual
Look in the service manual
Look in the service manual
Look in the service manual
Look in the service manual
Look in the service manual

If more 75 errors on one time
the argument is the sum

Look in the service manual

If more 75 errors on one time
the argument is the sum
If more 75 errors on one time
the argument is the sum
Error between sensor and joint
circuit
Status warning, general modus
change

Look in the service manual

Comm. Prob. between Mother
Board and Safety Control Board

Check cable

Look in the service manual
Check connections or very
heavy electrical noise
Check preceding errors in
log history

3 packages in a row lost from
Safety Control Board
Error=Empty command sent to

Servicemanual_UR5_en_rev3.1.1

CODE_111
CODE_116

robot
Something is pulling the robot
Realtime part warning

CODE_117

Restart SCB failed

CODE_150

CODE_172
CODE_184
CODE_191
CODE_191A1
CODE_191A2

Protective Stop: Position close
to joint limits
Protective Stop: Tool
orientation close to limits
Protective Stop: Position close
to safety plane limits
Protective Stop: Position
deviates from path
Protective Stop: Position in
singularity
Protective Stop: Robot cannot
maintain its position, check if
payload is correct
Protective Stop: Wrong
payload or mounting
detected, or something is
pushing the robot when
entering Teach mode
Illegal control mode
Joint self test not completed
Safety system violation
Joint position limit violated
Joint speed limit violated

CODE_191A3

TCP speed limit violated

CODE_191A4
CODE_191A5
CODE_191A6

TCP position limit violated
TCP orientation limit violated
Power limit violated

CODE_191A7
CODE_191A8
CODE_191A9

Joint torque window violated
Joint torque window too large
Reduced mode output
violation
Safeguard stop output
violation
Emergency stop output
violation
Momentum limit violation
Robot moving output violation
Robot is not braking in stop
mode
Robot is moving in stop mode

CODE_151
CODE_152
CODE_153
CODE_154
CODE_155

CODE_156

CODE_191A10
CODE_191A11
CODE_191A12
CODE_191A13
CODE_191A14
CODE_191A15

Possible CPU-overload due to
structure of user program
The Safety Control Board
couldn't be rebooted from the
controller.

Check Payload setting
Restructure user program
Reboot the robot

Robot can not move linear in a
singularity

Use jointspace movement
or change the motion

The robot may move
unexpected due to wrong
settings

Verify that the TCP
configuration and
mounting in the used
installation is correct

Reduce acceleration or
speed for joint
Reduce acceleration or
speed for joint

Reduce acceleration or
speed for joint
Software problem
Software problem
Software problem
Software problem
Software problem

Servicemanual_UR5_en_rev3.1.1

CODE_191A16
CODE_191A17
CODE_191A18
CODE_191A19
CODE_191A20
CODE_191A21
CODE_191A22
CODE_191A23
CODE_191A24
CODE_191A25
CODE_191A26
CODE_191A27
CODE_191A28
CODE_191A29
CODE_191A30
CODE_192
CODE_192A1
CODE_192A2
CODE_192A3
CODE_192A4

Robot did not stop in time
Received a null vector for TCP
orientation
Robot not stopping output
violation
Invalid safety IO configuration
Configuration information or
limit sets not received
The other safety processor
detected a violation
Received unknown command
from PC
Invalid setup of safety limits
Reduced Mode Output set,
while it should not be
Reduced Mode Output not
set, while it should be
Not Reduced Mode Output
set, while it should not be
Not Reduced Mode Output
not set, while it should be
Robot Emergency Stop
exceeded maximum stop time
System Emergency Stop
exceeded maximum stop time
Safeguard Stop exceeded
maximum stop time
Safety system fault
Robot still powered in
emergency stop
Robot emergency stop
disagreement
System emergency stop
disagreement
Safeguard stop disagreement

CODE_192A5

Euromap safeguard stop
disagreement

CODE_192A6

Joint position disagreement

CODE_192A7

Joint speed disagreement

CODE_192A8

Joint torque disagreement

CODE_192A9

TCP speed disagreement

CODE_192A10

TCP position disagreement

CODE_192A11

TCP orientation disagreement

Fault in config file, when no GUI
is used
Software problem
Fault in config file, when no GUI
is used
Software problem

Check Firmware
Check Firmware
Check Firmware
Check Firmware
Check Firmware
Check Firmware
Much too high payload
Much too high payload
Much too high payload

E-stop in teach pendant or in
Robot E-stop circuit problem
System E-stop circuit problem
Safeguard circuit problem
Euromap circuit problem

Check cables or replace
Safety Control Board (SCB)
Check cables or replace
Safety Control Board (SCB)
Check cables or replace
Safety Control Board (SCB)
Check cables from Safety
Control Board to Euromap
to external machine
Reduce payload, check for
encoder problems
Reduce payload, check for
encoder problems
Reduce payload, check for
encoder problems
Reduce payload, check for
encoder problems
Reduce payload, check for
encoder problems
Reduce payload, check for

Servicemanual_UR5_en_rev3.1.1

encoder problems
CODE_192A12
CODE_192A13
CODE_192A14
CODE_192A15
CODE_192A16
CODE_192A17
CODE_192A18
CODE_192A19
CODE_192A20
CODE_192A21
CODE_192A22
CODE_192A23
CODE_192A24
CODE_192A25
CODE_192A26
CODE_192A27
CODE_192A28
CODE_192A29
CODE_192A30
CODE_192A31
CODE_192A32
CODE_192A33
CODE_192A34

CODE_192A35

CODE_192A36
CODE_192A37
CODE_193

Power disagreement
Joint torque window
disagreement
Reduced mode input
disagreement
Reduced mode output
disagreement
Safety output failed
Safeguard stop output
disagreement
The other safety processor is
in fault
Emergency stop output
disagreement
SPI output error detected
Momentum disagreement
Robot moving output
disagreement
Wrong processor ID
Wrong processor revision
Potential brownout detected
Emergency stop output
disagreement
Safeguard stop output
disagreement
Robot not stopping output
disagreement
Safeguard reset input
disagreement
Safety processor booted up in
fault mode
Reduced Mode Output
disagreement
Not Reduced Mode Output
disagreement
Checksum disagreement
between uA and uB
User safety config checksum
disagreement between uA and
GUI
Robot config checksum
disagreement between uA and
GUI
Online RAM test failed
Not all safety related
functionalities are running
One of the nodes is in fault
mode

Only in joint
Communication error or
Safety I/O uP-A and uP-B
disagreement
Safety I/O uP-A and uP-B
disagreement

Check cables

Safety I/O uP-A and uP-B
disagreement

Check Cables and Software
error on motherboard

Safety I/O uP-A and uP-B
disagreement
Cafety Control Board

Check Cables and Software
error on motherboard
Check 24 V supply

Safety I/O uP-A and uP-B
disagreement

Check Cables and Software
error on motherboard

Voltage drop on Safety Control
Board(SCB) or defect SCB
Safety I/O uP-A and uP-B
disagreement
Safety I/O uP-A and uP-B
disagreement
Safety I/O uP-A and uP-B
disagreement
Safety I/O uP-A and uP-B
disagreement

Safety I/O uP-A and uP-B
disagreement
Safety I/O uP-A and uP-B
disagreement
Problem in Software

Check Cables and Software
error on motherboard
Check Cables and Software
error on motherboard
Check Cables and Software
error on motherboard
Check cables

Check Cables and Software
error on motherboard
Check Cables and Software
error on motherboard

Problem in Software

SCB has detected an error

See previous error

Servicemanual_UR5_en_rev3.1.1

CODE_193A0
CODE_193A1
CODE_193A2
CODE_193A3
CODE_193A4
CODE_193A5
CODE_193A6
CODE_193A7
CODE_193A8
CODE_193A9
CODE_193A10
CODE_194
CODE_194A0
CODE_194A1
CODE_194A2
CODE_194A3
CODE_194A4
CODE_194A5
CODE_194A6
CODE_194A7
CODE_194A8
CODE_194A9
CODE_194A10
CODE_195

Joint 0
Joint 1
Joint 2
Joint 3
Joint 4
Joint 5
Tool
Screen 1
Screen 2
Euromap 1
Euromap 2
One of the nodes is not
booted or not present
Joint 0
Joint 1
Joint 2
Joint 3
Joint 4
Joint 5
Tool
Screen 1
Screen 2
Euromap 1
Euromap 2
Conveyor speed too high

CODE_196

MoveP speed too high

CODE_197
CODE_200
CODE_200A1

Blend overlap warning
Safety Control Board
hardware error
Hardware ID is wrong

CODE_200A2
CODE_200A3
CODE_200A4

MCU type is wrong
Part ID is wrong
RAM test failed

SCB: uP-A has detected an
error: Wrong SCB
SCB: uP-A has detected an error
SCB: uP-A has detected an error
SCB: uP-A has detected an error

CODE_200A5

SCB: uP-A has detected an error

CODE_200A6

pRom Crc test failed

CODE_200A7
CODE_200A8

Watchdog reset the processor
OVG signal test not passed

CODE_200A9

3V3A power good pin is low

SCB: uP-A has detected an
error: firmware error
SCB: uP-A has detected an error
SCB: uP-A has detected an
error: over voltage generator
SCB: uP-A has detected an error

CODE_200A10

3V3B power good pin is low

SCB: uP-A has detected an error

SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error
SCB has detected an error

See previous error
See previous error
See previous error
See previous error
See previous error
See previous error
See previous error
See previous error
See previous error
See previous error
See previous error

Make sure that conveyor
tracking is set correct up
Reduce speed or increase
blend radius in user
program

SCB: uP-A has detected an error

Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control

Servicemanual_UR5_en_rev3.1.1

CODE_200A11

5V power good is low

SCB: uP-A has detected an error

CODE_200A12

3V3 voltage too low

SCB: uP-A has detected an error

CODE_200A13

3v3 voltage too high

SCB: uP-A has detected an error

CODE_200A14

48V input is too low

CODE_200A15

48V input is too high

CODE_200A16

24V IO short circuited

Too high current

CODE_200A17

PC current is too high

Motherboard takes too high
current

CODE_200A18

Robot voltage is too low

CODE_200A19

Robot voltage is too high

CODE_200A20

24V IO voltage is too low

CODE_200A21

12V voltage is too high

CODE_200A22

12V voltage is too low

CODE_200A23

CODE_200A25

It took too long to stabilize
24V
It took too long to stabilize
24V IO
24V voltage is too high

CODE_200A26

24V IO voltage is too high

CODE_201

Setup of safety board failed

Invalid safety parameters have
been received

CODE_203

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

CODE_200A24

SCB error
SCB error
Safety Control Board error(SCB)

Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Replace Safety Control
Board (SCB)
Check: 48 V power supply,
current distributer energy
eater or replace SCB
Check: 48 V power supply,
current distributer energy
eater or replace SCB
Disconnect external
connections

Check: Short circuit in
robot arm, 48 V power
supply, current distributer
energy eater or replace
SCB
Check: 48 V power supply,
current distributer energy
eater or replace SCB
Disconnect I/O or replace
SCB
Check 12 V power supply,
cables or replace SCB
Check 12 V power supply,
cables or replace SCB
External 24 V problem or
replace SCB
External 24 V problem or
replace SCB
Replace Safety Control
Board (SCB)
Disconnect I/O or replace
SCB
Verify that the setup of the
Safety Configuration is
valid
Reload the installation

Servicemanual_UR5_en_rev3.1.1

5.2 LED indicators on Safety Control Board
Safety Control Board (SCB)













12V-PSU
12V
5V
-4V
3V3A
3V3B
48V
24V
R
A
B

On when the power plug is connected.
System: On when the power on has been activated
On when “12 V System” is on and indicate that 5 V is ok.
On when “12 V System” is on and indicate that - 4 V to analog I/O is ok.
On when 5V is on and indicate 3.3 V for logic Safety circuit A
On when 5V is on and indicate 3.3 V for logic Safety circuit B
48 V is present on the safety control board
48 V is detected and ok, indicate that internal 24 V is present for I/O’s
48 V on robot arm
Status for Logic A: a blink sequence
Status for Logic B: a blink sequence

Servicemanual_UR5_en_rev3.1.1

5.3 Error phenomena
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing

ControlBox = NO
CONTROLLER displayed at
INITIALIZING screen

Replace ethernet cable between motherboard
and Safety Control Board and verify problem is
solved

YES

Defective ethernet cable

YES

Defective Safety Control
Board

YES

Defective motherboard

NO
Replace Safety Control Board and verify problem
is solved

Replace motherboard and verify problem is solved

Servicemanual_UR5_en_rev3.1.1

5.3.2 NO CABLE displayed during power up

NO CABLE displayed during
power up > controller shuts
off after few seconds

Measure that 230V AC is present on power input
connector on 12V power supply

Replace current distributor

Replace 12V power supply

Replace Safety Control
Board

YES

Check that 12V PSU LED is lid. The top LED in the
row in the right side of the Safety Control Board

YES

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.

YES
Replace motherboard

Servicemanual_UR5_en_rev3.1.1

5.3.3 Force limit protective stop

Force Limit Protective Stop

Payload and tcp settings in Installation\TCP
Configuration must correspond with actual tool.
Are settings incorrect?

YES

Adjust payload and tcp
settings

YES

Adjust center of mass using
script code set_payload()

Is center of mass very different from tcp point?

NO
Are waypoints positioned very close to cylindrical
area around base of robot where robot can not
operate?

YES

Adjust waypoints away
from this area or reduce
speed/acceleration

Is robot moving with excessive speed or
accelerating very hard?

YES

Reduce speed or
acceleration

NO
Press teach button on back of TP and check the
teach function of all joints > any abnormal friction
or behavior observed?

YES

Inspect joint with abnormal
behavior, joint might have
mechanical failure

NO
Contact distributor from where robot has been
purchased

Servicemanual_UR5_en_rev3.1.1

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

Check log history for error messages and consult
the section Error Codes for detailed explanation

Power controller OFF/ON

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

YES

Replace 48V power supply

YES

Replace current distributor

NO
Measure that 12V DC is present in the red
connector/flatcable on the current distributor

NO
Replace Safety Control
Board

Servicemanual_UR5_en_rev3.1.1

Communication failure with
a joint or the tool connector

Check log history for error messages and consult
the section Error Codes for detailed explanation

Go to LOW LEVEL CONTROL in EXPERT MODE
(consult chapter 4.2 for how to access EXPERT
MODE)

Go to tab POWER ON/OFF and press TURN
POWER ON. Does state of tool switch from
BROKEN COMM. ERROR to READY?

Unmount tool and check
black comm. connector is
fully inserted in pcb

YES

Does state of tool switch to
READY?

NO
Continue to
next page

Replace tool

Servicemanual_UR5_en_rev3.1.1

Continued

Go to tab POWER ON/OFF and press TURN
POWER ON. Does state of all joints J0-J5 switch
from BROKEN COMM. ERROR to READY?

Remove blue lid of joint and
check black comm.
connector is fully inserted

YES

Does state of joint switch to
READY?

Communication ok to joints and tool

Replace joint

Servicemanual_UR5_en_rev3.1.1

5.3.5 Checklist after a collision

Checklist after a collision

Check log history for error messages and consult
the section Error Codes for detailed explanation

Stop robot program and eventually press the
Emergency button prior to entering the work cell

Visually inspect robot arm.
Are any parts visually damaged, like damages on
one of the blue lids?

YES

Remove lid and inspect
parts inside of joint

YES

Inspect joint with abnormal
behavior

Press teach button on back of TP and check the
teach function of all joints > any abnormal friction
or behavior observed?
NO
Press teach button on back of TP and check the
teach function of all joints > any excessive noise
observed?

YES

Inspect joint with abnormal
noise. If click noises appear,
check brake pin

Start the robot program in
NOreduced speed and
verify robot is running as intended

Servicemanual_UR5_en_rev3.1.1

5.4 Electrical drawing
5.4.1 Schematic overview
Diagrams in pdf or in E-plan format, can be found on our support platform under the download section.

Servicemanual_UR5_en_rev3.1.1

5.4.2 E-Plan diagrams
Diagrams in pdf or in E-plan format, can be found on our support platform under the downloads section.

Servicemanual_UR5_en_rev3.1.1

6 Spare parts
6.1 Spare part list
Item no.

Item designation

Controller:
122905
122900
122091
180001
171021
122600
172290
177002
177003
172080
122745
164219
171030
177503
106800
122671
122673
123670

Controller incl. Teach Pendant UR5
Controller excl. Teach Pendant UR5
Teach Pendant incl. Touch Screen & power cable UR5 & UR10
Stylus Pen
Flash card
Motherboard kit
Safety Control board kit
Power Supply Unit 12V
Power Supply Unit 48V
Current Distributor PCB
Energy-eater incl. fan CB3
Wire bundle controller output UR5
RAM module
Filter kit for controller
Euromap E67 kit CB3
Euromap E67 Bypass Plug
Euromap E67 module CB3
Euromap E67 cable 6 m

Robot arm:
111105
122050
122123
122223
122323
123100
122121
122221
122321
122041
103305
103405

UR5 robotarm stand-alone CB3
Base Mounting Bracket incl. Cable 6 m UR5
Joint Size 3 Base UR5
Joint Size 3 Shoulder UR5
Joint Size 3 Elbow UR5
Elbow counterpart and Lower arm kit UR5
Joint Size 1 Wrist 1 UR5
Joint Size 1 Wrist 2 UR5
Joint Size 1 Wrist 3 UR5
Tool Mounting Bracket UR5
Sealing set UR5, external. Visible flat rings between joints
Lid set complete UR5 incl. seal in the lid

Asessories:
173100

Cable for tool: external

Servicemanual_UR5_en_rev3.1.1

131099
139033
132407
107000
131501
131502

Lid Tool protective cap Alu. For tool connector
Bracket for Mounting Teach Pendant
Bracket for Mounting Controller
Safety Control board Terminal kit
Bracket for mounting robot arm UR5 (Item profile)
Bracket for mounting robot arm UR5 (Bosch profile)

6.2 Service kit

Item no.
109010
109101
109102
109110
182200
109103
109105
109106
109107
109104
164084
109180

Item designation
Service kit UR5/UR10
(kit includes all of the below part no.’s)
Spanner Hex 5.5mm
UR5 & UR10
Spanner Hex 7.0mm
UR5 & UR10
Spanner Hex 10.0mm
UR10 only
Screwdriver Flat 2.5
UR5 & UR10
Screwdriver torx T10
UR5 & UR10
Torque wrench Hex 5.5mm Size 1 and Size 2 (1.3 Nm)
UR5 & UR10
Torque wrench Hex 7.0mm Size 3 (3.0 Nm)
UR5 & UR10
Torque wrench Hex 10.0mm Size 4 (8.0 Nm)
UR10 only
Torque screwdriver torx T10 (0.4 Nm)
UR5 & UR10
Bypass cable (for setting joint-ID)
UR5 & UR10
ESD wrist strap
UR5 & UR10

100

Servicemanual_UR5_en_rev3.1.1

7 Packing of robot
Packing of robot and controller box for shipment


Remove any external tooling and external electrical connections.



Load program Put_into_box_ur5.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 chapter 3.1.2.


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



Pack robot arm and Controller box in designated boxes.

101

Servicemanual_UR5_en_rev3.1.1

8 Changelog

8.1 Changelog
Date

Revision

Action

3. May 2014
19. June 2014
29. July 2014

UR5_en_3.0
UR5_en_3.0.1
UR5_en_3.0.2

Added
Changed
Changed

20. Oct. 2014

UR5_en_3.1.1

Changed

Changes
Revision 3.0 released
Pictures and illustrations changed to match 3. gen. robot
Error codes, Spareparts changed to match 3. Gen robot
and ESD handling added
Electrical doc., E-plan , Spare parts update and error code
update. New structure for disassemble/assemble guide.
ESD handling modified.

102

Servicemanual_UR5_en_rev3.1.1

Source Exif Data:

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File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.5
Linearized                      : No
Author                          : Universal Robots
Create Date                     : 2014:10:22 10:40:50+02:00
Creator                         : Microsoft® Word 2010
Modify Date                     : 2014:10:22 10:41:48+01:00
Producer                        : Microsoft® Word 2010
Title                           : ServiceManual_UR5_en_3.1.1
Language                        : da-DK
Tagged PDF                      : Yes
Page Mode                       : UseOutlines
Page Count                      : 102

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ServiceManual_UR5_en_3.1.1 Service Manual UR5 En 3.1.1

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