ServiceManual_UR5_en_3.1.1 Service Manual UR5 En 3.1.1

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

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

5. 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

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

8 Changelog .............................................................................................................................................. 102

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

 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.

 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

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

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.

 Service and Replacement of parts

3.1 Robot arm

3.1.1 Robot arm configuration

J1

Shoulder

J0

Base

J5

Wrist 3

J3

Wrist 1

J2

Elbow

J4

Wrist 2

Upper arm

Lower arm

Base mounting bracket

Tool flange

Elbow counter part

3.1.13 Tool flange – Wrist 3 joint

3.1.12 Wrist 3 joint – Wrist 2 joint

3.1.11 Wrist 2 joint– Wrist 1 joint

3.1.10 Wrist 1 joint – Lower arm

3.1.9 Elbow counter part – Elbow joint

3.1.8 Elbow joint – Upper arm

3.1.7 Upper arm – Shoulder joint

3.1.6 Shoulder joint – Base joint

3.1.5 Base joint – Base mounting bracket

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.

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.

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.

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.

3.1.4 Torque values

UR5 torque values

CONNECTION

TORQUE

HEAD SIZE

BASE PLATE

J0 BASE

3.0Nm

7 mm.

[J0] BASE

J[1] Shoulder

3.0Nm

7 mm.

[J1] SHOULDER

LOWER ARM

3.0Nm

7 mm.

LOWER ARM

[J2] ELBOW

3.0Nm

7 mm.

[J2] ELBOW

HIGHER ARM

3.0Nm

7 mm.

HIGHER 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

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 use to get the correct calibrated torque.

3.0Nm

1.3Nm

3.0Nm

1.3Nm

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

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.

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.

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.

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.

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.

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)

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.

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.

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.

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 = 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 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.

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.

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.

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.

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.

 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.

lightbot

 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.

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.

 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 degree 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.

 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.

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

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)

 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

 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.

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

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

 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

 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

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.

 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.

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.

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.

 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.

 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.

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.

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.

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.

 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.

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.

 Enter password lightbot and press OK.

 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.

lightbot

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.

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 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.

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

Explanation

How to fix

CODE_0

No error

CODE_1

Outbuffer overflow error

CODE_1A1

Buffer of stored warnings

overflowed

CODE_1A2

Outbuffer to RS485

overflowed (problem with PCs

message)

CODE_2

Inbuffer overflow error

CODE_3

Processor overloaded error

Processor in any part could give

this error.

CODE_4

Broken communication

CODE_4A1

Communication with PC lost.

Between Safety Control Board

and Motherboard

CODE_4A2

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

CODE_4A3

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

CODE_4A4

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 TCP/IP-12V

connection between

Motherboard and Teach

Pendant. b) Exchange

Teach Pendant

CODE_4A5

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 TCP/IP-12V

connection between

Motherboard and Teach

Pendant. b) Exchange

Teach Pendant

CODE_4A6

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

CODE_4A7

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

CODE_4A8

Primary EUROMAP67 uP

present, but euromap67 is

disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

CODE_4A9

Secondary EUROMAP67 uP

present, but euromap67 is

disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

CODE_4A10

Primary Teach Pendant

present, but Teach Pendant

safety is disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

CODE_4A11

Secondary Teach Pendant uP

present, Teach Pendant safety

is disabled

Incorrect safety configuration

Update the miscellaneous

settings in the Safety

Configuration

CODE_4A12

Communication with joint 0

lost

More than 1 package lost

CODE_4A13

Communication with joint 1

lost

More than 1 package lost

CODE_4A14

Communication with joint 2

lost

More than 1 package lost

CODE_4A15

Communication with joint 3

lost

More than 1 package lost

CODE_4A16

Communication with joint 4

lost

More than 1 package lost

CODE_4A17

Communication with joint 5

lost

More than 1 package lost

CODE_4A18

Communication with tool lost

More than 1 package lost

CODE_4A65

Lost package from Primary

Teach Pendant

1 package lost - warning

CODE_4A66

Lost package from Secondary

Teach Pendant

1 package lost - warning

CODE_4A67

Lost package from Primary

Euromap67

1 package lost - warning

CODE_4A68

Lost package from Secondary

Euromap67

1 package lost - warning

CODE_4A69

Lost package from Secondary

Masterboard

1 package lost - warning

CODE_4A70

Lost package from joint 0

1 package lost - warning

CODE_4A71

Lost package from joint 1

1 package lost - warning

CODE_4A72

Lost package from joint 2

1 package lost - warning

CODE_4A73

Lost package from joint 3

1 package lost - warning

CODE_4A74

Lost package from joint 4

1 package lost - warning

CODE_4A75

Lost package from joint 5

1 package lost - warning

CODE_4A76

Lost package from tool

1 package lost - warning

CODE_4A77

Lost package from uPA to

joints

1 package lost - warning

CODE_4A78

Lost package from uPA to

teach pendant

1 package lost - warning

CODE_4A79

Lost package from uPA to uPB

1 package lost - warning

CODE_4A80

Lost package from uPB

1 package lost - warning

CODE_4A81

Packet counter disagreement

in packet from Primary

Screen

CODE_4A82

Packet counter disagreement

in packet from Secondary

Screen

CODE_4A83

Packet counter disagreement

in packet from Primary

Euromap67

CODE_4A84

Packet counter disagreement

in packet from Secondary

Euromap67

CODE_4A85

Packet counter disagreement

in packet from Safety Control

Board B

CODE_4A86

Packet counter disagreement

in packet from joint 0

CODE_4A87

Packet counter disagreement

in packet from joint 1

CODE_4A88

Packet counter disagreement

in packet from joint 2

CODE_4A89

Packet counter disagreement

in packet from joint 3

CODE_4A90

Packet counter disagreement

in packet from joint 4

CODE_4A91

Packet counter disagreement

in packet from joint 5

CODE_4A92

Packet counter disagreement

in packet from tool

CODE_4A93

Packet counter disagreement

in packet from processor A to

joints

CODE_4A94

Packet counter disagreement

in packet from processor A to

B

CODE_4A95

Packet counter disagreement

in packet from processor A to

Teach Pendant and EUROMAP

CODE_5

Heavy processor load warning

CODE_10

Broken PC communication

error

Eventually update the

software

CODE_10A1

Lost packet from PC

Eventually update the

software

CODE_10A101

PC packet received too early

Eventually update the

software

CODE_10A102

Packet counter does not

match

Eventually update the

software

CODE_10A103

PC is sending packets too

often

Eventually update the

software

CODE_11

Bad CRC error

Serial communication problem

with joint

Check black 2-wire

connectors and wires in

joints. Eventually 2 joints

with the same ID.

CODE_12

Unknown message error

CODE_14

Debug message

CODE_17

Inbuffer overflow in package

from PC

Communication error between

Safety Control Board and

Motherboard

Check ethernet connection

between circuit boards.

Eventually update the

software

CODE_26

Motor Encoder index drift

detected

Joint mechanical problem

Replace joint

CODE_27

Calibration data is invalid or

does not exist, selftest is

needed!

CODE_29

Online Calibration data

checksum failed

Calibration data is not in the

joint

a) Power OFF and Power

ON. b) replace joint

CODE_30

Master received data from too

many joints

CODE_31

Caught wrong message (not

from master)

Serial communication problem

with joint

Check black 2-wire

connectors and wires in

joints

CODE_32

Flash write verify failed

Debug message

Ignor

CODE_33

Calibration flash checksum

failed

CODE_34

Program flash checksum failed

Update Firmware

CODE_34A0

Program flash checksum failed

during bootloading

Update Firmware

CODE_34A1

Program flash checksum failed

at runtime

Update Firmware

CODE_35

Joint ID is undefined

CODE_36

Illegal bootloader command

Debug message

Ignor

CODE_37

Inbuffer parse error

Serial communication problem

with joint

Check black 2-wire

connectors and wires in

joints

CODE_38

Online RAM test failed

Replace Item

CODE_38A1

Data-bus test failed

Replace Item

CODE_38A2

Address-bus stuck-high test

failed

Replace Item

CODE_38A3

Address-bus stuck-low test

failed

Replace Item

CODE_38A4

Address-bus shorted test

failed

Replace Item

CODE_38A5

Memory-cell test failed

Replace Item

CODE_39

Logic and Temporal

Monitoring Fault

CODE_39A1

Max current deviation failure

CODE_39A2

Max joint-encoder speed

exceeded

CODE_39A3

Max motor-encoder speed

exceeded

CODE_39A4

Illegal state change in joint

detected

CODE_39A5

Too fast state change in joint

detected

CODE_39A6

5V regulator voltage too low

Replace joint

CODE_39A7

5V regulator voltage too high

Replace joint

CODE_39A100

Watchpoint fault: ADC task

timeout

CODE_39A101

Watchpoint fault: Motor-

Control task timeout

CODE_39A102

Watchpoint fault: Motor-

encoder task timeout

CODE_39A103

Watchpoint fault: Joint-

encoder task timeout

CODE_39A104

Watchpoint fault:

Communication task timeout

CODE_39A105

Watchpoint fault: RAM-test

task timeout

CODE_39A106

Watchpoint fault: CalVal-test

task timeout

CODE_39A107

Watchpoint fault: ROM-test

task timeout

CODE_40

AD-Converter hit high limit

joint

EMC issue external or

electronics internal

Check grounding and

shielding for EMC problems

CODE_44

CRC check failure on primary

bus

Serial communication problem

with joint or secondary bus

node

Check black 2-wire

connectors and wires in

joints

CODE_44A0

Joint 0

Replace joint 0

CODE_44A1

Joint 1

Replace joint 1

CODE_44A2

Joint 2

Replace joint 2

CODE_44A3

Joint 3

Replace joint 3

CODE_44A4

Joint 4

Replace joint 4

CODE_44A5

Joint 5

Replace joint 5

CODE_44A6

Tool

Replace Tool mounting

bracket

CODE_45

AD-Converter error

Replace Item

CODE_46

Loose gearbox or bad encoder

mounting

Mechanical problem in gear

related to encoder mounting

Replace joint

CODE_47

AD-Converter hit low limit

EMC issue external or

electronics internal

a) Check grounding and

shielding for EMC

problems. b) Replace Item

CODE_48

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

CODE_49

RS485 receive warning

CODE_49A200

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

CODE_50

Robot powerup failure

Electrical error control box

Remove all external

connections to I/O-

interface of Safty Control

Board. Check for short

circuit. Argument of error

code specifies in details

what causes the error.

CODE_50A1

Voltage detected at 24V rail

before startup

CODE_50A2

Voltage present at unpowered

robot

CODE_50A5

Powersupply voltage too low

CODE_50A6

Powersupply voltage too high

CODE_50A11

Voltage not detected at 24V

rail after startup

24 V to the I/O interface in the

controller

CODE_50A15

Warning, waiting for

SafetySYS2

SafetySYS2 = Processor B on

Safety Control Board

CODE_50A16

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

CODE_50A17

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

CODE_50A18

Warning, waiting for

SafetySYS1

SafetySYS1 = Processor A on

Safety Control Board

CODE_50A20

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

high)

CODE_50A21

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

low)

CODE_50A22

Robot current sensor reading

too high

CODE_50A23

Robot current sensor reading

too low

CODE_50A24

48V not present (Check

internal connection)

CODE_50A25

Robot voltage present at 48V

PSU powereup

CODE_50A26

Voltage present on

unpowered 48V power supply

CODE_50A27

12V, 3V3 or ADC error (12V

too high)

CODE_50A28

12V, 3V3 or ADC error (12V

too low)

CODE_50A29

Analog I/O error (-12V too

high)

CODE_50A30

Analog I/O error (-12V too

low)

CODE_50A31

The other safetySYS do not

initialize

CODE_50A80

Last CPU reset caused by Low-

Power-Reset

CODE_50A81

Last CPU reset caused by

Window-Watchdog-Reset

CODE_50A82

Last CPU reset caused by

Independent-Watchdog-Reset

CODE_50A83

Last CPU reset caused by

Software-Reset

CODE_50A84

Last CPU reset caused by

External-Pin-Reset

CODE_50A85

Last CPU reset caused by

Brown-Out-Reset

CODE_50A99

Wrong software on PCB

CODE_50A100

Cable not connected

Robot Problem: Robot Cable is

not detected

CODE_50A101

Short circuit in robot detected

Robot Problem: 48V

CODE_50A102

Voltage rising too slowly

Robot Problem: 48V

CODE_50A103

Voltage failed to reach

acceptable level

Robot Problem: 48V

CODE_51

CRC check failure on

secondary bus

CODE_51A0

Processor B

CODE_51A1

Primary screen processor

CODE_51A2

Secondary screen processor

CODE_51A3

Primary E67

CODE_51A4

Secondary E67

CODE_53

IO overcurrent detected

Safety Control Board error

Remove all external

connections to I/O-

interface of Safety Control

Board. Check for short

circuit

CODE_53AMA

STER

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

CODE_53ATO

OL

IO overcurrent detected, max

is 600mA

Tool error

Remove tool connector.

Check for short circuit

CODE_55

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

CODE_55A23

Safety relay error (minus

connection)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

CODE_55A24

Safety relay error (plus

connection)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

CODE_55A33

Safety relay error (a relay is

stuck)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

CODE_55A34

Safety relay error (relays are

not on)

Current distributor error

Fault: Cable SCB-Current

distributor or 48V Power

supply or Current

distributor.

CODE_55A50

Voltage present at unpowered

robot

SCB hardware fault

Replace Safety Control

Board (SCB)

CODE_55A51

Voltage will not disappear

from robot

SCB hardware fault

Replace Safety Control

Board (SCB)

CODE_55A52

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

low)

SCB hardware fault

Replace Safety Control

Board (SCB)

CODE_55A53

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

high)

SCB hardware fault

Replace Safety Control

Board (SCB)

CODE_55A90

Bootloader error, robot

voltage too low or current too

high

CODE_55A91

Bootloader error, robot

voltage too high

CODE_55A100

Safety violation

CODE_55A101

Safety Channel Error In Safety

Control Board

CODE_55A102

Safety Channel Error In Screen

CODE_55A103

Safety Channel Error In

Euromap67 Interface

CODE_55A109

Received fault message from

PC

CODE_55A110

Safety State is changing too

often

CODE_55A111

On/Off State is changing too

often

CODE_55A112

Robot current sensors

readings differ

CODE_55A120

Robot current is too high while

emergency stopped

CODE_55A121

Robot current is too high while

safeguard stopped

CODE_56

Overvoltage shutdown

Voltage exceeded 55V

Check Energy Eater. Cable

to Energy eater, Replace

Energy Eater

CODE_57

Brake release failure

Check Brake, solonoide,

Payload, TCP and Mount

CODE_57A1

Joint did not move or motor

encoder is not functioning

Check Brake, solonoide,

Payload, TCP and Mount

CODE_57A2

Large movement detected

during brake release

Check Brake, solonoide,

Payload, TCP and Mount

CODE_57A3

Robot was not able to brake

release, see log for details

Check Brake, solonoide,

Payload, TCP and Mount

CODE_58

Motor encoder not calibrated

Callibrate joint

CODE_59

Overcurrent shutdown

Overcurrent in joint. Argument

= Current in Amps.

Check for short circuit.

Check program for

singularity issues. Replace

joint if necessary

CODE_62

Joint temperature

CODE_62A1

High (80 C)

Warning

CODE_62A3

Static load too high warning

Warning

CODE_62A11

Shut down (85 C)

Stop

CODE_62A13

Static load too high

Stop

Check Payload

CODE_63

Selftest failed

CODE_68

SPI error

Joint: Absolut encoder on joint

communication error

Replace joint

CODE_70

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

CODE_71

Startup check error

Fault: Firmware in joint

CODE_71A1

Hardware is size1, software is

not

Fault: Firmware in joint

CODE_71A2

Hardware is size2, software is

not

Fault: Firmware in joint

CODE_71A3

Hardware is size3, software is

not

Fault: Firmware in joint

CODE_71A4

Hardware is size4, software is

not

Fault: Firmware in joint

CODE_71A5

Invalid hardware size read

CODE_71A6

Motor indication signal not

working

CODE_71A7

Phase 1 and phase 2 not

working

The motor wires are damaged

or bad connection in

screwterminals

CODE_71A8

Phase 2 not working

The motor wires are damaged

or bad connection in

screwterminals

CODE_71A9

Phase 1 not working

The motor wires are damaged

or bad connection in

screwterminals

CODE_71A10

Invalid motor test result

CODE_71A11

ADC calibration failed

Only in joint

CODE_72

Power Supply Unit failure

48 V Power problem

CODE_72A1

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

CODE_72A2

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

CODE_72A3

2 PSUs active, but we expect 1

(UR5)

UR5 flash card in UR10 robot

Check that the flash card

and robot match

CODE_73

Brake test failed during

selftest, check brakepin

CODE_74

Joint encoder warning

Magnetic encoder error

(Absolut encoder)

CODE_74A2

Speed reading is not valid

If more 74 errors on one time

the argument is the sum

Look in the service manual

CODE_74A8

Supply voltage is out of range

If more 74 errors on one time

the argument is the sum

Look in the service manual

CODE_74A16

Temperature is out of range

If more 74 errors on one time

the argument is the sum

Look in the service manual

CODE_74A64

Signal low =Too far from

magnetic ring

If more 74 errors on one time

the argument is the sum

Look in the service manual

CODE_74A128

Signal saturation =Too close to

magnetic ring

If more 74 errors on one time

the argument is the sum

Look in the service manual

CODE_75

Joint encoder error

If more 75 errors on one time

the argument is the sum

Look in the service manual

CODE_75A1

Invalid decode: Readhead

misalignment, ring damaged

or external magnetic field

present.

If more 75 errors on one time

the argument is the sum

Look in the service manual

CODE_75A4

System error=malfunction or

inconsistent calibration

detected

If more 75 errors on one time

the argument is the sum

Look in the service manual

CODE_75A32

Signal lost =Misaligned

readhead or damaged ring

If more 75 errors on one time

the argument is the sum

Look in the service manual

CODE_75A128

Signal saturation =Too close to

magnetic ring

If more 75 errors on one time

the argument is the sum

Look in the service manual

CODE_76

Joint encoder communication

CRC error

Error between sensor and joint

circuit

Check connections or very

heavy electrical noise

CODE_100

Robot changed mode

Status warning, general modus

change

Check preceding errors in

log history

CODE_101

Real Robot Connected

CODE_102

Real Robot not connected -

Simulating Robot

CODE_103

UR Ethernet Error

Comm. Prob. between Mother

Board and Safety Control Board

Check cable

CODE_103A1

3 packages in a row lost from

Safety Control Board

CODE_104

Error=Empty command sent to

robot

CODE_111

Something is pulling the robot

Check Payload setting

CODE_116

Realtime part warning

Possible CPU-overload due to

structure of user program

Restructure user program

CODE_117

Restart SCB failed

The Safety Control Board

couldn't be rebooted from the

controller.

Reboot the robot

CODE_150

Protective Stop: Position close

to joint limits

CODE_151

Protective Stop: Tool

orientation close to limits

CODE_152

Protective Stop: Position close

to safety plane limits

CODE_153

Protective Stop: Position

deviates from path

CODE_154

Protective Stop: Position in

singularity

Robot can not move linear in a

singularity

Use jointspace movement

or change the motion

CODE_155

Protective Stop: Robot cannot

maintain its position, check if

payload is correct

CODE_156

Protective Stop: Wrong

payload or mounting

detected, or something is

pushing the robot when

entering Teach mode

The robot may move

unexpected due to wrong

settings

Verify that the TCP

configuration and

mounting in the used

installation is correct

CODE_172

Illegal control mode

CODE_184

Joint self test not completed

CODE_191

Safety system violation

CODE_191A1

Joint position limit violated

CODE_191A2

Joint speed limit violated

Reduce acceleration or

speed for joint

CODE_191A3

TCP speed limit violated

Reduce acceleration or

speed for joint

CODE_191A4

TCP position limit violated

CODE_191A5

TCP orientation limit violated

CODE_191A6

Power limit violated

Reduce acceleration or

speed for joint

CODE_191A7

Joint torque window violated

Software problem

CODE_191A8

Joint torque window too large

Software problem

CODE_191A9

Reduced mode output

violation

Software problem

CODE_191A10

Safeguard stop output

violation

Software problem

CODE_191A11

Emergency stop output

violation

Software problem

CODE_191A12

Momentum limit violation

CODE_191A13

Robot moving output violation

CODE_191A14

Robot is not braking in stop

mode

CODE_191A15

Robot is moving in stop mode

CODE_191A16

Robot did not stop in time

CODE_191A17

Received a null vector for TCP

orientation

Fault in config file, when no GUI

is used

CODE_191A18

Robot not stopping output

violation

Software problem

CODE_191A19

Invalid safety IO configuration

Fault in config file, when no GUI

is used

CODE_191A20

Configuration information or

limit sets not received

Software problem

CODE_191A21

The other safety processor

detected a violation

CODE_191A22

Received unknown command

from PC

Check Firmware

CODE_191A23

Invalid setup of safety limits

Check Firmware

CODE_191A24

Reduced Mode Output set,

while it should not be

Check Firmware

CODE_191A25

Reduced Mode Output not

set, while it should be

Check Firmware

CODE_191A26

Not Reduced Mode Output

set, while it should not be

Check Firmware

CODE_191A27

Not Reduced Mode Output

not set, while it should be

Check Firmware

CODE_191A28

Robot Emergency Stop

exceeded maximum stop time

Much too high payload

CODE_191A29

System Emergency Stop

exceeded maximum stop time

Much too high payload

CODE_191A30

Safeguard Stop exceeded

maximum stop time

Much too high payload

CODE_192

Safety system fault

CODE_192A1

Robot still powered in

emergency stop

CODE_192A2

Robot emergency stop

disagreement

E-stop in teach pendant or in

Robot E-stop circuit problem

Check cables or replace

Safety Control Board (SCB)

CODE_192A3

System emergency stop

disagreement

System E-stop circuit problem

Check cables or replace

Safety Control Board (SCB)

CODE_192A4

Safeguard stop disagreement

Safeguard circuit problem

Check cables or replace

Safety Control Board (SCB)

CODE_192A5

Euromap safeguard stop

disagreement

Euromap circuit problem

Check cables from Safety

Control Board to Euromap

to external machine

CODE_192A6

Joint position disagreement

Reduce payload, check for

encoder problems

CODE_192A7

Joint speed disagreement

Reduce payload, check for

encoder problems

CODE_192A8

Joint torque disagreement

Reduce payload, check for

encoder problems

CODE_192A9

TCP speed disagreement

Reduce payload, check for

encoder problems

CODE_192A10

TCP position disagreement

Reduce payload, check for

encoder problems

CODE_192A11

TCP orientation disagreement

Reduce payload, check for

encoder problems

CODE_192A12

Power disagreement

Only in joint

CODE_192A13

Joint torque window

disagreement

Communication error or

CODE_192A14

Reduced mode input

disagreement

Safety I/O uP-A and uP-B

disagreement

Check cables

CODE_192A15

Reduced mode output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A16

Safety output failed

CODE_192A17

Safeguard stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A18

The other safety processor is

in fault

CODE_192A19

Emergency stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A20

SPI output error detected

Cafety Control Board

Check 24 V supply

CODE_192A21

Momentum disagreement

CODE_192A22

Robot moving output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A23

Wrong processor ID

CODE_192A24

Wrong processor revision

CODE_192A25

Potential brownout detected

Voltage drop on Safety Control

Board(SCB) or defect SCB

CODE_192A26

Emergency stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A27

Safeguard stop output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A28

Robot not stopping output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A29

Safeguard reset input

disagreement

Safety I/O uP-A and uP-B

disagreement

Check cables

CODE_192A30

Safety processor booted up in

fault mode

CODE_192A31

Reduced Mode Output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A32

Not Reduced Mode Output

disagreement

Safety I/O uP-A and uP-B

disagreement

Check Cables and Software

error on motherboard

CODE_192A33

Checksum disagreement

between uA and uB

Problem in Software

CODE_192A34

User safety config checksum

disagreement between uA and

GUI

Problem in Software

CODE_192A35

Robot config checksum

disagreement between uA and

GUI

Problem in Software

CODE_192A36

Online RAM test failed

CODE_192A37

Not all safety related

functionalities are running

CODE_193

One of the nodes is in fault

mode

SCB has detected an error

See previous error

CODE_193A0

Joint 0

SCB has detected an error

See previous error

CODE_193A1

Joint 1

SCB has detected an error

See previous error

CODE_193A2

Joint 2

SCB has detected an error

See previous error

CODE_193A3

Joint 3

SCB has detected an error

See previous error

CODE_193A4

Joint 4

SCB has detected an error

See previous error

CODE_193A5

Joint 5

SCB has detected an error

See previous error

CODE_193A6

Tool

SCB has detected an error

See previous error

CODE_193A7

Screen 1

SCB has detected an error

See previous error

CODE_193A8

Screen 2

SCB has detected an error

See previous error

CODE_193A9

Euromap 1

SCB has detected an error

See previous error

CODE_193A10

Euromap 2

SCB has detected an error

See previous error

CODE_194

One of the nodes is not

booted or not present

CODE_194A0

Joint 0

SCB has detected an error

CODE_194A1

Joint 1

SCB has detected an error

CODE_194A2

Joint 2

SCB has detected an error

CODE_194A3

Joint 3

SCB has detected an error

CODE_194A4

Joint 4

SCB has detected an error

CODE_194A5

Joint 5

SCB has detected an error

CODE_194A6

Tool

SCB has detected an error

CODE_194A7

Screen 1

SCB has detected an error

CODE_194A8

Screen 2

SCB has detected an error

CODE_194A9

Euromap 1

SCB has detected an error

CODE_194A10

Euromap 2

SCB has detected an error

CODE_195

Conveyor speed too high

Conveyor speed higher than

robot is able to run

Make sure that conveyor

tracking is set correct up

CODE_196

MoveP speed too high

Too high speed in relation to

blend radius

Reduce speed or increase

blend radius in user

program

CODE_197

Blend overlap warning

CODE_200

Safety Control Board

hardware error

SCB: uP-A has detected an error

CODE_200A1

Hardware ID is wrong

SCB: uP-A has detected an

error: Wrong SCB

CODE_200A2

MCU type is wrong

SCB: uP-A has detected an error

CODE_200A3

Part ID is wrong

SCB: uP-A has detected an error

CODE_200A4

RAM test failed

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A5

Register test failed

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A6

pRom Crc test failed

SCB: uP-A has detected an

error: firmware error

Replace Safety Control

Board (SCB)

CODE_200A7

Watchdog reset the processor

SCB: uP-A has detected an error

CODE_200A8

OVG signal test not passed

SCB: uP-A has detected an

error: over voltage generator

Replace Safety Control

Board (SCB)

CODE_200A9

3V3A power good pin is low

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A10

3V3B power good pin is low

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A11

5V power good is low

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A12

3V3 voltage too low

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A13

3v3 voltage too high

SCB: uP-A has detected an error

Replace Safety Control

Board (SCB)

CODE_200A14

48V input is too low

Check: 48 V power supply,

current distributer energy

eater or replace SCB

CODE_200A15

48V input is too high

Check: 48 V power supply,

current distributer energy

eater or replace SCB

CODE_200A16

24V IO short circuited

Too high current

Disconnect external

connections

CODE_200A17

PC current is too high

Motherboard takes too high

current

CODE_200A18

Robot voltage is too low

Check: Short circuit in

robot arm, 48 V power

supply, current distributer

energy eater or replace

SCB

CODE_200A19

Robot voltage is too high

Check: 48 V power supply,

current distributer energy

eater or replace SCB

CODE_200A20

24V IO voltage is too low

Disconnect I/O or replace

SCB

CODE_200A21

12V voltage is too high

Check 12 V power supply,

cables or replace SCB

CODE_200A22

12V voltage is too low

Check 12 V power supply,

cables or replace SCB

CODE_200A23

It took too long to stabilize

24V

SCB error

External 24 V problem or

replace SCB

CODE_200A24

It took too long to stabilize

24V IO

SCB error

External 24 V problem or

replace SCB

CODE_200A25

24V voltage is too high

Safety Control Board error(SCB)

Replace Safety Control

Board (SCB)

CODE_200A26

24V IO voltage is too high

Disconnect I/O or replace

SCB

CODE_201

Setup of safety board failed

Invalid safety parameters have

been received

Verify that the setup of the

Safety Configuration is

valid

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

Reload the installation

5.2 LED indicators on Safety Control Board

Safety Control Board (SCB)

 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

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

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 Force limit protective stop

Force Limit 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 using

script code set_payload()

YES

NO

Is robot moving with excessive speed or

accelerating very hard?

Reduce speed or

acceleration

YES

NO

Press teach button on back of TP and check the

teach function of all joints > 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

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 POWER ON/OFF and press TURN

POWER ON. Does state of tool switch from

BROKEN COMM. ERROR to READY?

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 and check

black comm. connector is

fully inserted in pcb

YES

NO

Continue to

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?

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 teach button on back of TP and check the

teach 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 teach button on back of TP and check the

teach 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 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.

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.

6 Spare parts

6.1 Spare part list

Item no.

Item designation

Controller:

122905

Controller incl. Teach Pendant UR5

122900

Controller excl. Teach Pendant UR5

122091

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

180001

Stylus Pen

171021

Flash card

122600

Motherboard kit

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

164219

Wire bundle controller output UR5

171030

RAM module

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:

111105

UR5 robotarm stand-alone CB3

122050

Base Mounting Bracket incl. Cable 6 m UR5

122123

Joint Size 3 Base UR5

122223

Joint Size 3 Shoulder UR5

122323

Joint Size 3 Elbow UR5

123100

Elbow counterpart and Lower arm kit UR5

122121

Joint Size 1 Wrist 1 UR5

122221

Joint Size 1 Wrist 2 UR5

122321

Joint Size 1 Wrist 3 UR5

122041

Tool Mounting Bracket UR5

103305

Sealing set UR5, external. Visible flat rings between joints

103405

Lid set complete UR5 incl. seal in the lid

Asessories:

173100

Cable for tool: external

131099

Lid Tool protective cap Alu. For tool connector

139033

Bracket for Mounting Teach Pendant

132407

Bracket for Mounting Controller

107000

Safety Control board Terminal kit

131501

Bracket for mounting robot arm UR5 (Item profile)

131502

Bracket for mounting robot arm UR5 (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

182200

Screwdriver Flat 2.5

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 T10 (0.4 Nm)

UR5 & UR10

164084

Bypass cable (for setting joint-ID)

UR5 & UR10

109180

ESD wrist strap

UR5 & UR10

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.

8 Changelog

8.1 Changelog

Date

Revision

Action

Changes

3. May 2014

UR5_en_3.0

Added

Revision 3.0 released

19. June 2014

UR5_en_3.0.1

Changed

Pictures and illustrations changed to match 3. gen. robot

29. July 2014

UR5_en_3.0.2

Changed

Error codes, Spareparts changed to match 3. Gen robot

and ESD handling added

20. Oct. 2014

UR5_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.

ServiceManual_UR5_en_3.1.1 Service Manual UR5 En 3.1.1

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