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ServiceManual UR5 en 3.0

1. SEI Servicemanual_UR5_en_rev3 0 2 85 All rights reserved UNIVERSAL ROBOTS 6 Spare parts 6 1 Spare part list Item no Controller 122905 122900 122091 171021 122600 172290 177002 177003 172080 122745 164219 171030 177503 Robot arm 122050 122123 122223 122323 122121 122221 122321 122041 103305 103405 Asessories 173100 139033 132407 107000 131501 131502 All rights reserved Item designation Controller incl Teach Pendant UR5 Controller excl Teach Pendant UR5 Teach Pendant incl Touch Screen amp power cable UR5 amp UR10 Flash card Motherboard kit Safety Controlboard Kit Power Supply Unit 12V Power Supply Unit 48V Current Distributor PCB Energy eater incl fan Wire bundle controller output UR5 RAM module Filter kit for controller Base Mounting Bracket incl Cable 6m UR5 Joint Size 3 Base UR5 Joint Size 3 Shoulder URS Joint Size 3 Elbow URS Joint Size 1 Wrist 1 URS Joint Size 1 Wrist 2 URS Joint Size 1 Wrist 3 URS Tool Mounting Bracket UR5 Sealing set URS external Lid set complete URS incl seal Cable f tool external Bracket f Mounting Teach Pendant Bracket f Mounting Controller Safety Controlboard Terminal Kit Bracket f mounting robotarm URS Item profile Bracket f mounting robotarm URS Bosch profile 86 Servicemanual_UR5_en_rev3 0 2 6 2 Tool part list Item no 109005 109101 109102 109103 109105 109106 109108 109109 16
2. SETUP Robot About SHUT DOWN Robot All rights reserved 62 Servicemanual UR en_rev3 0 2 e Enter password lightbot and press OK 2 Universal Robots Graphical Programming Environment Enter password e You are now in Expert Mode press Low Level Control SG Universal Robots Graphical Programming Environment PolyScope Expert Mode t lightbot Expert Mode Please select EDIT Text File About System Information Java info Low Level Control Runtime Java Version 1 6 Kinematics Calibration 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Return to Normal Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB UNIVERSAL ROBOTS e Select the Firmware tab mark All joints and press UPDATE firmware 2 Universal Robots Graphical Programming Environment jo jl J2 J3 JI J5 Tool Masterboard Masterboard General Move Calibration Tool Firmware Power On Off Current joint UPDATE Firmw STATUS Set ID of current joint to E l All lointsl Skip bootloader update v Exchange IDs Set it Back Info Setting stepsize to 0 0005 rad sec Info Setting st
3. Troubleshooting 5 1 Error codes Code CODE_0 CODE 1 CODE_1A1 CODE_1A2 CODE 2 CODE 3 CODE_4 CODE AA CODE AA3 CODE AA3 CODE AAA CODE AA CODE_4A6 CODE_4A7 CODE_4A8 CODE_4A9 CODE_4A10 CODE_4A11 CODE_4A12 CODE_4A13 Error description No error Outbuffer overflow error Buffer of stored warnings overflowed Outbuffer to RS485 overflowed problem with PCs message Inbuffer overflow error Processor overloaded error Broken communication Communication with PC lost Communication with Safety Control Board A uP lost Communication with Safety Control Board B uP lost Communication with primary Teach Pendant uP lost Communication with secondary Teach Pendant uP lost Communication with primary EJROMAP67 uP lost Communication with secondary EUROMAP67 uP lost 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 O lost Communication with joint 1 lost All rights reserved 66 UNIVERSAL ROBOTS Explanation Incorrect safety configuration Incorrect safety configuration Incorrect safety configuration Incorrect safety configuration Serial communication problem with one or more joints Serial communication How to fix Update the miscellaneous se
4. more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Servicemanual_UR5_ en_rev3 0 2 UNIVERSAL ROBOTS CODE_4A76 Lost package from tool Serial communication problem with one or more joints CODE_4A77 Lost package from uPA to joints CODE_4A78 Lost package from uPA to teach pendant CODE_4A79 Lost package from uPA to uPB CODE_4A80 Lost package from uPB 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 Euromap6 CODE_4A85 Packet counter disagreement in packet from Safety Control Board B CODE_4A86 Packet counter disagreement in packet from joint O 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 p
5. 00000000 DO 00000000 AI1 Masterboard INITIALIZING V 20 0 CR General Move Calibration Tool l Firmware Power On Off Turn power on Turn power off 0 0 AI2 D A01 A02 0 0 0 00 mA CIO 1 00 mA T 22 80 J2 BROKEN COMMUNICATION ERROR J3 BROKEN COMMUNICATION ERROR J4 BROKEN COMMUNICATION ERROR J5 BROKEN COMMUNICATION ERROR BROKEN COMMUNICATION ERROR a All rights reserved 42 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Select General tab and select the desired joint by either using the dropdown list or directly press on the joint state line JO READY P 0 0000 S 0 000 C 0 000 V READY P 0 0000 S C 0 000 V J2 READY P 0 0000 S 0 000 C 0 000 V J3 READY P 0 0000 S 0 000 C 0 000 V J4 READY P 0 0000 S 0 000 C 0 000 V J5 READY P 0 0000 S 0 000 C 0 000 V Tool ON DI 00 Al 47 6 TM 21 70 TE 35 40 47 6 TM 21 70 TE 47 6 TM 21 70 TE 38 80 47 6 TM 21 70 TE 33 40 47 6 TM 22 40 TE 35 40 47 6 TM 20 90 TE 34 40 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 A 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 4 00 mA T 22 80 Calibration Firmware Joint ID Power On Off Arm robot Arm current joint Backdrive current joint Back I
6. Error Codes for detailed explanation Stop robot program and eventually press the Emergency button prior to entering the work cell Visually inspect robot arm Remove lid and inspect Are any parts visually damaged like damages on parts inside of joint one of the blue lids Press teach button on back of TP and check the Inspect joint with abnormal teach function of all joints gt any abnormal friction behavior or behavior observed Press teach button on back of TP and check the Inspect joint with abnormal teach function of all joints gt any excessive noise noise If click noises appear observed check brake pin Start the robot program in reduced speed and verify robot is running as intended All rights reserved 84 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 5 3 Schematic drawing peoga Od YN WILNACISNO9D y Ae NL Jewpig SYN EH uo ZL0Z 80 0 34eq SLOSOY IVSYJAINN DIGOCLUIOISpIW feow ov oor or a a se va ea a0 va wa owe fave Tove fowo ono Jone Toro fone ono foo Tw Tv os ve owe Jove ave ve oss vas a v3 yndu JeMog Prov ov ow we e we ne we we we we 00 toa Poca fron roa oo roa foo E ESA ws froafmafwafon wf wl a wo p ovir wos Gers JO DBUUOD JOGOY yaixa N3305 e Awa aaa n gt S o 2 e 3 Ag OND OND L M e DO ACL AZ Gers jayea ABsoug LIN NSd A8 LNSd Agr gZ Jonqiysig zua ung VE UIN ZL S2 SY Alddng Jemod ACL
7. Program flash checksum failed during bootloading Program flash checksum failed at runtime Joint ID is undefined Illegal bootloader command Inbuffer parse error Serial communication problem with joint 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 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 Motor Control task timeout Watchpoint fault Motor encoder task timeout Watchpoint fault Joint encoder task timeout Watchpoint fault Communication task timeout Check ethernet connection between circuit boards Replace joint Check green 2 wire connectors and wires in joints Check green 2 wire connectors and wires in joints All rights reserved 69 Servicemanual_ URS en_rev3 0 2 CODE_39A105 CODE_39A106 CODE_39A107 CODE_40 CODE_44 CODE_44A0 CODE_44A1 CODE_44A2 CODE_44A3 CODE_44A4 CODE_44A5 CODE_44A6 CODE_45 CODE_46 CODE_47 CODE_48 CODE_49 CODE_49A200 CODE_50 CODE_50A1 CODE_50A2 CODE_50A5 CODE_50A6 CODE_50A11 CODE_50A15 CODE_50A16 All rights reserved 70 UNIVERSAL ROBOTS Watchpo
8. Shut down 85 C Static load too high Selftest failed SPI error Close to gearbox shear limit Acceleration deceleration to high Mechanical problem in gear related to encoder mounting 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 Phase 2 not working Phase 1 not working Invalid motor test result ADC calibration failed Power Supply Unit failure PSU was not able to deliver 48V O PSUs are active PSU was not able to deliver 48V or UR10 flash card in UR5 robot 1 PSU active but we expect 2 UR10 Reduce acceleration in user program Replace joint if necessary Check power connection between power supply and Safety Control Board Check power connection between power supply and Safety Control Board 2 PSUs active but we expect 1 URS and check that the flash card and robot match Check that the flash card and robot match URS flash card in UR10 robot Brake test failed during selftest check brakepin Joint encoder warning Speed reading is not valid Supply voltage is out of range Temperature is out of range Signal low Too far from magnetic ring Signal saturation Too close to magnetic ring Joint encoder error Invalid decode Readhead misalignment ring damaged or external magne
9. cable between controller and robot arm for any damages e Inspect flat rings for wear and damages replace flat rings if worn out or damaged e Inspect blue lids on all joints for any cracks or damages replace blue lids if cracked or damaged e 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 5Nm If any damages are observed on a robot within the warranty period contact the distributor from where the robot has been purchased All rights reserved 8 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 Service and Replacement of parts 3 1 Robot arm 3 1 1 Robot arm configuration J5 Wrist 3 ba Tool flange J3 F Wrist 1 J4 Wrist 2 Lower arm J2 Elbow Upper arm J1 Shoulder Baseplate All rights reserved 9 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 2 Brake release If required the brake on a joint can be released without power connected IMPORTANT NOTICE e Before releasing a brake it is extremely important to dismount any dangerous tooling for avoiding any hazardous situations e lf releasing the brake on Base joint Shoulder joint or Elbow joint it is important to make proper mechanical support prior to releasing the brake e Always make sure no personnel are located under the arm when releasing the brake e Do not move the joint more than necessary abso
10. it around the joint housing e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screw with a 7 mm open ended spanner about two full rounds approximately 3 mm for each screw e 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 All rights reserved 15 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Pull away the Base joint from Shoulder joint e Replace Base joint and gently insert Base joint with screws and washers into the Shoulder joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Base joint and Shoulder joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 3 0Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm e Reconnect connectors as illustrated e Mount blue lid on Base joint and tighten with 0 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 16 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 5 Replacement of Shoulder joint How to replace Shoulder joint e Move robot to a comfortable position for replacing the joint If neces
11. may have been overloaded on an overrun or it may 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 supply to any potential dangerous tool attached on the robot arm and 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 All rights reserved 4 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 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
12. pushing the robot unexpected due to when entering Teach mode wrong settings Illegal control mode Joint self test not completed Safety system violation Joint position limit violated Joint speed limit violated TCP speed limit violated TCP position limit violated TCP orientation limit violated Power limit violated Joint torque window violated Joint torque window too large Check preceding errors in log history Restructure user program Reboot the robot Use jointspace movement or change the motion Verify that the TCP configuration and mounting in the used installation is correct All rights reserved 74 Servicemanual_ URS en_rev3 0 2 CODE_191A9 CODE_191A10 CODE_191A11 CODE_191A12 CODE_191A13 CODE_191A14 CODE_191A15 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 CODE_192A5 CODE_192A6 CODE_192A7 CODE_192A8 CODE_192A9 CODE_192A10 CODE_192A11 CODE_192A12 CODE_192A13 CODE_192A14 CODE_192A15 CODE_192A16 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 Robot did not stop in time Received a null vector for TCP orientation Robot not stopping out
13. 00 AIl 0 0 A 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 4 00 mA T 23 50 General Move Calibration Firmware Joint ID Power On Off Zero current joint position Zero current joint position Zero all joint positions Motor calibrate joint motor Kess Back U UI Tase a Info Setting stepsize to 0 01 rad sec Info Setting current joint to 0 Info Setting current joint to 1 Info Arming joint 1 Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Setting velocity to 0 0300 rads sec Info Sending stop all command Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Sending stop all command mro Setting StTEpSize to U Info Switching to velocity control FE Press Back for exiting Low Level Control JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 40 90 Jl OK P 1 1129 S 0 000 C 1 663 V 47 6 TM 22 40 TE 41 90 J2 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 21 80 TE 43 60 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 23 00 TE 39 20 J4 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 23 60 TE 41 00 J5 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 22 10 TE 39 90 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 A2 0 0 AO1 0 0 AO2 0 0 Masterbo
14. 4084 All rights reserved Item designation Tool kit URS kit includes all of the below part no s Spanner Hex 5 5mm Spanner Hex 7 0mm Screwdriver torx T10 Torque wrench Hex 5 5mm Size 1 and Size 2 Torque wrench Hex 7 0mm Size 3 Calibration tool size 1 Calibration tool size 3 Bypass cable for setting joint ID 8 UNIVERSAL ROBOTS Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 7 Packing of robot Packing of robot and controller box for shipment e Remove any external tooling and external electrical connections e Load program Put_into_box_ur5 urp and follow instructions while removing mounting bolts File 10 25 50 Program Installation Move I O Log Command Graphics Structure kk as Put into box URS Y Robot Program CO V Move Home Waypoint_25 Popu Waypoint_26 Popup Home Waypoint_23 Popup e simh W gt CI LI Speed OO Previous Next gt 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 e Power down disconnect power and disconnect robot arm from controller e Pack robot arm and Controller box in designated boxes All rights reserved 88 Se
15. A2 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 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 Joint O 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 O Joint 1 Joint 2 Joint 3 Joint 4 Joint 5 Tool Screen 1 All rights reserved 76 UNIVERSAL ROBOTS Servicemanual_UR5_ en_rev3 0 2 CODE_194A8 CODE_194A9 CODE_194A10 CODE_195 CODE_196 CODE_197 CODE_200 CODE_200A1 CODE_200A2 CODE_200A3 CODE_200A4 CODE_200A5 CODE_200A6 CODE_200A7
16. CODE_200A8 CODE_200A9 CODE_200A10 CODE _200A11 CODE_200A12 CODE_200A13 CODE_200A14 CODE_200A15 CODE_200A16 CODE_200A17 CODE_200A18 CODE_200A19 CODE_200A20 CODE _200A21 CODE_200A22 CODE_200A23 CODE_200A24 CODE_200A25 CODE_200A26 CODE 201 CODE 203 Screen 2 Euromap 1 Euromap 2 Conveyor speed too high MoveP speed too high Blend overlap warning Safety Control Board hardware error Hardware ID is wrong MCU type is wrong Part ID is wrong RAM test failed Register test failed pRom Crc test failed Watchdog reset the processor OVG signal test not passed 3V3A power good pin is low 3V3B power good pin is low 5V power good is low 3V3 voltage too low 3v3 voltage too high 48V input is too low 48V input is too high 24V IO short circuited PC current is too high Robot voltage is too low Robot voltage is too high 24V IO voltage is too low 12V voltage is too high 12V voltage is too low It took too long to stabilize 24V It took too long to stabilize 24V IO 24V voltage is too high 24V IO voltage is too high Setup of safety board failed PolyScope detected a mismatch between the shown and to be applied safety parameters All rights reserved 77 UNIVERSAL ROBOTS Make sure that conveyor tracking is set correct up Reduce speed or increase blend radius in user program Conveyor speed higher than robot is able to run Too high speed in relation to blend radius Verify that the setup of the Saf
17. ND Black connector bus cable All rights reserved 33 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Gently remove black flexible flat ring between Wrist 2 and Wrist 3 with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the grey Teflon ring apart 8 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull Wrist 2 joint 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 All rights reserved 34 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Pull away Wrist 2 joint from Wrist 3 joint gt Wrist 2 joint and Wrist 3 joint has now been separated e For separating Wrist 3 joint from tool flange consult chapter 3 1 9 Replacement of tool flange e Replace Wrist 3 and gently insert Wrist 3 joint with screws and washers into Wrist 2 joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Wrist 2 joint and Wrist 3 joint in opposite directions until a mechanical stop is met e Tighten the 8 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm e Reconne
18. OTS 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 on robot with older version it is required to install each update in sequence If it ain t broken 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 e Software should only be updated after consulting Distributor from where the robot has been purchased or if representing a Distributor after consulting Universal Robots e Universal Robots do not recommend updating software without proper instruction in how to update software e When updating firmware it is strictly forbidden to turn off controller during update e Universal Robots can be 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 Login is required only applicable for Distributors Please note If representing an end customer contact the Distributor from where the robot has been purchased for requesting software updates Instruction for updating software e Download software update Carefully read requirements on support site relating to which software must be installed on robot prior to updating to the
19. UNIVERSAL ROBOTS Service Manual Revision UR5_en_3 0 2 Robot UR5 with CB3 controller Valid trom robot s n 2014350001 UNIVERSAL ROBOTS Contents 1 2 Gener Ona O EE 4 LEPU e EE 4 EE EE 5 DISC AIM EE 5 PREVENTIVE Maintenance EE 6 SEENEN 6 2 1 1 INSPECTION plan Safety FUNCTIONS ica ticcvasctscecsvadouecored5ucracaSeeacnacdbensnnedosnccusebsavs eleven setbenresalasiesiatieoenad 6 LIL VIS UNS OCCU ODN E 6 2 1 3 Cleaning and replacement of UC 7 DD RODO e E E E E E E E E ertvcedteascreeetas 8 22 E aen O E 8 Service and Replacement of parts ssssssssesssseessrrerssrrressrererrrrrsrreresrresssreresererssreresererssreresereesseerereeeesseerene 9 SA FROG E E 9 i alle I co ole mre ge Ree ET EC Te E 9 Bled E FIG a Se E E E A E heir nate E EE E E 10 a Renacemento e EE 11 Dc Mg WO Ee Eng or Base EE 14 Au R ephcement or SOUS ON NG EE 17 LEO EEN E Ol lO WW IO WM EE 19 3 1 6 Replacement OF WAIST 1 e ln EE 23 3 1 7 Replacement Of Wrist 2 Joint essiiissasisisninrissennis eenn ieni ar EE EE ANENE ii 29 31S Rephcemnent or Wr 3 oN EE 33 3 1 9 Replacement of tool te 37 i pra led TR if Ro 6 TEE 40 ee JONG C an e WE 41 SEENEN 47 eal BE te af cad ea Bool E Parte serere rr ne ne eee eee 47 3 2 2 Replacement Of motherboard cccccccesseccceesececceseccccsseccceenececseeeeceeeesecessunecessueeccessusecesseneceeseges 48 3 2 3 Replacement of Safety Control Board 51 3 24 Replacement of teach pendan
20. acket from processor Ato 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 CODE_10A1 Lost packet from PC CODE_10A101 PC packet received too early CODE_10A102 Packet counter does not match CODE_10A103_ PC is sending packets too often CODE_11 Bad CRC error Serial Check green 2 wire connectors and wires in joints communication problem with joint All rights reserved 68 Servicemanual_ URS en_rev3 0 2 CODE_12 CODE_14 CODE_17 CODE_26 CODE_27 CODE_29 CODE_30 CODE_31 CODE_32 CODE_33 CODE 24 CODE_34A0 CODE _34A1 CODE_35 CODE_36 CODE_37 CODE 28 CODE _38A1 CODE_38A2 CODE_38A3 CODE _38A4 CODE_38A5 CODE_39 CODE_39A1 CODE_39A2 CODE_39A3 CODE _39A4 CODE_39A5 CODE_39A6 CODE_39A7 CODE_39A100 CODE_39A101 CODE_39A102 CODE_39A103 CODE_39A104 UNIVERSAL ROBOTS Unknown message error Debug message Inbuffer overflow in package from PC Communication error between Safety Control Board and Motherboard Motor Encoder index drift detected Joint mechanical problem 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 Serial communication problem with joint Flash write verify failed Calibration flash checksum failed Program flash checksum failed
21. and Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Sending stop all command e Use the Up and Down buttons for navigating the joint to the correct zero position according to the following illustrations Press STOP when the joint is in the correct position JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 39 90 Jl OK P 1 1129 S 0 000 C 1 666 V 47 6 TM 21 80 TE 39 90 J2 READY P 0 0000 S J3 READY P 0 0000 S J4 READY P 0 0000 S J5 READY P 0 0000 S Tool ON DI 00 A1 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 0 000 C 0 000 V 47 6 TM 21 80 TE 42 50 0 000 C 0 000 V 47 6 TM 22 90 TE 37 90 0 000 C 0 000 V 47 6 TM 22 90 TE 39 90 0 000 C 0 000 V 47 6 TM 21 80 TE 38 30 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 30 General Move Calibration Current Control Step size Firmware f Joint ID Power On Off Velocity control 0 01 rad sec v Info Info Info Info Info Info Info Info Info Info Info Info E Back U UL Tad sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Setting v
22. ard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 70 General Move Calibration Firmware Joint ID Power On Off Zero current joint position Zero all joint positions Motor calibrate joint motor son n mro Setting Stepsize to U UL raa sec F Info Switching to velocity control men Info Setting stepsize to 0 01 rad sec Info Setting current joint to 0 Info Setting current joint to 1 Info Arming joint 1 Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Setting velocity to 0 0300 rads sec Info Sending stop all command Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Sending stop all command Back in Expert Mode press Return to Normal SG Universal Robots Graphical Programming Environment PolyScope Expert Mode Please select Expert Mode EDIT Text File About Low Level Control System Information Java info Kinematics Calibration Runtime Java Version 1 6 0_26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB Verify zero position by moving the robot to HOME If not satisfied with the zero position perform the procedure
23. arts in a grounded metal cabinet case e Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity All rights reserved 47 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 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 e Shut down the controller and disconnect the power cable open the controller cabinet and loosen the 3 Torx screws e and remove the alu cover plate UNIVERSAL ROBOTS All rights reserved 48 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e 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 Matches Robot Arm no e Replace Motherboard with new e If controller is equipped with long hole brackets make sure to replace them with circular hole brackets Tighten the 4 screws gently All rights reserved 49 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Insert the 6 cables in correct positions e Re install Flash card and RAM block e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 50 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 3 2 3 Replaceme
24. at causes the error Check the cable or change in the Safety Configuration of the Servicemanual_UR5_ en_rev3 0 2 CODE_50A17 CODE _50A18 CODE_50A20 CODE_50A21 CODE_50A22 CODE_50A23 CODE_50A24 CODE_50A25 CODE_50A26 CODE_50A27 CODE_50A28 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 CODE_51 CODE_51A0 CODE_51A1 CODE_51A2 CODE_51A3 CODE_51A4 CODE_53 CODE 53AMA STER All rights reserved 71 UNIVERSAL ROBOTS Loose wire or incorrect safety configuration 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 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 Low Power 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 no
25. ct 4 cables Red plug with black cable Black USB cable Black DVI cable Black cable for RS232 connection to touchscreen 343 D OC ET ben HES ae eee F e Remove the bracket foot of the controller box that holds the cable inlet and pull out the cables and plugs through this hole e Replace teach pendant with new insert cable in cable inlet and perform reconnection of all plugs and mounting of alu cover in reversed order of the above description e Connect power and verify that teach pendant works properly All rights reserved 53 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 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 alu cover plates as in chapter 3 2 2 Replacement of motherboard and 3 2 3 Replacement of Safety Control Board e Remove the handle on Controller box by loosen the 2 screws holding it e Removes the 2 wires for the fan e Remove the 2 nuts in the bottom of Controller module All rights reserved 54 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Gently take out the controller module from the Controller box without disconnecting the robot cable and power cable e Power supplies are located in the rack under the controller module the two 48V power supplies are the lower ones in the rack Before dismounting th
26. ct connectors as illustrated into Wrist 3 All rights reserved 35 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS e Mount blue lid on Wrist 3 joint and tighten with 0 SNm gt Wrist 2 joint and Wrist 3 joint has now been assembled e For assembling Wrist 3 joint and tool flange consult chapter 3 1 9 Replacement of tool flange e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 36 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 3 1 9 Replacement of tool flange How to replace tool flange e Move robot to a comfortable position for replacing the tool flange If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove grease plug e Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint housing All rights reserved 37 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS e Slide the grey Teflon ring apart 8 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e 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 e Pull away the tool from Wrist 3 joint e Disconnect the two connectors All rights reserved 38 Servicemanual_UR5_
27. d for assembling new Wrist 1 joint with Wrist 2 joint All rights reserved 26 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Replace Wrist 1 and gently insert Wrist 1 joint with screws and washers into Wrist 2 joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting Wrist 1 joint and Wrist 2 joint in opposite directions until a mechanical stop is met e Tighten the 8 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm e Reconnect connectors as illustrated into Wrist 2 e Mount blue lid on Wrist 2 joint and tighten with 0 5Nm gt New Wrist 1 joint and Wrist 2 joint has now been assembled proceed for assembling new Wrist 1 joint and lower arm All rights reserved 27 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS e Gently insert Wrist 1 joint with screws and washers into the lower arm e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting Wrist 1 joint and lower arm in opposite directions until a mechanical stop is met e Tighten the 8 screws lightly then tighten in cross order with 1 3Nm e Gently put back the gasket e Mount the grease plug and tighten with 0 8Nm e Reconnect wires between lower arm and Wrist 1 joint as illustrated
28. downloaded version e Save it in the root folder on a USB stick e Insert USB stick into USB connector on right hand side of teach pendant e Goto main screen of PolyScope All rights reserved 60 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 2 Universal Robots Graphical Programming Environment PolyScope Robot User Interface Please select RUN Program UNIVERSAL ROBOTS DEER SETUP Robot SHUT DOWN Robot About e Press button SETUP Robot e Inleft side menu select UPDATE Robot SG Universal Robots Graphical Programming Environment SETUP Robot Please select INITIALIZE Robot LANGUAGE Select UPDATE Robot Set PASSWORD CALIBRATE Screen PolyScope 1 6 8719 Jul 30 2012 15 59 40 Setup NETWORK BACK e Press button Search for searching after software update on USB stick 2 Universal Robots Graphical Programming Environment SETUP Robot K Update robot software Please select INITIALIZE Robot LANGUAGE Select Click Search to download a list of possible updates for this robot UPDATE Robot Description Set PASSWORD CALIBRATE Screen Setup NETWORK BACK Update e Mark the found software update and press UPDATE e Press YES for updating the software e Await robot update sof
29. e All rights reserved 21 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Pull away the Elbow joint from upper arm e Replace Elbow joint and gently insert lower arm into the Elbow joint e Tighten the 10 screws lightly then tighten in cross order with respectively 3 0Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm e Reconnect wires between Elbow joint and upper arm as illustrated e Mount blue lid on Base joint and tighten with 0 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 22 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 6 Replacement of Wrist 1 joint How to replace Wrist 1 joint Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface Shut down the controller Remove blue lid on Wrist 1 joint Disconnect wires between lower arm and Wrist 1 joint 1 x red wire 48V DC 1 x black wire GND Black connector bus cable 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 All rights reserved 23 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e With a screw driver or similar tool gently remove nylon ring as illustrated e 8 screws become visib
30. e teach pendant e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 57 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 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 alu cover plate and cables for teach pendant as in chapter3 2 4 Replacement of teach pendant For replacing the current distributor follow exactly the same steps as for the procedure in chapter 3 2 5 Replacement of 48V power supply e Current distributor is placed on top of rack e Before dismounting the current distributor mark and disconnect the cables from the circuit board oot al ee L LAT LAV 138 S s ogou Wwsuaninn d CS All rights reserved 58 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Replace current distributor with new e Reconnect the wires for the current distributor e Re install Controller module in reverse order and connect the 2 wires for the fan and cables for the teach pendant e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 59 Servicemanual UR en_rev3 0 2 UNIVERSAL ROB
31. e 48V power supply mark and disconnect the cables from that supply e Remove the screws respectively of the defective 48V power supply from the side of the rack All rights reserved 55 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Replace 48V power supply with new e Reconnect the wires for the 48V power supply e Re install Controller module in reverse order and connect the 2 wires for the fan and cables for the teach pendant e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 Screws e Connect power and verify that teach pendant works properly All rights reserved 56 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 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 alu cover plate and cables for teach pendant as in chapter 3 2 4 Replacement of teach pendant For replacing the 12V power supply follow exactly the same steps as for the procedure in chapter 3 2 5 Replacement of 48V power supply e The 12V power supply is placed in top of rack The screws holding it in the frame are placed on the sides g E A a A E E e Replace 12V power supply with new e Reconnect the wires for the 12V power supply e Re install Controller module in reverse order and connect the 2 wires for the fan and cables for th
32. e Mount blue lid on Wrist 1 joint and tighten with 0 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 28 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 3 1 7 Replacement of Wrist 2 joint How to replace Wrist 2 joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove blue lid on Wrist 2 joint SE e ee e Disconnect wires between Wrist 1 joint and Wrist 2 joint 2 x red wire 48V DC 2 x black wire GND Black connector bus cable All rights reserved 29 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e 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 e Slide the grey Teflon ring apart 8 screws become visible 4 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e 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 All rights reserved 30 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Pull away Wrist 1 joint from Wrist 2 joint gt Wrist 1 joint and Wrist 2 joint has now been separated Perform same procedure
33. each side of joint Untighten gently the screw with a 7 mm open ended spanner about two full rounds approximately 3 mm for each screw All rights reserved 19 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Pull Elbow joint and lower arm apart and gently twist the two parts in opposite directions around 10 mm until a mechanical stop is met holes are keyhole type e Disconnect wires between Elbow joint and lower arm 1 x red wire 48V DC 1 x black wire GND Green connector bus cable e Replace Elbow joint and reconnect wires between Elbow joint and lower arm accordingly e Gently insert lower arm with screws and washers into the Elbow joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Elbow joint and lower arm in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with respectively 3 0Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm All rights reserved 20 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e For separating upper arm from Elbow joint remove blue lid on Shoulder joint e Disconnect wires between Elbow joint and upper arm 1 x red wire 48V DC 1 x black wire GND Black connector bus cable e Unmount screws around the upper arm as indicated on the pictur
34. el Error In Masterboard 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 Overvoltage shutdown Voltage exceeded 55V Brake release failure 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 Overcurrent in joint Joint temperature Check Motherboard Masterboard Screenboard Current distributor Euromap if installed Bypass safety connections to O interface of Masterboard Check Energy Eaters Replace Energy Eater Check for short circuit Check program for singularity issues Replace joint if necessary All rights reserved 72 Servicemanual_ URS en_rev3 0 2 CODE 62A1 CODE_62A3 CODE _62A11 CODE_62A13 CODE _63 CODE_68 CODE_70 CODE_71 CODE_71A1 CODE_71A2 CODE_71A3 CODE_71A4 CODE_71A5 CODE_71A6 CODE_71A7 CODE_71A8 CODE_71A9 CODE_71A10 CODE_71A11 CODE_72 CODE_72A1 CODE_72A2 CODE_72A3 CODE_73 CODE_74 CODE_74A2 CODE_74A8 CODE_74A16 CODE_74A64 CODE_74A128 CODE_75 CODE_75A1 All rights reserved 73 UNIVERSAL ROBOTS High 80 C Static load too high warning
35. elocity to 0 0300 rads sec Sending stop all command Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Sending stop all command All rights reserved 44 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Zero position illustrations Base Shoulder Elbow Wrist 1 Base zero position is aligned to Shoulder Elbow and Wrist 1 zero positions are connector in back of robot base Vertical aligned if Base if horizontal Make sure that base of robot is positioned horizontal use leveler for aligning joints Wrist 2 Wrist 3 Wrist 2 zero position is aligned similar Wrist 3 zero position is aligned so tool connector to Base joint is pointing upward Mount two bolts in tool holes and use leveler for aligning joint All rights reserved 45 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS Select Calibration tab and press Zero current joint position for calibrating the joint JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 40 80 Jl OK P 1 1129 S 0 000 C 1 643 V 47 6 TM 22 00 TE 40 90 J2 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 42 90 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 90 TE 38 90 J4 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 23 10 TE 40 80 J5 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 21 90 TE 39 00 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 000000
36. en_rev3 0 2 UNIVERSAL ROBOTS e Replace tool flange and reconnect connectors as illustrated e Replace tool and reconnect wires correctly e Gently insert tool flange with screws and washers into the Wrist 3 joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the tool flange and Wrist 3 joint in opposite directions until a mechanical stop is met e Tighten the 8 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm All rights reserved 39 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 3 1 10 Torque values UR5 torque values CONNECTION TORQUE HEAD SIZE BASE PLATE JO BASE 3 0Nm 7mm JO BASE J 1 Shoulder 3 0Nm 7mm HIGHER ARM J3 WRIST 1 1 3Nm 5 5 mm J5 WRIST 3 TOOL 1 3Nm 5 5mm Blue lid 0 5Nm Torx 10 1 3Nm 1 3Nm 1 3Nm 3 0Nm 3 0Nm 3 0Nm All rights reserved 40 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 11 Joint calibration After replacement of joint it is required to calibrate the new joint in order to find the correct zero position of joint Instruction for calibrating a joint e Jog robot to HOME position Illustration shows the HOME position which is defined as zero position of all joints e Drag a finger from left to right across
37. epsize to 0 01 rad sec Info Switching to velocity control Info Setting stepsize to 0 01 rad sec Info Setting current joint to 0 e Firmware update is being processed await message that robot firmware updated successfully It is strictly forbidden to turn off controller during this update e After successful update press Back All rights reserved 63 Servicemanual_UR5_en_rev3 0 2 Back in Expert Mode press Return to Normal SG Universal Robots Graphical Programming Environment PolyScope Expert Mode Expert Mode About System Information Java info Runtime Java Version 1 6 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB Please select EDIT Text File Low Level Control Kinematics Calibration Return to Normal Firmware has now been updated All rights reserved 64 UNIVERSAL ROBOTS Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 4 3 Using Magic files For easy backup Universal Robots provides Magic files for automatic copy of data from controller to USB stick These files are available Function e URmagic log file copies the entire log history file to USB stick e URmagic backup programs copies all p
38. ety Configuration is valid Reload the installation Invalid safety parameters have been received The PolyScope continuously verifies that the shown safety parameters are equal to the running parameters Servicemanual_UR5_ en_rev3 0 2 UNIVERSAL ROBOTS 5 2 Error phenomena 5 2 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 Defective ethernet cable solved Replace Safety Control Board and verify problem Defective Safety Control is solved Board Replace motherboard and verify problem is solved Defective motherboard All rights reserved 78 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 5 2 2 NO CABLE displayed during power up NO CABLE displayed during power up gt controller shuts off after few seconds Measure that 230V AC is present on power input Replace current distributor connector on 12V power supply Measure that 12V DC is present on 12V_IN connector on Safety Control Board and diode Replace 12V power supply marked 12V in top right corner of Safety Control During power up within first few seconds check Replace Safety Control that the top four diodes in top right corner of Board Safety Control Board are lit before they turns off Replace motherboard All rights reserved 79 Servicemanual _UR5_en_rev3 0 2 5 2 3 Force limit protective s
39. for separating Wrist 2 joint and Wrist 3 joint and proceed when done Replace Wrist 2 and gently insert Wrist 2 joint with screws and washers into Wrist 1 joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Wrist 1 joint and Wrist 2 joint in opposite directions until a mechanical stop is met Tighten the 8 screws lightly then tighten in cross order with 1 3Nm Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring Mount the grease plug and tighten with 0 8Nm Reconnect connectors as illustrated into Wrist 2 All rights reserved 31 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Mount blue lid on Wrist 2 joint and tighten with 0 SNm gt Wrist 1 joint and Wrist 2 joint has now been assembled Perform same procedure for assembling Wrist 2 joint and Wrist 3 joint e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 32 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 3 1 8 Replacement of Wrist 3 joint How to replace Wrist 3 joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove blue lid on Wrist 3 joint SE e ee e Disconnect wires between Wrist 2 joint and Wrist 3 joint 2 x red wire 48V DC 2 x black wire G
40. int fault RAM test task timeout Watchpoint fault CalVal test task timeout Watchpoint fault ROM test task timeout AD Converter hit high limit joint EMC issue external or electronics internal Serial communication problem with joint or secondary bus node CRC check failure on primary bus Joint O Joint 1 Joint 2 Joint 3 Joint 4 Joint 5 Tool AD Converter error Mechanical problem in gear related to encoder mounting EMC issue external or electronics internal Error on 48V powerbus Loose gearbox or bad encoder mounting AD Converter hit low limit Powerbus voltage drop detected RS485 receive warning Secondary RS485 bus is down Electrical error control box Robot powerup failure 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 Loose wire or incorrect safety configuration The Teach Pendant does not respond Check grounding and shielding for EMC problems Check green 2 wire connectors and wires in joints Replace joint Check grounding and shielding for EMC problems Check 48V output from PSU Check current distributor PCB Replacement of 48V PSU or current distributor is necessary Remove all external connections to O interface of Masterboard Check for short circuit Argument of error code specifies in details wh
41. 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 All rights reserved 5 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 2 Preventive Maintenance 2 1 Controller 2 1 1 Inspection plan Safety Functions e Atleast once ina year the correct functioning of all safety functions should be tested 2 1 2 Visual inspection e Disconnect power cable from controller e Open cabinet door e Check connectors are properly inserted on printed circuit boards e Check for any dirt dust inside of controller e H any dirt dust is present gently use vacuum cleaning for removing particles All rights reserved 6 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 2 1 3 Cleaning and replacement of filters e Controller box contains two filters one on each side of controller e Remove filters from controller box and clean them thoroughly using compressed air Replace filters if necessary All rights reserved 7 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 2 2 Robot arm 2 2 1 Visual inspection e Move robot arm to HOME position if possible e Turn off and disconnect power cable from controller e Inspect
42. l rights reserved 12 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Replace base plate and reconnect wires according to illustration e Gently insert base plate with screws and washers into the Base joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the base plate and Base joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 3 0Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm All rights reserved 13 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 4 Replacement of Base joint How to replace Base joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e For separating base plate from Base joint consult chapter 3 1 3 Replacement of base plate e Remove blue lid on Base joint ege e Disconnect wires between Base joint and Shoulder joint 1 x red wire 48V DC 1 x black wire GND Black connector bus cable e Remove grease plug at Shoulder joint All rights reserved 14 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or similar tool and twist
43. le 4 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e 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 e Pull away the lower arm from Wrist 1 joint gt Lower arm and Wrist 1 joint has now been separated proceed for separating Wrist 1 from Wrist 2 All rights reserved 24 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Remove blue lid on Wrist 2 joint e 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 5 z e 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 All rights reserved 25 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Slide the grey Teflon ring apart 8 screws become visible 4 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e 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 e Pull away Wrist 1 joint from Wrist 2 joint gt Wrist 1 joint and Wrist 2 joint has now been separated procee
44. lute max is 180 degrees in order for the robot to find its original physical position Procedure for releasing the joint e Shut down Controller e Remove blue lid on joint e Push pin brake down for releasing joint can then be rotated Brake on Base Shoulder and Elbow joints and on all Wrist joints e Make sure to mount blue lid properly on joint before turning on Controller All rights reserved 10 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 3 Replacement of base plate How to replace base plate e Move robot to a comfortable position for replacing the base If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove grease plug e Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint housing All rights reserved 11 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screw with a 7 mm open ended spanner about two full rounds approximately 3 mm for each screw e 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 e Disconnect wires between base plate and Base joint 1 x red wire 48V DC 1 x black wire GND Black connector bus cable NB polarized Al
45. nfo Info Info Info Info Info Info Setting stepsize to null Setting stepsize to 0 0005 rad sec Setting stepsize to 0 01 rad sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 e Press Arm current joint for releasing the brake on the selected joint JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 37 90 Jl INITIALIZING P 0 0000 S 0 000 C 2 204 V 47 6 TM 21 80 TE 37 60 J2 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 40 90 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 60 TE 35 80 J4 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 22 90 TE 37 80 J5 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 70 TE 36 50 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 All 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 4 00 mA T 23 00 General Move Calibration Firmware Joint ID Power On Off Current joint Joint 1 Shoulder Arm robot Arm current joint Backdrive current joint Back Setting stepsize to null Setting stepsize to 0 0005 rad sec Setting stepsize to 0 01 rad sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joi
46. nt 1 e Select Move tab and press either Up or Down for the joint to find its index mark For every time the button is pressed the velocity of joint will be increased JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 39 90 2 Jl OK P 1 1129 S 0 000 C 1 666 V 47 6 TM 21 80 TE 39 90 J2 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 42 50 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 90 TE 37 90 J4 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 90 TE 39 90 J5 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 38 30 Tool ON DI 00 A1 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 All 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 30 General Move Calibration Firmware Joint ID Power On Off Current Control Velocity control a ge RE Gees e Info Info Info Info Info Info Info Info Info Info Info Info Back Out Tag sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Setting velocity to 0 0300 rads sec Sending stop all command Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Sending stop all command All
47. nt 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 e Shut down the controller and disconnect the power cable open the controller cabinet and loosen the 5 Torx screws e Carefully remove all plugs and connectors it is recommended to mark the cable positions or take a picture of them UNIVERSAL 3OTS e em tr N Iran GNE mo Larne Sl E emm SI e and remove the alu cover plate All rights reserved 51 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Carefully remove all plugs and connectors it is recommended to mark the cable positions or take a picture of them e Remove 13 screws holding the Safety Control Board e Replace Safety Control Board with new and tighten the 15 screws to hold the board e Insert all connectors and plugs in correct positions e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 52 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 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 alu cover plates as in chapter 3 2 2 Replacement of motherboard and 3 2 3 Replacement of Safety Control Board e Disconne
48. once again All rights reserved 46 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 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 e Keep the ESD sensitive part in its original shipping container a special ESD bag until the part is ready to be installed e Make the least possible body movements to prevent an increase of static electricity from clothing fibers carpets and furniture e 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 e 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 e Do not place the ESD sensitive part on insulating 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 bag e 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 e Prevent ESD sensitive parts from being accidentally touched by other personnel and do not put unprotected ESD sensitive parts on a table e f possible keep all ESD sensitive p
49. put 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 Euromap safeguard stop disagreement Joint position disagreement Joint speed disagreement Joint torque disagreement TCP speed disagreement TCP position disagreement TCP orientation disagreement Power disagreement Joint torque window disagreement Reduced mode input disagreement Reduced mode output disagreement Safety output failed All rights reserved 75 UNIVERSAL ROBOTS Servicemanual_UR5_en_rev3 0 2 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 CODE_193A0 CODE_193A1 CODE_193
50. r up measure that 230V AC is present on 48V_PSU1 connector on current distributor PCB Measure that 12V DC is present in the red Replace current distributor connector flatcable on the current distributor Replace Safety Control Board All rights reserved 81 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 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 Unmount tool and check POWER ON Does state of tool switch from green comm connector is BROKEN COMM ERROR to READY fully inserted in pcb Does state of tool switch to READY NO Continue to next page Replace tool All rights reserved 82 Servicemanual UR en_rev3 0 2 Go to tab POWER ON OFF and press TURN POWER ON Does state of all joints JO J5 switch from BROKEN COMM ERROR to READY YES Communication ok to joints and tool All rights reserved 83 NO YES UNIVERSAL ROBOTS Remove blue lid of joint and check green comm connector is fully inserted Does state of joint switch to READY NO Replace joint Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 5 2 5 Checklist after a collision Checklist after a collision Check log history for error messages and consult the section
51. rights reserved 43 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Await that state of the joint changes to OK then press STOP Index mark has now been found index mark is not the same position as zero position JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 39 90 jl OK P 1 1129 S 0 000 C 1 666 V 47 6 TM 21 80 TE 39 90 J2 READY P 0 0000 S J3 READY P 0 0000 S J4 READY P 0 0000 S J5 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 0 000 C 0 000 V 47 6 TM 0 000 C 0 000 V 47 6 TM 0 000 C 0 000 V 47 6 TM Tool ON DI 00 A1 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 21 80 TE 42 50 22 90 TE 37 90 22 90 TE 39 90 21 80 TE 38 30 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 30 General Move Calibration Current Control Step size Firmware Joint ID Power On Off Velocity control 0 01 rad sec v Up Down Info Info Info Info Info Info Info Info Info Info Info Info Back U UL Tag sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Setting velocity to 0 0300 rads sec Sending stop all comm
52. rograms and installation files to USB stick e URmagic configuration files copies all configuration files to USB stick e URmagic upload programs copies all programs and installation files from USB stick e URmagic screenshot generates a screenshot of GUI when USB stick is inserted Go to www support universal robots com download for downloading Magic files Login is required only applicable for Distributors Please note If representing an end customer contact the Distributor from where the robot has been purchased for requiring Magic files Instruction for using Magic files e Download Magic file e Save it in the root folder on a USB stick e Insert USB stick into USB connector on right hand side of teach pendant e After afew 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 e Await a green lt USB sign appears on the screen then you can safely remove the USB stick e Remove USB stick and you re done The Magic file creates a folder on USB stick named after 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 before after the last file has been run Multiple folders will be created and named after serial number added with a sequential no like 201220xxx4_0 201220xxx4_1 etc All rights reserved 65 Servicemanual UR en_rev3 0 2 5
53. rvicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 8 Changelog 8 1 Changelog Date Revision Action Changes 3 May 2014 UR en 30 Added Revision 3 0 released 19 June 2014 URS en 3 0 1 Changed Pictures and illustrations changed to match 3 gen robot 29 July 2014 URS en 3 0 2 Changed Error codes Spareparts changed to match 3 Gen robot and ESD handling added All rights reserved 89 Servicemanual UR en_rev3 0 2
54. sary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e For separating Base joint from Shoulder joint consult chapter 3 1 4 Replacement of Base joint e Remove blue lid on Shoulder joint ege e Disconnect wires between Shoulder joint and upper arm 1 x red wire 48V DC 1 x black wire GND Black connector bus cable All rights reserved 17 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS e Unmount screws around the upper arm as indicated on the illustration e Pull away the Shoulder joint from upper arm e Replace Shoulder joint and mount screws into shoulder joint e Tighten screws lightly then tighten in cross order with 3 0Nm e Reconnect wires as illustrated e Mount blue lid on Base joint and tighten with 0 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 18 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 3 1 6 Replacement of Elbow joint How to replace Elbow joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove grease plug at Elbow joint e Gently remove black flexible flat ring between Elbow and lower arm with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the grey Teflon ring apart 10 screws become visible 5 on
55. t EE 53 3 2 5 Replacement of 48V power suppl 54 All rights reserved 2 Servicemanual_UR5_en_rev3 0 2 4 UNIVERSAL ROBOTS 3 2 6 Replacement Of 12V power suppl 57 3 2 7 Replacement of current distributor stas dr tens nEr E UEAn NEEC EErEE EEEN E isn 58 GENEE EE 60 Wa Bee Een 60 BEEN JO eg goe TEE 62 Ms WSUS IV IG dE 65 TNO WDE SOO dE 66 EE 66 EEN 78 5 2 1 ControlBox NO CONTROLLER displayed in Initializing cccccccssseccceesececeeeeceeeeeseeesaeseceeeeneses 78 5 2 2 NO CABLE displayed during power UD sciicsssicivessiciecesiavcdvonattcedsaanccasossatdenesanssiawnntedusepoesadvonseuiesoeavecs 79 Do Force MIE OLE CIV SCO EE 80 5 24 Power on failure ue EE e sccoseadicusispawaveencagescustute veuacidsieudnnceseaansadateuadedarenenianutvanasesesateruardedenens 81 5 29 CHECKIISE ATLEL A CONNISION cnarenssssczaveconsacnwnenesinnsdonsadaur EEEE CAE ER Si 84 e EE 85 PaE ac ces cece cc ence em rata arc co E eee atic E A 86 CE Sl ln TE 86 SEH POON e Ce gi CN 87 PACK eg ODN EE 88 DEER 89 e E Ee E 89 All rights reserved 3 Servicemanual UR en_rev3 0 2 UNIVERSAL ROBOTS 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 on the robot For example the robot
56. t connected 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 Masterboard error max is 800mA Installation the miscellaneous settings Check the cable or change in the Safety Configuration of the Installation the miscellaneous settings Remove all external connections to I O interface of Masterboard Check for short circuit Servicemanual_UR5_ en_rev3 0 2 CODE_53ATO OL CODE_55 CODE_55A23 CODE_55A24 CODE_55A33 CODE_55A34 CODE_55A50 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 CODE_56 CODE_57 CODE_57A1 CODE_57A2 CODE_57A3 CODE_58 CODE_59 CODE_62 UNIVERSAL ROBOTS max is 600mA Safety system error Safety system malfunction Safety relay error minus connection Safety relay error plus connection Safety relay error a relay is stuck Safety relay error relays are not on 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 Chann
57. the UN IVERSAL sign on main screen of PolyScope 2 Universal Robots Graphical Programming Environment PolyScope Robot User Interface Please select RUN Program ROBOTS en SETUP Robot About SHUT DOWN Robot All rights reserved 41 Servicemanual_UR5_en_rev3 0 2 Enter password lightbot and press OK DG Universal Robots Graphical Programming Environment Enter password You are now in Expert Mode press Low Level Control 2 Universal Robots Graphical Programming Environment lightbot Cancel PolyScope Expert Mode Expert Mode About System Information Java info Runtime Java Version 1 6 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB Please select EDIT Text File Low Level Control Kinematics Calibration Return to Normal UNIVERSAL ROBOTS Select Power On Off tab and press Turn power on for enabling power to motors Jo BROKEN COMMUNICATION ERROR J1 BROKEN COMMUNICATION ERROR J2 BROKEN COMMUNICATION ERROR J3 BROKEN COMMUNICATION ERROR J4 BROKEN COMMUNICATION ERROR J5 BROKEN COMMUNICATION ERROR Tool BROKEN COMMUNICATION ERROR Masterboard DI
58. tic field present Servicemanual_UR5_ en_rev3 0 2 CODE_75A4 CODE_75A32 CODE_76 CODE_100 CODE_101 CODE_102 CODE_103 CODE_103A1 CODE_104 CODE_111 CODE_116 CODE_117 CODE_150 CODE_151 CODE_152 CODE_153 CODE_154 CODE_155 CODE_156 CODE_172 CODE _184 CODE_191 CODE_191A1 CODE_191A2 CODE_191A3 CODE_191A4 CODE_191A5 CODE_191A6 CODE_191A7 CODE_191A8 UNIVERSAL ROBOTS System error malfunction or inconsistent calibration detected Signal lost Misaligned readhead or damaged ring Joint encoder communication CRC error Robot changed mode Status warning general modus change Real Robot Connected Real Robot not connected Simulating Robot UR Ethernet Error 3 packages in a row lost from Safety Control Board Error Empty command sent to robot Something is pulling the robot Realtime part warning Possible CPU overload due to structure of user program Restart SCB failed The Safety Control Board couldn t be rebooted from the controller 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 Robot can not move linear in a singularity Protective Stop Robot cannot maintain its position check if payload is correct Protective Stop Wrong payload or mounting The robot may move detected or something is
59. top Force Limit Protective Stop Payload and tcp settings in Installation Mounting must correspond with actual tool Are settings incorrect Is center of mass very different from tcp point Are waypoints positioned very close to cylindrical area around base of robot where robot can not operate Are robot moving with excessive speed or accelerating very hard Press teach button on back of TP and check the teach function of all joints gt any abnormal friction or behavior observed Contact distributor from where robot has been purchased All rights reserved UNIVERSAL ROBOTS Adjust payload and tcp settings Adjust center of mass using script code set_payload software v1 7 or newer Adjust waypoints away from this area or reduce speed acceleration Reduce speed or acceleration Inspect joint with abnormal behavior joint might have mechanical failure Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 5 2 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 Replace 48V power supply powe
60. ttings 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 Servicemanual_UR5_en_rev3 0 2 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 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 O 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 All rights reserved 67 UNIVERSAL ROBOTS problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or more joints Serial communication problem with one or
61. tware after successful update controller will automatically shut power off e Remove USB stick and boot robot All rights reserved 61 Servicemanual_UR5_en_rev3 0 2 UNIVERSAL ROBOTS 4 2 Update joint firmware Each joint on robot arm is provided with firmware for controlling the joint For normal operation firmware update is not required Software can be updated on robot without updating the firmware IMPORTANT NOTICE e Firmware should only be updated after consulting Distributor from where the robot has been purchased or if representing a Distributor after consulting Universal Robots e Universal Robots do not recommend updating firmware without proper instruction in how to update firmware e When updating firmware it is strictly forbidden to turn off controller or to remove cable between controller and robot arm during update e Universal Robots can be no means be held responsible for any failed update caused by improper operation Instruction for updating firmware Prior to updating firmware it is required to update the robot software Please refer to chapter 4 2 for updating software When updating robot software the firmware will automatically be copied to a folder on the controller e Drag a finger from left to right across the UNIVERSAL sign on main screen of PolyScope Universal Robots Graphical Programming Environment PolyScope Robot User Interface Please select RUN Program UNIVERSAL ROBOTS EEN

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