Universal Robots UR10 Service Manual

With cb3.0/3.1-controller

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Summary of Contents for Universal Robots UR10

Page 1 Service Manual Revision UR10_en_3.1.3 "Original instructions" Robot: UR10 with CB3.0/3.1-controller CB3.0 valid from robot s/n 2014300001 to 2016301178 CB3.1 valid from robot s/n 2016301179...
Page 2: Table Of Contents
2.2.1 Visual inspection ........................9 3. Service and Replacement of parts ....................... 10 3.1 Robot arm ............................10 3.1.1 Before returning any part to Universal Robots ..............10 3.1.2 Robot arm configuration ....................11 3.1.3 Brake release ........................12 3.1.4 General guidance to separate joint from counterpart ............13 3.1.5 Torque values ........................
Page 3 3.2.1 Handling ESD-sensitive parts ..................... 44 3.2.2 Replacement of motherboard 3.0 ..................48 3.2.3 Replacement of motherboard 3.1 ..................51 3.2.4 Replacement of Safety Control Board ................54 3.2.5 Replacement of teach pendant..................57 3.2.6 Replacement of 48V power supply ..................59 3.2.7 Replacement of 12V power supply ..................
Page 4: General Information
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.
Page 5: Company Details
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.
Page 6: Preventive Maintenance
2 Preventive Maintenance 2.1 Controller 2.1.1 Inspection plan, Safety Functions The safety functions of the robots must be tested at least once a year to ensure correct function. The following tests must be performed.  Test that the Emergency Stop button on the Teach Pendant functions: Press the Emergency Stop button on the Teach Pendant Observe that the robot stops and turns off the power to the joints Power on robot again...
Page 7  Verify safety settings: 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: Check which safety inputs and outputs are active and test that they can be triggered. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 8: Visual Inspection
2.1.2 Visual inspection  Disconnect power cable from controller  Check terminals are properly inserted on Safety Control Board  Check all connections on Motherboard and connection between Safety Control Board and Motherboard  Check for any dirt/dust inside of controller, clean with vacuum cleaner if needed »...
Page 9: Robot Arm
2.2 Robot arm 2.2.1 Visual inspection  If you observe dirt/oil on the robot arm you simply clean it with a soft cloth. Cleaning agent: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha In very rare cases the grease is from the inside of the joint. There is still enough grease in the gear for life time you just clean the joint with a cloth.
Page 10: Service And Replacement Of Parts
Universal Robots cannot be held responsible for damage caused to non-UR equipment mounted on the robot.  Backup all relevant files before sending the robot/part to UR. Universal Robots cannot be held responsible for loss of programs, data or files stored in the robot. Safety notice: If the robot/part has been in contact with, or working in environments, where dangerous chemicals or materials are present, the robot must be cleaned before shipment.
Page 11: Robot Arm Configuration
3.1.2 Robot arm configuration 3.1.14 Tool flange – Wrist 3 joint 3.1.13 Wrist 3 joint – Wrist 2 joint 3.1.12 Wrist 2 joint – Wrist 1 joint 3.1.11 Wrist 1 joint – Lower arm Error! Reference source not found. 3.1.9 Elbow joint – Upper arm 3.1.8 Upper arm –...
Page 12: Brake Release
3.1.3 Brake release If required, the brake on a joint can be released without power connected. IMPORTANT NOTICE:  Before releasing a brake, it is extremely important to dismount any dangerous parts to avoid any hazardous situations.  If releasing the brake on Base joint, Shoulder joint or Elbow joint, it is important to make proper mechanical support prior to releasing the brake.
Page 13: General Guidance To Separate Joint From Counterpart
3.1.4 General guidance to separate joint from counterpart Disassemble: 1. Check if the necessary tools and documentation are available before starting a repair. Service kit with torque tools, ESD Wristband, etc. b. Thoroughly read and understand this guide. 2. Move the robot to a comfortable position for disassembly or if necessary dismount entire robot arm from work cell and place on a solid surface.
Page 14 7. Disconnect wires 8. Remove alignment screw. 9. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint housing. 10. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws with an open-ended spanner approximately two full turns each.
Page 15 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.
Page 16 5. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring. 0.4Nm. 6. Mount the alignment screw and tighten with Twist the communication cable 1.5 to 2 full rounds before it is connected. (To reduce electrical noise in the system) 0.4Nm.
Page 17: Torque Values
3.1.5 Torque values UR10 torque values CONNECTION TORQUE HEAD SIZE Base mounting bracket J0 BASE 8.0Nm 10 mm. [J0] Base [J1] Shoulder 8.0Nm 10 mm. [J1] Shoulder Upper arm 8.0Nm 10 mm. Upper arm [J2] Elbow 2.6-3.0Nm 7 mm. [J2] Elbow Elbow counter part 2.6-3.0Nm...
Page 18: Base Joint - Base Mounting Bracket
3.1.6 Base joint – Base mounting bracket Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Shut down the controller. 2. Remove alignment screw. 3. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint housing.
Page 19 Base joint – Base mounting bracket: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Replace base mounting bracket and reconnect wires according to illustration: Twist the communication cable 1.5 to 2 full rounds before it is connected. (To reduce electrical noise in the system) 3.
Page 20: Shoulder Joint - Base Joint
3.1.7 Shoulder joint – Base joint Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Shut down the controller. 2. Remove blue lid on Base joint. 3. Connect ESD wristband 4. Disconnect wires between Base joint and Shoulder joint 2 x red wire = 48V DC 2 x black wire...
Page 21 Shoulder joint – Base joint: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Gently insert Base joint with screws and washers into the Shoulder joint. 2. Make sure the washers are fully inserted and located on the correct side (this is important) before gently twisting the Base joint and Shoulder joint in opposite directions until a mechanical stop is met.
Page 22: Upper Arm - Shoulder Joint
3.1.8 Upper arm – Shoulder joint Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Shut down the controller. 2. Remove blue lid on Shoulder joint. 3. Connect ESD wristband 4. Disconnect wires between Upper arm and Shoulder joint 1 x red wire = 48V DC 1 x black wire...
Page 23 Upper arm – Shoulder joint: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Gently insert Shoulder joint with screws and washers into the upper arm. 2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important) before gently twisting the parts in opposite directions until a mechanical stop is met.
Page 24: Elbow Joint - Upper Arm
3.1.9 Elbow joint – Upper arm Disassemble and assemble Procedure for separating Elbow joint from Upper arm is similar to separation of Upper arm and Shoulder joint, consult chapter 3.1.8 Upper arm – Shoulder joint Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1.
Page 25 Elbow counterpart – Elbow joint: assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Gently insert Elbow joint with screws and washers into the Elbow counterpart. 2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important) before gently twisting the parts in opposite directions until a mechanical stop is met.
Page 26: Wrist 1 Joint - Lower Arm
3.1.11 Wrist 1 joint – Lower arm Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart Shut down the controller. 1. Remove blue lid on Wrist 1 joint. 2. Connect ESD wristband 3. Disconnect wires between lower arm and Wrist 1 joint. 1 x red wire = 48V DC 1 x black wire...
Page 27 Wrist 1 joint – Lower arm: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Gently insert Wrist 1 joint with screws and washers into the lower arm. 2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important) before gently twisting the parts in opposite directions until a mechanical stop is met.
Page 28: Wrist 2 Joint - Wrist 1 Joint
3.1.12 Wrist 2 joint – Wrist 1 joint Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart Shut down the controller. 1. Remove blue lid on Wrist 1 joint. 2. Connect ESD wristband 3. Disconnect wires between Wrist 1 joint and Wrist 2 joint 1 x red wire = 48V DC 1 x black wire...
Page 29 Wrist 2 joint – Wrist 1 joint: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Gently insert Wrist 1 joint with screws and washers into Wrist 2 joint. 2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important) before gently twisting the parts in opposite directions until a mechanical stop is met.
Page 30: Wrist 3 Joint - Wrist 2 Joint
3.1.13 Wrist 3 joint – Wrist 2 joint Disassemble and assemble Procedure for separating Wrist 3 joint from Wrist 2 is similar to separation of Wrist 2 joint and Wrist 1 joint, consult chapter 3.1.12 Wrist 2 joint – Wrist 1 joint 3.1.14 Tool flange –...
Page 31 Tool flange – Wrist 3 joint: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Connect ESD wristband 2. Replace tool flange and reconnect connectors as illustrated. Twist the communication cable 1.5 to 2 full rounds before it is connected (To reduce electrical noise in the system) 4.
Page 32: Instructions For Calibrating A Joint
3.1.15 Instructions for calibrating a joint After replacement calibration of the new joint is required in order to find the correct zero position. If it is possible and necessary, perform the 3.1.16 Dual Robot calibration alternative perform a joint calibration. Instructions for calibrating a joint: 1.
Page 35 7. Select the desired joint by directly clicking the status line for that joint. 8. Press Arm current joint to release the brake on the selected joint. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 36 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. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 37 9. Zero position illustrations Base: Shoulder, Elbow, Wrist 1: Base zero position is aligned so that the Shoulder, Elbow and Wrist 1 zero output flange is output flange is offset 180 degrees from vertical aligned (if Base if horizontal). the cable in back of robot base. Make sure that base of robot is horizontal, use spirit level to align joints.
Page 39 12. Press Return to Normal. 13. Verify zero position by moving the robot to HOME. If not satisfied with the zero position, perform the procedure once again. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 40: Dual Robot Calibration
3.1.16 Dual Robot calibration Dual Robot Calibration kit (Part no: 185500) Dual Robot Calibration is a calibration that calibrates the robot in the full work space. All robots are Dual Robot Calibrated when they are produced. If a joint has been replaced on a calibrated robot the calibration is not correct anymore. There are 2 options: Performing a Dual Robot Calibration after replacement of a joint will let the robot continue in the production line without modifying waypoints in the robot program.
Page 41: Change Joint Id
3.1.17 Change joint ID Each joint has a unique ID no. It is NOT possible to have two joints with the same ID no. on the same robot. Joint Base Shoulder Elbow Wrist 1 Wrist 2 Wrist 3 Example: Wrist 1 (J3) has to be replaced. Spare joint is a Wrist 3 (J5) 1.
Page 42 5. Select Joint ID 6. Select J5 (The one to be changed) 7. Uncheck “Exchange IDs” box 8. In dropdown box, select ID no. 3 9. Press Set it 10. Confirm Change ID 11. After you have turned power on you can see the joint J5 has changed to J3. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 43: Joint Spare Part Adaptation
3.1.18 Joint spare part adaptation The UR5 and UR10 are constructed of 4 joint sizes and have to be setup on the robot: Recommended spare joints for UR5 and UR10 are marked with: Robot: UR10 Wrist 3: ID =5 Size 1*...
Page 44: Controller
3.2 Controller 3.2.1 Handling ESD-sensitive parts To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic cards: Keep the ESD-sensitive part in its original shipping container. (a special "ESD bag") until the part is ready to be installed Put the ESD wrist strap on your...
Page 45 Step 2: Step 1: Take NEW board out of ESD bag. Put OLD board into spare ESD bag. Hold the ESD-sensitive part by its edges; do not touch its pins. If a pluggable module is being removed, then use the correct tool. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 46 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.
Page 47 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. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 48: Replacement Of Motherboard 3.0
3.2.2 Replacement of motherboard 3.0 Take care of ESD handling 3.2.1 Handling ESD-sensitive parts Motherboard 3.0 uses flash memory card. Motherboard 3.1 uses USB memory stick. 1. Shut down the controller and disconnect the power cable, open the controller cabinet and loosen the 3 Torx screws 2.
Page 49 3. Disconnect cable connections from motherboard: 1. White plug with white, brown, yellow and green wires. 12 V Power 2. Black USB cable for TP USB connector 3. Ethernet cable to external connector 4. Ethernet cable to Safety control board SCB 5.
Page 50 12. Remove the 4 screws from the 2 holding brackets NB! Ethernet cable to Safety Control Board 13. Replace Motherboard with new one 14. If controller is equipped with long-hole brackets, make sure to replace them with circular-hole brackets. Tighten the 4 screws gently 15.
Page 51: Replacement Of Motherboard 3.1
3.2.3 Replacement of motherboard 3.1 Take care of ESD handling 3.2.1 Handling ESD-sensitive parts Motherboard 3.0 uses flash memory card. Motherboard 3.1 uses USB memory stick. 1. Shut down the controller and disconnect the power cable, open the controller cabinet and loosen the 3 Torx screws 2.
Page 52 3. Disconnect cable connections from motherboard: 1. White plug with white, brown, yellow and green wires. 12 V Power 2. DVI-cable for TP screen 3. Ethernet cable to Safety control board SCB 4. Ethernet cable to external connector 5. Black USB cable for TP USB connector 6.
Page 53 5. Replace Motherboard. 6. Insert the 6 cables in correct connectors. 7. Re-install USB stick for UR system SW. 8. Carefully put back the aluminum cover plate, make sure to mount it correct and fix it with the 3 screws All rights reserved Servicemanual_UR10_en_3.1.3...
Page 54: Replacement Of Safety Control Board
3.2.4 Replacement of Safety Control Board Take care of ESD handling 3.2.1 Handling ESD-sensitive parts How to replace Safety Control Board in Controller box 1. Check that the software on the robot is as new as the firmware version on the SCB. If the software on the robot is too old, then you get an error C203A0.
Page 55 2. Shut down the controller and disconnect the power cable, open the controller cabinet Carefully remove all plugs and connectors 3. Loosen the 5 Torx screws and remove the aluminum cover. All rights reserved Servicemanual_UR10_en_3.1.3...
Page 56 4. Carefully remove all plugs and connectors 5. Remove 14 screws holding the Safety Control Board. 6. Replace Safety Control Board with new one and tighten the 14 screws to hold the board 7. Insert all connectors and plugs in correct positions. Eventually see section 5.4.1 Schematic overview 8.
Page 57: Replacement Of Teach Pendant
3.2.5 Replacement of teach pendant Take care of ESD handling 3.2.1 Handling ESD-sensitive parts Note: use the same procedure for power down and removing the aluminum cover plates as in chapter 3.2.2 Replacement of motherboard 3.0 3.2.3 Replacement of motherboard 3.1 3.2.4 Replacement of Safety Control Board 1.
Page 58 2. Remove the bracket (foot of the controller box) that holds the cable inlet and pull out the cables and plugs through this hole. 3. Replace teach pendant with new, insert cable in cable inlet and perform reconnection of all plugs and mounting of aluminum cover in reverse order to the above description.
Page 59: Replacement Of 48V Power Supply
3.2.6 Replacement of 48V power supply Take care of ESD handling 3.2.1 Handling ESD-sensitive parts How to replace 48V power supply in Controller box Note: use the same procedure for power down and removing the aluminum cover plates as in chapter 3.2.2 Replacement of motherboard 3.0 3.2.3 Replacement of motherboard 3.1...
Page 60 5. Power supplies are located in the rack under the controller module, the two 48V power supplies are the lower ones in the rack. (UR5 have one and the UR10 have two 48V power supplies) Before dismounting the 48V power supply, mark and disconnect the cables from that supply.
Page 61 6. Remove the screws respectively of the defective 48V power supply from the side of the rack. 7. Replace 48V power supply with new one. 8. Reconnect the wires for the 48V power supply. 9. Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the teach pendant.
Page 62: Replacement Of 12V Power Supply
3.2.7 Replacement of 12V power supply Take care of ESD handling 3.2.1 Handling ESD-sensitive parts How to replace 12V power supply in Controller box Note: use the same procedure for power down and removing the aluminum cover plate and cables for teach pendant as in chapter 3.2.5 Replacement of teach pendant To replace the 12V power supply follow exactly the same steps as for the procedure in chapter...
Page 63: Replacement Of Current Distributor
3.2.8 Replacement of current distributor Take care of ESD handling 3.2.1 Handling ESD-sensitive parts How to replace current distributor in Controller box Note: use the same procedure for power down and removing the aluminum cover plate and cables for teach pendant as in chapter 3.2.5 Replacement of teach pendant 1.
Page 64: Software
4. Software 4.1 Update software Universal Robots software is named PolyScope. Read This Prior to Updating Your Software: Updating the software may cause changes or restrictions to functionality. 1. Do not downgrade the software to earlier version than the version the robot was produced with.
Page 65 6. In left side menu, select Update Robot. 7. Press button Search for searching after software update on USB-stick. 8. Select the desired software update and press UPDATE. 9. Press YES to update the software. 10. Wait for update to complete, after successful update controller will automatically reboot. 11.
Page 66: Update Joint Firmware
Software version before 3.1.16828: IMPORTANT NOTICE: 19. When updating firmware controller power MUST NOT be turned off during update. 20. Universal Robots can by no means be held responsible for any failed update caused by improper operation. Instructions for updating firmware: Prior to updating firmware, robot software must be updated.
Page 67 3. You are now in Expert Mode, press Low Level Control. 4. Press Turn power on to go into BOOTLOADER 5. Select the Firmware tab, mark All joints and press UPDATE Firmware. 6. Firmware update is being processed, await message that robot firmware updated successfully. Controller MUST NOT be powered off during this update.
Page 69: Using Magic Files
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 ...
Page 70: Troubleshooting
5. Troubleshooting In the error codes different words have been used for the same thing:  On the Safety Control Board: Processor A = A uP = SafetySys1  On the Safety Control Board: Processor B = B uP = SafetySys2 PSU = Power Supply PC = Controller Open log files with Support Log Reader.
Page 71 C4A6 Communication with primary If either processor A or a) Check Euromap67 EUROMAP67 uP lost processer B is communicating, connection between Euromap67 or cable between Motherboard and the Motherboard and Euromap67. B) Exchange Euromap is defect Euromap67 C4A7 Communication with If either processor A or a) Check Euromap67 secondary EUROMAP67 uP...
Page 72 C4A76 Lost package from tool 1 package lost – warning C4A77 Lost package from uPA to 1 package lost – warning joints C4A78 Lost package from uPA to 1 package lost – warning teach pendant C4A79 Lost package from uPA to uPB 1 package lost –...
Page 73 Broken PC communication Eventually update the error software C10A1 Lost packet from PC Eventually update the software C10A101 PC packet received too early Eventually update the software C10A102 Packet counter does not Eventually update the match software C10A103 PC is sending packets too often Eventually update the software Bad CRC error...
Page 74 Inbuffer parse error Serial communication problem Check black 2-wire with joint connectors and wires in joints Online RAM test failed Replace Item C38A1 Data-bus test failed Replace Item C38A2 Address-bus stuck-high test Replace Item failed C38A3 Address-bus stuck-low test Replace Item failed C38A4 Address-bus shorted test failed...
Page 75 C44A1 Joint 1 CRC check failure on Serial communication problem Replace joint 1 primary bus with joint or secondary bus node C44A2 Joint 2 CRC check failure on Serial communication problem Replace joint 2 primary bus with joint or secondary bus node C44A3 Joint 3 CRC check failure on...
Page 76 C50A5 Powersupply voltage too low C50A6 Powersupply voltage too high C50A11 Voltage not detected at 24V 24 V to the I/O interface in the rail after startup controller C50A15 Warning, waiting for SafetySYS2 = Processor B on SafetySYS2 Safety Control Board C50A16 The Teach Pendant does not Loose wire or incorrect safety...
Page 77 C50A43 Warning, waiting for CB2 type answer from primary processor C50A50 Processor A 3.3V supply voltage out of bounds C50A51 Robot voltage below threshold C50A52 Robot voltage above threshold C50A53 58V generator deviation error C50A54 5V regulator too low C50A55 5V regulator too high C50A56 -4V generator too low...
Page 78 C53A2 IO overcurrent detected, max Tool error Remove tool connector. is 600mA Check for short circuit Safety system error Safety system malfunction Check Motherboard, Safety Control Board, Screenboard, Current distributor (Euromap, if installed). Bypass safety connections to I/O- interface of Safety Control Board C55A23 Safety relay error (minus...
Page 79 C55A112 Robot current sensors readings differ C55A120 Robot current is too high while emergency stopped C55A121 Robot current is too high while safeguard stopped Overvoltage shutdown Voltage exceeded 55V Check Energy Eater. Cable to Energy eater, Replace Energy Eater Brake release failure Check Brake, solenoid, Payload, TCP and Mount C57A1...
Page 80 C72A2 1 PSU active, but we expect 2 PSU was not able to deliver Check power connection (UR10) 48V or UR10 flash card in UR5 between power supply and robot Safety Control Board and check that the flash card and robot match...
Page 81 C74A207 Joint encoder error Example: Argument 207 is the Example. sum of 128,64,8,4,2,1 which means that all the errors in connection to argument 1, 2, 4, 8, 64 and 128 have been reported. Joint encoder error Magnetic encoder error (Absolut encoder) C75A1 Invalid decode: Readhead Error: The argument is the sum...
Page 82 C102 Real Robot not connected – Simulating Robot C103 UR Ethernet Error Comm. Prob. Between Mother Check cable Board and Safety Control Board C103A1 Connection to Safety Control PC did not receive 3 packets in Check that the Ethernet Board lost a row cable between PC board and Safety Control Board is...
Page 83 this case, click “Power Off Robot”. 3. If the position is correct, please tick the check box below the 3D graphics and click “Robot Position Verified” C161 Protective stop: Large 1. Verify that the robot movement of the robot position in the 3D graphics detected while it was powered matches the real robot, to off.
Page 84 C171A10 Blend radius too small error in a MoveP C171A11 Overlapping Blends in a Decrease the blend radius MoveL, a waypoint was or choose waypoints that skipped are further apart. C171A12 Overlapping Blends in a Decrease the blend radius MoveL, a waypoint was or choose waypoints that skipped are further apart.
Page 85 C191A15 Robot is moving in stop mode When the robot is stopped Is the robot physically due to a safety violation or a pushed while safeguard safeguard stop, the safety stopped? system generates this error, if the robot moves while in this mode C191A16 Robot did not stop in time...
Page 86 C192A4 Safeguard stop disagreement Safeguard circuit problem Check cables or replace Safety Control Board (SCB) C192A5 Euromap safeguard stop Euromap circuit problem Check cables from Safety disagreement Control Board to Euromap to external machine C192A6 Joint position disagreement Reduce payload, check for encoder problems C192A7 Joint speed disagreement...
Page 87 C192A31 Reduced Mode Output Safety I/O uP-A and uP-B Check Cables and Software disagreement disagreement error on motherboard C192A32 Not Reduced Mode Output Safety I/O uP-A and uP-B Check Cables and Software disagreement disagreement error on motherboard C192A33 Checksum disagreement between uA and uB C192A34 User safety config checksum...
Page 88 C193A9 Euromap 1 is in fault mode SCB has detected an error See previous error or reboot system C193A10 Euromap 2 is in fault mode SCB has detected an error See previous error or reboot system C194 One of the nodes is not booted or not present C194A0 Joint 0 is not booted or not...
Page 89 C194A134 Tool not ready while brake Must be at least in IDLE mode 1. Check for loose release requested when the brake release is communication cable. 2. requested Replace Tool C195 Conveyor speed too high Conveyor speed higher than Make sure that conveyor robot is able to run tracking is set correct up C195A1...
Page 90 C200A16 24V IO short circuited Too high current Disconnect external connections C200A17 PC current is too high Motherboard takes too high current C200A18 Robot voltage is too low Check: Short circuit in robot arm, 48 V power supply, current distributer energy eater or replace SCB C200A19 Robot voltage is too high...
Page 91 C204A4 Robot is not braking in stop or If this happens, report it as pause mode a bug C204A5 Robot program resulted in invalid setpoint C204A6 Blending failed and resulted in Try changing the blend an invalid setpoint radius or contact technical support C205 Target speed does not match...
Page 92: Led Indicators And Fuses On Safety Control Board
5.2 LED indicators and Fuses on Safety Control Board Safety Control Board (SCB) Fuse 48 V: The 5 A fuse “48 V” protects all 48 V for over current in the system inclusive Euromap. This information is only for troubleshooting. Do NOT replace the fuse on any circumstances. Do ONLY replace the SCB with a new tested board.
Page 93 Normal startup sequence for a CB3.x UR10: 1. The 12V-PSU LED is on when the power plug is connected to a working power supply. 2. When the power button on the teach pendant is pressed, all LED indicators are turned on except for the 48V, 24V and R LEDs.
Page 94: Error Phenomena
5.3 Error phenomena 5.3.1 ControlBox: NO CONTROLLER displayed in Initializing ControlBox = NO CONTROLLER displayed at INITIALIZING screen Replace Ethernet cable between motherboard Defective Ethernet cable and Safety Control Board and verify problem is solved Replace Safety Control Board and verify problem Defective Safety Control is solved Board...
Page 95: No Cable Displayed During Power Up
5.3.2 NO CABLE displayed during power up NO CABLE displayed during power up > controller shuts off after few seconds Measure that 230V AC is present on power input Replace current distributor connector on 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.
Page 96: Protective Stop
5.3.3 Protective stop Read also article 18939 on the support site Protective Stop www.universal-robots.com/support Payload and tcp settings in Installation\TCP Adjust payload and tcp Configuration must correspond with actual tool. settings Are settings incorrect? Adjust center of mass in the Is center of mass very different from tcp point? TCP tap or using script code set_payload()
Page 97: Power On Failure In Initializing
5.3.4 Power on failure in Initializing If power turns off a few seconds after Robot Power is turned On in the Initializing window, there are many possible causes for this phenomenon. Most likely it is a control box failure or a communication failure with a joint or the tool. Control box failure Check log history for error messages and consult the section Error Codes for detailed explanation...
Page 98 Read also article 19744 on the support site Communication failure with a joint or the tool connector www.universal-robots.com/support 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) Unmount tool/joint and...
Page 99 Continued Go to tab General and press “TURN POWER ON” Remove blue lid of joint and and “Go to Idle” and “Arm robot”. Does state of check black comm. all joints J0-J5 switch from “Power OFF” to connector is fully inserted READY? Does state of joint switch to READY?
Page 100: Checklist After A Collision
5.3.5 Checklist after a collision Checklist after a collision Check log history for error messages and consult the section Error Codes for detailed explanation Stop robot program and eventually press the Emergency button prior to entering the work cell Visually inspect robot arm. Remove lid and inspect Are any parts visually damaged, like damages on parts inside of joint...
Page 101: Electrical Documentation
5.4 Electrical documentation 5.4.1 Schematic overview Diagrams in pdf or in E-plan format, can be found on the Support site: http://www.universal-robots.com/support/ All rights reserved Servicemanual_UR10_en_3.1.3...
Page 107: E-Plan Diagrams
5.4.2 E-Plan diagrams Diagrams in pdf or in E-plan format, can be found on the Support site: http://www.universal-robots.com/support/ All rights reserved Servicemanual_UR10_en_3.1.3...
Page 120: Spare Parts
Power Supply Unit 48V 172080 Current Distributor PCB 122745 Energy-eater incl. fan CB3 164229 Connector Epic w. cable UR10 CB3 (Controller output connector to robot arm) 171030 RAM module for Motherboard 3.0 171031 RAM module DDR3L for Motherboard 3.1 177503...
Page 121: Service Kit
Bracket for Mounting Teach Pendant 132407 Bracket for Mounting Controller 107000 Safety Control board Terminal Kit 131510 Bracket for mounting robot arm UR10 (Item & Bosch profile) 6.2 Service kit Item no. Item designation 109010 Service kit UR5/UR10 (kit includes all of the below part no.’s) 109101 Spanner Hex 5.5mm...
Page 122: Packing Of Robot
7. Packing of robot Packing of robot and controller box for shipment  Remove any external tooling and external electrical connections.  Download the Put_Into_Box program to a USB stick. Download it from: http://www.universal-robots.com/support/  Load program Put_into_box_ur10.urp and follow instructions while removing mounting bolts. While robot folds together, hold a piece of bubble wrap between Shoulder joint and wrists.
Page 123: Change Log
8. Change log Date Revision Action Changes 3. May 2014 UR10_en_3.0 Added First revision 3.0 released 19. June 2014 UR10_en_3.0.1 Changed Pictures and illustrations changed to match 3. gen. robot 11. July 2014 UR10_en_3.0.2 Changed Error codes, Spareparts changed to match 3. Gen robot and ESD handling added 20.

Universal Robots UR10 Service Manual

1 General Information

3 Service and Replacement of Parts

4 Software

5 Troubleshooting

6 Spare Parts

7 Packing of Robot

8 Change Log

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