Universal Robots UR5 Service Manual

With cb3.0/cb3.1-controller

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Service manual (238 pages)

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Summary of Contents for Universal Robots UR5

Page 1 Service Manual Revision UR5_en_3.2.0 "Original instructions" Robot: UR5 with CB3.0/CB3.1-controller CB3.0 valid from robot s/n 2014350001 to 2016351863 CB3.1 valid from robot s/n 2016351864...
Page 2: Table Of Contents
3.0.0 Handling ESD-sensitive parts ..................... 12 3.0.1 Recommended Tools ......................15 3.1 Robot arm ............................16 3.1.1 Before returning any part to Universal Robots ..............16 3.1.2 Robot arm configuration ....................17 3.1.3 Brake release ........................18 3.1.4 General guidance to separate joint from counterpart ............19 3.1.5 Torque values ........................
Page 3 5.1 Error codes ............................94 5.2 LED indicators and Fuses on Safety Control Board ............... 126 5.2.1 Normal startup sequence for a CB3.x UR5 ..............127 5.3 Error phenomena .......................... 128 5.3.1 Control Box: NO CONTROLLER displayed in Initializing ........... 128 5.3.2 NO CABLE displayed during power up ................
Page 4: General Information
However, any improper use of robot can potentially cause failures. If for example, the robot is overloaded, run with a load not recommended by Universal Robots, dropped during relocation., damaged by collision or any other improper usage, the warranty will be void.
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: Warning Symbols In This Manual
1.4 Warning Symbols in this Manual DANGER, WARNING, CAUTION, NOTICE and SAFETY INSTRUCTION statements are used throughout this manual to emphasize important and critical information. You MUST read these statements to help ensure safety and to prevent product damage. The statements are defined below. DANGER: These warnings mean that it is curtain or high probable that death or severe injuries will occur, if no precautions are taken.
Page 7: Preventive Maintenance
2. Preventive Maintenance It is recommended to perform preventive maintenance on the control box and robot at least once per year. In case of use in dirty or dusty environments it is recommended to increase the frequency. In case dust/dirt/oil is observed on the controller or robot arm, it can be wiped away using a cloth with cleaning agent.
Page 8 • Test Freedrive mode: • Unmount attachment or set TCP/Payload/CoG according to tool specifications • Set the robot in Free drive mode by holding the black Freedrive button on the back of the Teach Pendant • Move the robot to a position stretched out horizontally to the edge of its workspace •...
Page 9: Visual Inspection
2.1.2 Visual inspection • Disconnect power cable from controller • Check terminals are properly inserted on Safety Control Board and check for loose wires in the terminals • Check all connections on Motherboard and connection between Safety Control Board and Motherboard •...
Page 10: Cleaning And Replacement Of Filters
2.1.3 Cleaning and replacement of filters • Controller box has two filters, one mounted on each side of the box • Remove filters from controller box and clean them thoroughly using low pressure air o Replace filters if necessary o Gently remove the outer plastic frame and maintain the filter All rights reserved Servicemanual_UR5_en_3.2.0...
Page 11: Robot Arm
2.2 Robot arm 2.2.1 Visual inspection NOTICE: Never use compressed air to clean the robot as it can damage the seals and internal components. Move robot arm to HOME position (if possible) • Turn off and disconnect power cable from controller •...
Page 12: Service And Replacement Of Parts
3. Service and Replacement of parts 3.0.0 Handling ESD-sensitive parts To prevent damage to ESD-sensitive parts, follow the instructions below. These are in addition to standard precautions such as turning off power before removing logic cards. Keep the ESD-sensitive part in its original shipping container.
Page 13 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. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 14 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 Machine covers and metal tables are electrical grounds.
Page 15: Recommended Tools
Prevent ESD-sensitive parts from being accidentally touched by other personnel and do not put unprotected ESD- sensitive parts on a table. Be extra careful in working with ESD-sensitive parts when cold-weather and heating is used because low humidity increases static electricity. 3.0.1 Recommended Tools Robot arm: •...
Page 16: Robot Arm
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 INSTRUCTION...
Page 17: Robot Arm Configuration
3.1.2 Robot arm configuration 3.1.14 Tool flange – Wrist 3 joint Wrist 3 Tool flange 3.1.13 Wrist 3 joint – Wrist 2 joint 3.1.12 Wrist 2 joint – Wrist 1 joint Wrist 2 Wrist 1 3.1.11 Wrist 1 joint – Lower arm Elbow counterpart and lower...
Page 18: Brake Release
3.1.3 Brake release If required, the brake on a joint can be released without power connected. CAUTION: • 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 19: General Guidance To Separate Joint From Counterpart
3.1.4 General guidance to separate joint from counterpart Disassemble: 1. Ensure that the necessary tools and documentation are available before starting the repair. 1.1. Service kit with torque tools, ESD Wristband, etc. 1.2. 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 20 7. Disconnect wires. 8. Remove alignment screw (Not present on newer joint housings). 9. Gently remove black flexible flat ring with a small flathead screwdriver or similar tool and pull it back over joint housing away from its original position. 10.
Page 21 Assemble: After replacing a joint etc. do as follows to assemble the robot arm. 1. Gently insert a screw with washer already on the thread into each of the ten threaded holes in the joint housing (the joint will most likely have these already inserted). 2.
Page 22 4. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring. 0.4Nm. 5. Mount the alignment screw (if present) and tighten with Twist the communication cable 1.5 to 2 full rounds before connecting. (To reduce electrical noise in the system) 0.4Nm.
Page 23: Torque Values
3.1.5 Torque values UR5 torque values CONNECTION TORQUE HEAD SIZE Base mounting bracket J0 Base 2.6-3.0Nm 7 mm. [J0] Base [J1] Shoulder 2.6-3.0Nm 7 mm. [J1] Shoulder Upper arm 2.6-3.0Nm Hex key 3 Upper arm [J2] Elbow 2.6-3.0Nm Hex key 3...
Page 24: 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 25 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 plate 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 26: 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 1 x red wire = 48V DC 1 x black wire...
Page 27 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 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: 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 29 Upper arm – Shoulder joint: Assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart 1. Gently assembly the Shoulder joint with upper arm end mount screws into shoulder joint. in cross order with 3.0Nm. 2.
Page 30: 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 3.1.10 Elbow counterpart – Elbow joint Disassemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart...
Page 31 Elbow counterpart – Elbow joint: assemble For details and photos please see: 3.1.4 General guidance to separate joint from counterpart Reconnect connectors. Twist the communication cable 1.5 to 2 full rounds before it is connected. (To reduce electrical noise in the system) 3.
Page 32: 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 1. Shut down the controller. 2. Remove blue lid on Wrist 1 joint. 3. Connect ESD wristband 4. Disconnect wires between lower arm and Wrist 1 joint. 1 x red wire = 48V DC 1 x black wire...
Page 33 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 34: 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 35 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 36: 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 37 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 38: Instructions For Calibrating A Joint
1. Jog robot to HOME position Illustration shows the HOME position, which is defined as zero position of all joints. 2. Swipe from left to right across the UNIVERSAL ROBOTS logo on main screen of PolyScope. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 39 3. Enter password lightbot and press OK. lightbot 4. You are now in Expert Mode, press Low Level Control. WARNING: In Low Level Control, only the safety settings in the Polyscope Installation tab are active. The protective stop is NOT active. Set all safety settings to their lowest settings before moving the robot.
Page 41 7. Select the desired joint by directly clicking the status line for that joint. Currently selected joint is highlighted in blue. 8. Press Arm current joint to release the brake on the selected joint. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 42 Use the Up and Down buttons in the Move window to rotate 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_UR5_en_3.2.0...
Page 43 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 output flange is offset 180 degrees from vertically aligned (assuming Base is horizontal). the cable at the back of the robot base. Make sure that base of robot is horizontal, use spirit level to align joints.
Page 45 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_UR5_en_3.2.0...
Page 46: Dual Robot Calibration
3.1.16 Dual Robot Calibration. Dual Robot Calibration kit (Part no: 185500) The Dual Robot Calibration process calibrates the robot across its full workspace. All robots are Dual Robot Calibrated before leaving the factory. If a joint has been replaced, then the factory calibration is no longer valid. There are 2 options: •...
Page 47: Change Joint Id
3.1.17 Change joint ID Each joint has a unique ID no. Having two joints with the same ID on a robot will cause communication problems and the robot will not be able to operate. Joint Base Shoulder Elbow Wrist 1 Wrist 2 Wrist 3 Example:...
Page 48 5. Select Joint ID tab 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. When the robot is powered on again, J5 will be displayed as J3. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 49: Joint Spare Part Adaptation
Size 4 * When using a joint in a different location i.e. UR5 base as UR5 Elbow, it may be necessary to change ID, connect all joints electrically, turn the joint 180 degrees in low level control by using the Move Tab Up/Down function, before mechanically assembling the robot.
Page 50: Wire Bundle Installation Guide
3.1.19 Wire bundle installation guide General As well as the Wire bundle kit for the correct joint size, the Following ESD approved tools are recommended for this replacement: • Tool for pressing in the pins • Small flat nose plier •...
Page 51 Size 1 – part number: 103501 • Insert wire bundle through joint as shown on photo, with the cable tie flush against the tool flange. • Mount the grommet into the flex plate with the tweezers or the small flat nose screwdriver. •...
Page 52 • Mount a cable tie on top of the grommet. • Tighten and cut it off with the cable tie tool. • Take the power connector: • When inserting the connector pins, make sure the barbs, shown with green arrows, are located as shown on the photo.
Page 53 • When connecting to the tool flange, tie a loose knot in the communication wire in order to shorten it and minimize the risk of trapping the wire and damaging it when reattaching the tool flange. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 54 Size 3 – part number: 103503 • Inset wire bundle as shown on photo example, with the cable tie towards the flange. • Mount the grommet into the flex plate with the tweezers or the small flat nose screwdriver. • Hold the heat shrink with tweezers while sliding down the grommet into position.
Page 55 • Mount a cable tie on top of the grommet. • Tighten and cut it off with the cable tie tool. • The two power cables (two thicker, red and black wires) needs to be stripped (approx. 5mm). • Mount the cable shoes •...
Page 56 Lower arm – part number: 103508 Note: The lower arm wire bundle kit contains wire bundle for multiple robot types. Please be sure use the correct length. • Slide the end with the two black connectors through the hole from the elbow end – see photo example.
Page 57 Upper arm – part number: 103509 Note: The lower arm wire bundle kit contains wire bundle for multiple robot types. Please be sure use the correct length. • Both ends of this wire bundle are identical so inserting in either direction is acceptable. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 58: Controller
3.2 Controller 3.2.1 Replacement of Motherboard 3.0 WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts NOTICE:...
Page 59 2. Remove the aluminum cover plate 3. Disconnect cable connections from motherboard: 1. White plug with white, brown, yellow and green wires. 12 V Power 2. Black USB cable for Teach Pendant USB connector 3. Ethernet cable to external connector 4.
Page 60 4. Remove the 4 screws from the 2 holding brackets NB! Ethernet cable to Safety Control Board 5. If controller is equipped with long-hole brackets, make sure to replace them with circular-hole brackets 6. Replace Motherboard and tighten the 4 screws gently 7.
Page 61: Replacement Of Motherboard 3.1
3.2.2 Replacement of Motherboard 3.1 WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts NOTICE:...
Page 62 2. Remove the aluminum cover plate 3. Disconnect cable connections from motherboard: 1. White plug with white, brown, yellow and green wires. 12 V Power 2. DVI-cable for Teach Pendant screen 3. Ethernet cable to Safety control board SCB 4. Ethernet cable to external connector 5.
Page 63 4. Remove the 4 screws from the 2 holding brackets 5. Replace Motherboard. 6. Insert the 6 cables in correct connectors. Pay special attention to the Ethernet cable to the Safety Control Board. It must be connected to the right connector on the mother board 7.
Page 64: Upgrading Of Motherboard 3.0 To 3.1
3.2.3 Upgrading of Motherboard 3.0 to 3.1 WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. Introduction • This section provides guidelines for exchanging an existing CB3 motherboard with a new CB3.1 motherboard.
Page 65 3.2.3.1 Hardware • Always use an ESD wristband when working on the controller. 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. •...
Page 66 • Remove the cable that connects the motherboard and Safety Control Board. This cable is no longer needed and should be disposed of. • Unscrew the motherboard by loosening the 4 x 2.5mm Allen screws and the 4 x 5,5 hex standoffs that hold the RS232 and DVI connectors All rights reserved Servicemanual_UR5_en_3.2.0...
Page 67 • Mount the smaller standoffs where the motherboard screws were before. Place the black cable from the Teach Pendant and the Ethernet cable on the left side of the Standoff as shown on the photo. Note: If your Ethernet cable has a black plug (Figure 1) at one end, then this end must be connected to the Safety Control Board.
Page 68 • Mount the motherboard onto the standoffs. Please note that the two screws toward the outside of the controller may be more difficult to get into position. • Now take the new cover for the motherboard and navigate the flat cable under the motherboard and to the connector as shown in the photo below All rights reserved Servicemanual_UR5_en_3.2.0...
Page 69 • Plug the new power cable from the SCB to the CB 3.1 motherboard as shown. • Screw on the new cover. Please note that the screw toward the outside of the controller may be difficult to get into position. •...
Page 70 Do not downgrade a robot with a CB3.1 motherboard, to a Software version below 3.1.1.7336. Doing so may cause unexpected behavior of the robot. Universal Robots assumes no responsibility for the outcome of this process. The instructions in this document shall be considered as general guidelines.
Page 71: Replacement Of Safety Control Board
3.2.4 Replacement of Safety Control Board WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts To replace Safety Control Board in Controller box:...
Page 72 2. Shut down the controller and disconnect the power cable, open the controller cabinet then carefully remove all plugs and connectors 3. remove the 5 Torx screws and followed by the aluminum cover. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 73 4. Carefully remove all plugs and connectors from the safety control board. 5. Remove the 14 screws holding the board in place. 6. Replace Safety Control Board with new one and tighten the 14 screws to fasten the board in place. 7.
Page 74: Replacement Of Teach Pendant
3.2.5 Replacement of Teach Pendant WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts Note: use the same procedure for power down and removing the aluminum cover...
Page 75 Motherboard 3.1 2. Remove the bracket (foot of the controller box) that holds the cable inlet and pull out the cables and plugs through this hole. 3. To install new teach pendant, thread cables through inlet, plug connectors into correct positions, then mount aluminum cover into place.
Page 76: Replacement Of 48V Power Supply
3.2.6 Replacement of 48V power supply WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts To replace 48V power supply in Controller box:...
Page 77 10. Power supplies are located in the rack under the controller module, the two 48V power supplies are the lower ones in the rack (UR3 and UR5 has one and UR10 has two 48V power supplies). Before removing the 48V power supply, label the wires then disconnect them from that supply.
Page 78 11. Remove the screws keeping the defective 48V power supply in place from the side of the rack. 12. Replace the defect 48V power supply with the new one. 13. Reconnect the wires for the 48V power supply. 14. Reinstall Controller module in reverse order and reconnect the 2 wires for the fan and cables for the teach pendant.
Page 79: Replacement Of 12V Power Supply
3.2.7 Replacement of 12V power supply WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts To replace 12V power supply in Controller box...
Page 80: Replacement Of Current Distributor
3.2.8 Replacement of Current distributor WARNING: Before replacing ANY components inside the control box, it is IMPORTANT to do a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete rebooting sequence. When completing the following replacement, please follow the guidelines laid out in section 3.0 Handling ESD-sensitive parts To replace current distributor in Controller box:...
Page 81 6. Carefully put back the aluminum cover plate, make sure to mount it correctly and fix it in place with the 5 screws. 7. Connect power and verify that teach pendant functions correctly. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 82: Software
Read the complete section prior to updating your software. Controller power MUST NOT be turned off during software update process. Universal Robots assume no responsibility for any failed update caused by improper operation. Updating the software may cause changes to some functionality. Always check with the release notes on the Universal Robots support site.
Page 83 6. In left side menu, select Update Robot. 7. Press button Search to search for software update files 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 84: Update Joint Firmware
. When updating robot software, the firmware will automatically be copied to a folder on the controller. 1. Swipe from left to right across the UNIVERSAL ROBOTS logo on main screen of PolyScope. 2. Enter password lightbot and press OK.
Page 85 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 87: 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 88: Backup Of Data
4.4 Backup of data NOTICE: When copying/moving files and folders, incorrect action might corrupt the file system. This section explains the process of moving required files when upgrading from motherboard with compact flashcard to motherboard with USB. 4.4.1 Hardware requirements The following hardware is needed: Compact Flash Card from the old motherboard A standard flash card reader that can read the CF-card (not included in motherboard upgrade kit).
Page 89: Software Requirements
4.4.2 Software requirements A Linux software file system driver is required; Universal robots recommend the free Linux-partition driver Ext2Fsd but other windows Linux reader can be used as well (these are however not tested by Universal Robots). 4.4.3 How to access Linux partition from Windows Download and install Ext2Fsd.
Page 90: Copy The Data From Cf-Card To Ur-Usb
4.4.4 Copy the data from CF-card to UR-USB 1. Take CF-card from control box and insert the CF-card in card reader and the UR-USB in one of the computers USB ports. Open windows explorer navigate to the CF-card open the folder “programs”, select all the files in the folder, right click and select Copy.
Page 92 In the root folder view select the folders and files highlighted in yellow, then right-click and select Copy. If the .urpass.file or .ursafetypass.file is not visible on the CF- card, then the files don’t need to be saved All rights reserved Servicemanual_UR5_en_3.2.0...
Page 93 Navigate to the UR-USB right-click on the folder root and select paste. A prompt will popup when the files are being copied, in the prompt choose Copy and replace. Check the checkbox marked yellow. 2. All required files are copied. UR-USB can now be inserted in new motherboard and booted All rights reserved Servicemanual_UR5_en_3.2.0...
Page 94: 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 Abbreviations in the troubleshooting chapter PSU = Power Supply PC = Controller...
Page 95 overloading the communication between the Safety Control Board and Motherboard. b) Do a Complete rebooting sequence as per section 5.3.7 c) Update the software Communication with Safety Control If either processor A or processer B is a) Check TCP/IP connection between Motherboard and Safety Board A uP lost communicating, the Safety Control Board Control Board.
Page 96 Primary Teach Pendant present, but Incorrect safety configuration a) Update the miscellaneous settings in the Safety Configuration C4A10 Teach Pendant safety is disabled b) Do a Complete rebooting sequence as per section 5.3.7 Secondary Teach Pendant uP Incorrect safety configuration a) Update the miscellaneous settings in the Safety Configuration C4A11 present, Teach Pendant safety is...
Page 97 Lost package from Secondary 1 package lost – warning If this appears often in the log, then: C4A69 Masterboard a) Verify that the communication cables are connected properly b) Do a Complete rebooting sequence as per section 5.3.7 Lost package from joint 0 Serial communication problem with one or If this appears often in the log, then: C4A70...
Page 98 Lost package from uPB 1 package lost – warning If this appears often in the log, then: C4A80 a) Verify that the communication cables are connected properly b) Do a Complete rebooting sequence as per section 5.3.7 Packet counter disagreement in Safety processor 1 in Teach pendant has a If this appears often in the log, then: C4A81...
Page 99 Packet counter disagreement in If this appears often in the log, then: C4A91 packet from joint 5 a) Verify that the communication cables are connected properly b) Do a Complete rebooting sequence as per section 5.3.7 Packet counter disagreement in If this appears often in the log, then: C4A92 packet from tool...
Page 100 Debug message C14A1 {float} Should not occur in the field If you see this error on a robot, report it to Universal Robots. C14A2 {signed} Should not occur in the field If you see this error on a robot, report it to Universal Robots.
Page 101 Inbuffer parse error Serial communication problem with joint Check black 2-wire connectors and wires in joints Online RAM test failed Check the log file for what item is reporting this error. Replace the reporting item Data-bus test failed Check the log file for what item is reporting this error. Replace C38A1 the reporting item Address-bus stuck-high test failed...
Page 102 Watchpoint fault: Joint-encoder task C39A103 timeout Watchpoint fault: Communication C39A104 task timeout Watchpoint fault: RAM-test task C39A105 timeout Watchpoint fault: CalVal-test task C39A106 timeout Watchpoint fault: ROM-test task C39A107 timeout AD-Converter hit high limit joint EMC issue external or electronics internal Check grounding and shielding for EMC problems CRC check failure on primary bus Serial communication problem with joint...
Page 103 c) If this happens more than two times in a row, contact your local service provider for assistance Joint 5 CRC check failure on primary Serial communication problem with joint a) Check black 2-wire connectors and wires in joints or secondary bus node b) Do a Complete rebooting sequence as per section 5.3.7 C44A5 c) If this happens more than two times in a row, contact your...
Page 104 Voltage not detected at 24V rail after 24 V to the I/O interface in the controller C50A11 startup Warning, waiting for SafetySYS2 SafetySYS2 = Processor B on Safety Control C50A15 Board The Teach Pendant does not respond Loose wire or incorrect safety a) Check the Teach Pendant cable and connections.
Page 105 C50A29 Analog I/O error (-12V too high) C50A30 Analog I/O error (-12V too low) C50A31 The other safetySYS do not initialize C50A40 Wrong voltage from Power supply1 C50A41 Wrong voltage from Power supply2 Voltage will not disappear from C50A42 Power supply Warning, waiting for CB2 type C50A43 answer from primary processor...
Page 106 Short circuit in robot detected or Robot Problem: 48V power supply or Check robot type. Look for short circuit in cable and in robot C50A101 wrong robot connected to control wrong robot type arm. C50A102 Voltage rising too slowly Robot Problem: 48V power supply Voltage failed to reach acceptable Robot Problem: 48V power supply C50A103...
Page 107 Safety relay error (relays are not on) Current distributor error a) Check cable from Safety Control Board to Current distributor C55A34 or 48V Power supply and Current distributor for issues b) Do a Complete rebooting sequence as per section 5.3.7 Voltage present at unpowered robot Safety Control Board hardware fault a) Do a Complete rebooting sequence as per section 5.3.7...
Page 108 Overvoltage shutdown Voltage exceeded 55V a) Check Energy Eaters cable and connections. b) Check Energy c) Replace Energy Eater Brake release failure a) Check Brake, solenoid b) Check TCP configuration, payload and mounting settings Joint did not move or motor encoder a) Check Brake, solenoid C57A1 is not functioning...
Page 109 Hardware is size1, wrong firmware at Fault: Firmware in joint Update firmware C71A1 the joint Hardware is size2, wrong firmware at Fault: Firmware in joint Update firmware C71A2 the joint Hardware is size3, wrong firmware at Fault: Firmware in joint Update firmware C71A3 the joint...
Page 110 Power supply was not able to deliver 48V Check power connection between Power supply and Safety C72A2 2 (UR10) or UR10 flash card in UR5 robot Control Board and check that the flashcard/USB and robot match 2 Power supplys active, but we...
Page 111 System error=malfunction or a) Do a Complete rebooting sequence as per section 5.3.7 C75A4 inconsistent calibration detected b) If this happens more than two times in a row, replace joint Supply voltage is out of range Check previous error C75A8 C75A16 Temperature is out of range Check previous error...
Page 112 Package lost from Safety Control C103A2 Board Ethernet connection initialization C103A3 with Safety Control Board failed C104 Error=Empty command sent to robot C111 Something is pulling the robot Check TCP configuration, payload and mounting settings Unknown robot type The robot type specified in the C115 configuration is unknown Realtime part warning...
Page 113 Protective stop: The robot was a) Verify that the robot position in the 3D graphics matches the real robot, to ensure that the encoders powered off last time due to a joint function before releasing the brakes. Stand back and monitor the robot performing its first program cycle as C160 position disagreement expected.
Page 114 Overlapping Blends in a MoveL, a Decrease the blend radius or choose waypoints that are further C171A12 waypoint was skipped apart. Overlapping Blends in a MoveL, a Decrease the blend radius or choose waypoints that are further C171A13 waypoint was skipped apart.
Page 115 C191A2 Joint speed limit violated C191A3 TCP speed limit violated C191A4 TCP position limit violated C191A5 TCP orientation limit violated C191A6 Power limit violated C191A7 Joint torque window violated C191A8 Joint torque window too large C191A9 Reduced mode output violation Safeguard stop output violation C191A10 C191A11...
Page 116 Reduced Mode Output set, while it a) Check Firmware/update firmware C191A24 should not be b) Do a Complete rebooting sequence as per section 5.3.7 Reduced Mode Output not set, while a) Check Firmware/update firmware C191A25 it should be b) Do a Complete rebooting sequence as per section 5.3.7 Not Reduced Mode Output set, while a) Check Firmware/update firmware C191A26...
Page 117 Robot still powered in emergency When emergency stop is active, the robot stop arm powers off. The controller is responsible for sending the power off C192A1 command. This error is generated, if the safety system detects that the robot arm still has power.
Page 118 C192A18 The other safety processor is in fault Emergency stop output Safety I/O uP-A and uP-B disagreement Check safety devices and cables/connections to these devices. C192A19 disagreement SPI output error detected Power supply for the I/O is not detected Check if the connection to the internal Power supply is correct. C192A20 If an external power supply is being used, check if it is powered on and correct voltage.
Page 119 Three position switch input C192A39 disagreement Operation mode switch input C192A40 disagreement One of the nodes is in fault mode Safety Control Board has detected an error a) See previous error C193 b) Do a Complete rebooting sequence as per section 5.3.7 Joint 0 is in fault mode Safety Control Board has detected an error a) See previous error...
Page 120 Euromap 2 is in fault mode Safety Control Board has detected an error a) See previous error C193A10 b) Do a Complete rebooting sequence as per section 5.3.7 One of the nodes is not booted or C194 not present C194A0 Joint 0 is not booted or not present Safety Control Board has detected an error C194A1...
Page 121 Conveyor speed too high Conveyor speed higher than robot is able Make sure that conveyor tracking is set correctly C195 to run Conveyor speed too high for joint Make sure that conveyor tracking is set correctly C195A1 speed safety limit Conveyor speed too high for TCP Make sure that conveyor tracking is set correctly C195A2...
Page 122 OVG signal test not passed Safety Control Board: uP-A has detected an a) Do a Complete rebooting sequence as per section 5.3.7 C200A8 error: over voltage generator b) If this happens more than two times in a row, replace Safety Control Board 3V3A power good pin is low Safety Control Board: uP-A has detected an...
Page 123 c) Check 48 V Power supply, current distributer, energy eater and Safety Control Board for issues Robot voltage is too high a) Do a Complete rebooting sequence as per section 5.3.7 C200A19 b) Check 48 V Power supply, current distributer, energy eater and Safety Control Board for issues 24V IO voltage is too low a) Do a Complete rebooting sequence as per section 5.3.7...
Page 124 PolyScope detected a mismatch The PolyScope continuously verifies that a) Check that the software version is the same or newer than between the shown and (to be) the shown safety parameters are equal to the firmware on the Safety Control Board. C203A0 applied safety parameters the running parameters...
Page 125 Target joint speed does not match C206A3 target joint position – Joint 3 (Wrist Target joint speed does not match C206A4 target joint position – Joint 4 (Wrist Target joint speed does not match C206A5 target joint position – Joint 5 (Wrist Fieldbus input disconnected Check fieldbus connections (RTDE, ModBus, EtherNet/IP and Profinet) or disable the fieldbus in the installation.
Page 126: Led Indicators And Fuses On Safety Control Board
5.2 LED indicators and Fuses on Safety Control Board Safety Control Board (SCB) 1) Fuse 48 V: The 5A fuse (F801) “48V” protects all 48V in the system inclusive of Euromap from over current. This information is only for troubleshooting. Do NOT replace the fuse under any circumstances. In case of failure, ONLY replace the SCB with a new tested board.
Page 127: Normal Startup Sequence For A Cb3.X Ur5
5.2.1 Normal startup sequence for a CB3.x UR5 1) The 12V-Power supply 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 128: Error Phenomena
5.3 Error phenomena 5.3.1 Control Box: NO CONTROLLER displayed in Initializing Control Box = 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 129: 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 5.2.1 Normal startup sequence for a CB3.x Replace 12V power supply In particular Step 1 Does it match the sequence mentioned?
Page 130: Protective Stop
5.3.3 Protective stop Read also article 18939 on the support site Protective Stop www.universal-robots.com/support Check TCP configuration, payload and mounting Adjust TCP configuration, settings it must correspond with actual tool and payload and mounting robot position. settings Are settings incorrect? b) Check that safety settings Adjust center of mass in the Is center of mass very different from TCP point?
Page 131: 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...
Page 132: 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 press the Emergency stop button prior to entering the work cell Visually inspect robot arm. Remove lid and inspect Are any parts visually damaged, such as any of the parts inside of joint...
Page 133: Communication To Joints And Tool
Check if there is connection to this joint. control box joint (J0) connections. Progress by connecting the next joint and check whether this also communicates. If none of the above steps resolves the issue, please contact your Universal Robots representative. All rights reserved Servicemanual_UR5_en_3.2.0...
Page 134: Complete Rebooting Sequence
5.3.7 Complete rebooting sequence. To do a complete reboot of the robot system follow these 5 steps: Push the power button on the To do a complete reboot, Teach pendant and follow the do the following… onscreen instructions Send power off command to Send power off command to Step 1 controller or inputs via I/O’s...
Page 135: Electrical Drawing
5.4 Electrical drawing 5.4.1 Schematic overview Diagrams in pdf or in E-plan format, can be found on the support site: www.universal-robots.com/support/ All rights reserved Servicemanual_UR5_en_3.2.0...
Page 141: E-Plan Diagrams
5.4.2 E-Plan diagrams Diagrams in pdf or in E-plan format, can be found on the support site: https://www.universal-robots.com/support/ All rights reserved Servicemanual_UR5_en_3.2.0...
Page 154: Spare Parts
122041 Tool Mounting Bracket UR5 CB3 122039 Tool Mounting Bracket UR5 CB2+ 122050 122050 Base Mounting Bracket Incl. Cable 6m UR5 122121 Joint Size 1 Wrist 1 UR5 CB3 122011 Joint Size 1 Wrist 1 UR5 +CB2 122221 Joint Size 1 Wrist 2 UR5 CB3...
Page 155 CB3 part CB2 Part Product Name UR3 UR5 UR10 122973 Controller excl. Teach Pendant UR3 122900 Controller excl. Teach Pendant UR5 CB3.1 122950 Controller excl. Teach Pendant UR10 CB3.1 122091 Teach Pendant complete CB3/CB3.1 122092 Teach Pendant complete CB2/CB2.1 122673...
Page 156 164084 * Bypass cable (for setting joint-ID) 185500 Dual calibration tool 131501 131501 Bracket for mounting robotarm UR5 (Item profile) 131502 131502 Bracket for mounting robotarm UR5 (BOSCH profile) 131503 Bracket for mounting robotarm UR3 (Item & BOSCH profile) 131510 131510 Bracket for mounting robotarm UR10 (Item &...
Page 157: Packing Of Robot
• Remove any external tooling and external electrical connections before shipment. • Universal Robots may reject the shipment if 3rd party products cannot be unmounted safely or they prohibit to the execution of required post repair tests. • Universal Robots assume no responsibility for 3rd party goods return shipment.
Page 158: Change Log
8. Change log Date Revision Action Changes 3. May 2014 UR5_en_3.0 Added Revision 3.0 released 19. June 2014 UR5_en_3.0.1 Changed Pictures and illustrations changed to match 3. gen. robot 29. July 2014 UR5_en_3.0.2 Changed Error codes, Spareparts changed to match 3. Gen robot and ESD handling added 20.

Universal Robots UR5 Service Manual

1 General Information

2 Preventive Maintenance

3 Service and Replacement of Parts

4 Software

5 Troubleshooting

6 Spare Parts

7 Packing of Robot

8 Change Log

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