Universal Robots UR20 Service Manual
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Universal Robots UR20 Service Manual

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UR20
Service Manual
Compatible robots: UR20
Control Box: e-Series Control box 5.5, OEM Control Box,
Original instructions (en)

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Summary of Contents for Universal Robots UR20

  • Page 1 UR20 Service Manual Compatible robots: UR20 Control Box: e-Series Control box 5.5, OEM Control Box, Original instructions (en)

  • Page 2: Table Of Contents

    4.2.3. Tool Flange 4.2.4. Replacement of Trim Plates 4.2.5. Joint Verification 4.2.6. Dual Robot Calibration 4.2.7. Program Correction by Key Waypoints 4.3. Control Box 4.3.1. Dismantling the Control Box 4.3.2. Torque Values 4.3.3. Replacing the 3PE Teach Pendant 5. Software Service Manual UR20...
  • Page 3 6.3. LED indicators and Fuse on Safety Control Board 6.3.1. LED Indicators on Safety Control Board 6.3.2. Fuse 6.4. Complete Rebooting Sequence 6.5. Robot Stop 6.5.1. Ignoring Robot Stops 7. Electrical drawings 8. Packing and Shipping of Robot/Spare Parts 9. Change log UR20 Service Manual...

  • Page 4: Introduction

    1. Introduction 1.1. About This Document The purpose of the Service Manual is to help Universal Robots (UR) users and integrators to safely perform service-related operations and troubleshooting. Universal Robots industrial robots are designed using high quality components to ensure a long life- time.

  • Page 5: Safety Message Types

    WARNING: HOT SURFACE Indicates a hazardous hot surface where injury can result from contact and non- contact proximity. CAUTION Indicates a hazardous situation which, if not avoided, could result in injury. GROUND Indicates grounding. UR20 Service Manual...
  • Page 6 Indicates more detailed information that should be consulted in the manual. This warning draws attention to procedures which serve to prevent or remedy emergencies or mal- functions: MANDATORY ACTION Procedures marked with this warning must be followed exactly. Service Manual UR20...

  • Page 7: Handling Esd-Sensitive Parts

    Hold the ESD-sensitive part by its edges. Do not touch its pins or hold directly on any exposed prints. NOTICE First place the OLD part in the spare ESD bag, then take out the NEW part of the ESD bag. UR20 Service Manual...
  • Page 8 If passing an ESD-sensitive part to another person, ensure both are wearing ESD wristband and the ESD wristband is attached to the system grounding point. NOTICE Be extra careful in working with ESD-sensitive parts when cold-weather and heating is used, because low humidity increases static electricity. Service Manual UR20...

  • Page 9: Recommended Inspection Activities

    3.1. Robot Arm 3.1.1. Inspection Plan The table below is a checklist of the type of inspections recommended by Universal Robots. Per- form inspections regularly as advised in the table. Any referenced parts found to be in an unac- ceptable state must be rectified or replaced.
  • Page 10 4. Check the base mounting bolts are properly tightened. 5. Check the tool flange bolts are properly tightened. 6. Inspect the flat rings for wear and damage. • Replace the flat rings if they are worn out or damaged. Service Manual UR20...

  • Page 11: Functional Inspection

    3.2. Control Box and Teach Pendant 3.2.1. Inspection Plan The table below is a checklist of the type of inspections recommended by Universal Robots. Per- form inspections regularly as advised in the table. Any referenced parts found to be in an unac- ceptable state must be rectified or replaced.

  • Page 12: Functional And Safety Inspection

    To test the Emergency Stop button on the Teach Pendant: 1. Press the Emergency Stop button on the Teach Pendant. 2. Observe the robot stops and shuts off power to the joints. 3. Power on robot again. Service Manual UR20...
  • Page 13 Failure to test Backdrive on all joints can lead to loss of functionality. • You must test Backdrive mode on all joints. Safety settings Verify the robot safety settings comply with the robot installation risk assessment. Additional safety inputs and outputs are still functioning UR20 Service Manual...

  • Page 14: Visual Inspection: Control Box

    To clean the Teach Pendant touch screen Use a mild, industrial cleaning agent without thinning agents or any aggressive additives. Do not use an abrasive material to wipe down the screen.Universal Robots does not promote a specific cleaning agent. To clean the Control Box filters There is a filter on either side of the Control Box.

  • Page 15: Service And Replacement Of Parts

    Reduced Mode output, or Not Reduced Mode output can actually detect the output changes Read Section 9 to learn how to pack down and ship the robot and/or spare parts. Packing and Ship- ping of Robot/Spare Parts UR20 Service Manual...

  • Page 16: Recommended Tools

    4.1.1. Recommended Tools Robot Arm Control Box UR20 Torque Wrench Service tools – part no.: Service tools – part no.: Service tools – part no.: [TDB] 109011 109011 Dual Robot Calibration tooling Cabinet key SD card reader part no.: [TDB]...

  • Page 17: Robot Arm

    4.2. Robot Arm UR20 Service Manual...

  • Page 18: Connection Torque Values

    4.2.1. Connection Torque Values The clamp connection is present between all joint assemblies. Clamp Size 2.5 Service Manual UR20...
  • Page 19 Hex key 4 5.5 Nm Wrist 1 Wrist 2 Wrist 3 Tool Flange Clamp Size 4 Size Thread Head Size Torque Joints Hex key 5 7.5 Nm Elbow Joint Clamp Size 5 Size Thread Head Size Torque Joints UR20 Service Manual...

  • Page 20: Clamp Connection

    Joint Size 5 15.8 Kg. Joint Size 4 9.1 Kg. Joint Size 2.5 2.9 Kg. Clamp Connection: Disassembly WARNING Unsupported joints can fall, or be dropped, resulting in injury. • Support joints while clamps are being removed. Service Manual UR20...
  • Page 21 1. Attach the ESD wristband from the spare part package or tool kit to an electrical grounded surface. 2. Remove the black flat-ring. You can use a pair of pointy tweezers or a small flathead screwdriver. 3. Remove the screws and the clamp on one side. UR20 Service Manual...
  • Page 22 4. Support the joint as you remove the second side of the clamp. 5. The joint is now loose and can be removed. 6. Gently unplug the connector from the PCB on joint. 7. The joint has now been dismounted Service Manual UR20...
  • Page 23 Failure to test the joint before replacing it, can lead to damage to property and/or equipment • Always perform a joint replacement test before using a new joint. See the 4.2.5. Joint Verification on page 24 section for more information. UR20 Service Manual...

  • Page 24: Tool Flange

    The tool flange is a Clamp Connection and is disassembled like a joint with this connection. See section Clamp Connection Power and communication plug is in the same plug. See section Clamp Connection Power and communication plug is in the same plug. Service Manual UR20...
  • Page 25 UR20 Service Manual...

  • Page 26: Replacement Of Trim Plates

    4.2.4. Replacement of Trim Plates The trim plates on a UR20 is attached with a different method than what is used on the e-Series robots. By applying pressure correctly on the trim plate, it is possible to remove them without any tools.

  • Page 27: Joint Verification

    To perform a Dual Robot Calibration, you need: • 2 robots (same size and same generation) • Dual Robot Calibration Tooling Complete (Part no: TBD) You can download the Calibration Manual from the Universal Robots Support site www.universal- robots.com/support/ UR20...

  • Page 28: Program Correction By Key Waypoints

    Program Correction by Key Waypoints helps adjusting programs waypoints when a program is moved from an uncalibrated robot to another. The technique can also be used to make programs work after replacements of joints. Please refer to the Calibration Manual from the Universal Robots Support site www.universal-robot- s.com/support/ for detailed description on how to use this feature.

  • Page 29: Torque Values

    Nut for internal CB bracket 10mm 2.25Nm Robot connector screw Torx T20 1.5Nm Screw for feet bracket Hex key 5 4.0Nm Screw and washer for cover plate Torx T20 1.5Nm Control Box and Teach pendant mounting nut 10mm 2.25Nm UR20 Service Manual...

  • Page 30: Replacing The 3Pe Teach Pendant

    4. Fully open/loosen the plastic grommet at the bottom of the Control Box and remove the Teach Pendant plug and cable. 5. Gently remove the Teach Pendant cable and Teach Pendant. To replace: 1. Place the 3PE Teach Pendant plug and cable in through the bottom of the control box and fully close/tighten the plastic grommet. Service Manual UR20...
  • Page 31 2. Push the 3PE Teach Pendant plug into the Teach Pendant port to connect. 3. Use two new cable ties to mount the 3PE Teach Pendant cables. 4. Connect the main power cable to the power source and power on the Control Box. UR20 Service Manual...

  • Page 32: Software

    (www.uni- versal-robots.com/support) completely prior to updating your software. Downgrading software is not supported. The UR20 is shipped with the PolyScope software version 6. It is not possible to downgrade the software to any version of software version 5. 5.1.1. Update Procedure 1.

  • Page 33: Using Support File

    14. Remove the USB stick. 5.2. Using Support File For easy backup, Universal Robots provides a feature called Support File, an automatically copy of the robot data from Control Box to the USB stick. 1. Access the Log tab, insert a USB stick and tap Support File.

  • Page 34: Backup Of Data

    When copying/moving files and folders, incorrect use might corrupt the file system. Contact your IT professional for assistance if you are not comfortable with this procedure. This section explains the process of moving required files during a robot backup. Service Manual UR20...

  • Page 35: Hardware Requirements

    When using Windows operation system, to read a Linux partition a software file system driver is required; in this example we are using “Linux File Systems for Windows” by Paragon but other Win- dows Linux reader can be used as well (these are however not tested by Universal Robots). NOTICE "Linux File Systems for Windows”...
  • Page 36 5. Software • root/log_history.bak [if existing] • root/histogram.properties • root/flightreports [Complete folder if existing] • root/.urcontrol/calibration.conf • root/.urcontrol/calibration.log • root/.urcontrol/robot_calibration_summary.txt Service Manual UR20...

  • Page 37: Troubleshooting

    Below are “communication” LEDs. They flash in different patterns, depending on the status. LED for Safety A and Safety B Green fast flash = Bootloader Green slow flash = Normal communication Red permanent = Error (Red flash can happen during bootup/power on, this is normal.) LED for FPGA UR20 Service Manual...

  • Page 38: Fuse

    • Terminals: Ag plated zinc alloy • Housing Material: PA66 • Complies with: SAE J2077, ISO 8820-3 • UL 248 Special Purpose Fuses 6.4. Complete Rebooting Sequence To completely reboot the robot system, follow the following steps: Service Manual UR20...

  • Page 39: Robot Stop

    6. Troubleshooting 6.5. Robot Stop Read also article 18939 on the support site www.universal-robots.com/support UR20 Service Manual...

  • Page 40: Ignoring Robot Stops

    In case the robots are pushed close to the lim- its, the robots can generate protective stops to indicate that they are not capable of following the desired trajectory.  After a protective stop, the following must be done before resuming operation: Service Manual UR20...
  • Page 41 If an integrator has set-up the application program to do automatic acknowledgement and reset of protective stops, the customer should contact the integrator change the program immediately, as such override voids the product warranty and masks fault detection. UR20 Service Manual...

  • Page 42: Electrical Drawings

    7. Electrical drawings 7. Electrical drawings Service Manual UR20...

  • Page 43: Packing And Shipping Of Robot/Spare Parts

    8. Packing and Shipping of Robot/Spare Parts Before shipping any robots or spare parts back to Universal Robots, verify the following: • All external tools and external electrical connections are removed. • The robot arm, Control Box, and Teach Pendant are packed responsibly.
  • Page 44 It may be necessary to disassemble the arm into two parts between the elbow joint and upper arm tube, and strap it securely to a pallet with two straps on the each tube before shipping. This will not void the warranty. Service Manual UR20...
  • Page 45 8. Packing and Shipping of Robot/Spare Parts UR20 Service Manual...
  • Page 46 8. Packing and Shipping of Robot/Spare Parts Service Manual UR20...

  • Page 47: Change Log

    9. Change log 9. Change log Date Revision Action Changes March 2023 1.0.0 Started July 2023 1.1.0 Safety msgs etc Software Version: 5.14 Document Version: UR20 Service Manual...

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