Universal Robots UR30 Service Manual
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Universal Robots UR30 Service Manual

Universal Robots UR30 Service Manual

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Service Manual
UR20/UR30
Compatible robots: UR20 and UR30
Control Box: Control box 5.4/5.5
Original instructions (en)

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Summary of Contents for Universal Robots UR30

  • Page 1 Service Manual UR20/UR30 Compatible robots: UR20 and UR30 Control Box: Control box 5.4/5.5 Original instructions (en)

  • Page 2: Table Of Contents

    Contents 1. Introduction 1.1. About This Document 1.2. Company Details 1.3. Copyright and disclaimers 1.4. Safety Message Types 2. Handling ESD-Sensitive Parts 3. Recommended Inspection Activities 3.1. Robot Arm 3.1.1. Inspection Plan 3.1.2. Visual Inspection: Robot arm 3.1.3. Functional Inspection 3.1.4. Cleaning your robot 3.2.
  • Page 3 5. Software 5.1. Long Term Support 5.2. Software Updates 5.2.1. Update Procedure 5.3. Using Support File 5.4. Using Magic Files 5.5. Backup of data 5.5.1. Hardware Requirements 5.5.2. Software Requirements 5.5.3. Accessing Linux Partition from Windows 5.5.4. Copying the data from SD card 6. Troubleshooting 6.1.

  • 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 lifetime.

  • Page 5: Safety Message Types

    1. Introduction NOTICE Universal Robots continues to improve reliability and performance of its products, and therefore reserves the right to upgrade the product without prior warning. Universal Robots takes care that the content of this document is precise and correct, but takes no responsibility for any errors or missing information. NOTICE Universal Robots disclaims any liability, even if all guidelines in this document are followed.
  • Page 6 1. Introduction PROTECTIVE GROUND Indicates protective grounding. NOTICE Indicates the risk damage to equipment and/or useful information that should be particularly noted. READ MANUAL 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 malfunctions: MANDATORY ACTION Procedures marked with this warning must be followed exactly.

  • Page 7: Handling Esd-Sensitive Parts

    2. Handling ESD-Sensitive Parts 2. Handling ESD-Sensitive Parts To prevent damage to ESD-sensitive parts i.e. Printed Circuit Board, follow the instructions below in addition to all the usual precautions, such as turning off the power before removing the circuit boards. See section Complete Rebooting Sequence NOTICE Be sure you have intact ESD Wristband and a spare ESD bag before replacing any...
  • Page 8 2. Handling ESD-Sensitive Parts NOTICE Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until the part is ready to be installed. NOTICE Put the ESD wristband on your wrist. Connect the wristband to the system ground point.
  • Page 9 2. Handling ESD-Sensitive Parts NOTICE First place the OLD part in the spare ESD bag, then take out the NEW part of the ESD bag. NOTICE Do not place the ESD-sensitive part on nonconductive material or on metal tables/surfaces. If you must put down the ESD-sensitive part for any reason, then first place it into the ESD bag.
  • Page 10 2. Handling ESD-Sensitive Parts NOTICE Machine covers and metal tables/surfaces are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.) NOTICE If passing an ESD-sensitive part to another person, ensure both are wearing ESD...
  • Page 11 2. Handling ESD-Sensitive Parts NOTICE Be extra careful in working with ESD-sensitive parts when cold-weather and heating is used, because low humidity increases static electricity. UR20 Service Manual...

  • Page 12: 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. Perform inspections regularly as advised in the table. Any referenced parts found to be in an unacceptable state must be rectified or replaced.
  • Page 13 3. Recommended Inspection Activities 1. Move the Robot Arm to ZERO position, if possible. 2. Turn off and disconnect the power cable from Control Box. 3. Inspect the cable between Control Box and Robot Arm for any damage. 4. Check the base mounting bolts are properly tightened. 5.

  • Page 14: 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. Perform inspections regularly as advised in the table. Any referenced parts found to be in an unacceptable state must be rectified or replaced.

  • Page 15: Functional And Safety Inspection

    3. Recommended Inspection Activities • 3.2.2. Functional and Safety Inspection below • 3.1.2. Visual Inspection: Robot arm on page 9 • 4.1. Pre-Use Assessment on page 17 • Control Box Inspection action type Timeframe Monthly Biannually Annually Check Emergency stop on Teach ✘ Pendant Check the 3PE buttons by pressing ✘...
  • Page 16 3. Recommended Inspection Activities 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. Freedrive To test Freedrive: 1.
  • Page 17 3. Recommended Inspection Activities • On the 3PE Teach Pendant, rapidly light-press, then light-press-and-hold the 3PE button. 3. Pull/Push the robot to a horizontally elongated position and release. 4. Verify the robot arm can maintain the position without support and without activating Freedrive.

  • Page 18: Visual Inspection: Control Box

    3. Recommended Inspection Activities 2. Press and hold Freedrive. Status changes to Backdrive 3. Move robot as in Freedrive. Joint brakes are released where needed once the Freedrive button is activated. The robot arm is “heavy” to move around in Backdrive, so efort is required to move the joints. NOTICE Failure to test Backdrive on all joints can lead to loss of functionality.

  • Page 19: Cleaning

    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 20: Service And Replacement Of Parts

    4. Service and Replacement of Parts 4. Service and Replacement of Parts 4.1. Pre-Use Assessment The tests and verifications, listed below, must all be conducted before using the robot for the first time or after any modifications are made. • Verify all safety inputs and outputs are correctly connected. •...

  • Page 21: Recommended Tools

    4.1.1. Recommended Tools Robot Arm Control Box UR20/UR30 Arm Toolkit – part General Service toolkit – part no.: 200121 no.: 200119 Dual Robot Calibration tooling Cabinet key SD card reader part no.: [TDB] (double-bit key) UR20 Service Manual...

  • Page 22: Robot Arm

    4.2. Robot Arm 4.2.1. Joint Interchangeablilty On the UR20 and UR30 robot arms only joint size 2.5 wrist 1 and wrist 2 can be switched in service situations. Every other part has their own spare part number. Service Manual UR20...
  • Page 23 UR20 Service Manual...

  • Page 24: Connection Torque Values

    4.2.2. Connection Torque Values The clamp connection is present between all joint assemblies. Clamp Size 2.5 Service Manual UR20...
  • Page 25 Size Thread Head Size Torque Joints 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...

  • Page 26: Clamp Connection

    Hex key 5 7.5 Nm Base Flange Base Joint Shoulder Joint NOTICE Click the torque tool a minimum of three times before use, to get the correct calibrated torque. 4.2.3. Clamp Connection The following two sections describe how to disassemble and assemble a joint with a clamp connection.
  • Page 27 Clamp Connection: Disassembly WARNING Unsupported joints can fall, or be dropped, resulting in injury. • Support joints while clamps are being removed. NOTICE Failure to support the joint/s while clamps are removed can result in damage to equipment. • Prevent the joint/s from falling while removing the clamp/s by doing any of the following: •...
  • Page 28 3. Remove the screws and the clamp on one side. 4. Support the joint as you remove the second side of the clamp. 5. The joint is now loose and can be removed. Service Manual UR20...
  • Page 29 6. Gently unplug the connector from the PCB on joint. 7. The joint has now been dismounted UR20 Service Manual...
  • Page 30 Clamp Connection: Assembly The assembly is done in reverse of the disassembly. However, a few things must be noted before starting to assemble the clamp connection NOTICE Failure to replace the black flat ring can lower the IP cllassification and cause damage to property and/or equipment.
  • Page 31 NOTICE Improper connection between the joints can lead to damage to to property and/or equipment • Assemble the joints in a vertical position to ensure proper connection. • Ensure the index marks are placed above each other. • The clamps must be assembled at the index marks as illustrated below. CAUTION Ensure the screws are inserted in the correct clamp.

  • Page 32: Tool Flange

    When tightening the clamp must be done in steps. Do not exceed recommended torque here. 4.2.2. Connection Torque Values on page 21 To assemble: 1. Tighten the bolt at one side so there is a 2 mm gap between the clamp ends. 2.
  • Page 33 UR20 Service Manual...

  • Page 34: Replacement Of Trim Plates

    4.2.5. 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 35: Joint Verification

    4.2.6. Joint Verification A replacement joint needs to be verified by the controller to be assigned the correct ID. The steps below appear automatically when the robot arm is powered on for the first time. NOTICE Failure to test the joint before replacing it, can lead to damage to property and/or equipment •...
  • Page 36 3. Tap Test Joints to start joint verification. 4. Move all joints with the arrows respective to each joint. • If joints move as expected, tap Valid and a popup appears. Follow the popup instructions. • If joints do not move as expected (i.e., wrong joint moves or incorrect direction), tap Failed and a popup appears.

  • Page 37: Dual Robot Calibration

    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/ 4.2.8. 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.

  • Page 38: Control Box

    NOTICE Program Correction by Key Waypoints does not currently support the following: - Other types of waypoints with the exception fixed waypoints. - Move node with Use Joint Angles selected. The unsupported program nodes above may need to be corrected manually after the Program Correction by Key Waypoints process is complete.
  • Page 39 1. Power off Control Box – follow step 1 to 3 in section Complete Rebooting Sequence 2. Remove all the I/O Terminals, the Fuse, SD-card and any other I/O etc. that may be connected. 3. Remove the Teach Pendant, see Section Replacing of Teach Pendant 4.
  • Page 40 Power Supply UR5e, UR10e and UR16e UR3e Service Manual UR20...
  • Page 41 7. Remove the four screws on the bottom of the power supply, then remove the power supply. NOTICE When assembling, do not tighten the screws using torque greater than 1.0 8. Remove the twenty-two screws and remove the Control Board upward. UR20 Service Manual...

  • Page 42: Torque Values

    9. Removing the Energy Eater and fan assembly. Remove the four screws. Re-assembling the Control Box is done in reverse of the steps shown above. NOTICE When assembling, remember to place the round spacers behind the Energy Eater board. 4.3.2. Torque Values Torque values and notes for Control Box Below are the torque values used in the Control Box.

  • Page 43: Replacing The 3Pe Teach Pendant

    DESCRIPTION Tool size Torque 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 DESCRIPTION Tool size Torque...
  • Page 44 WARNING When the Teach Pendant is replaced, test the function of the 3PE buttons. NOTICE Replacing the Teach Pendant can result in the system reporting a fault on start-up. • Always select the correct configuration for the type of Teach Pendant. To remove: 1.

  • Page 45: Replacement Of Teach Pendant Cable

    4. Remove and discard the two cable ties used for mounting the Teach Pendant cables. 5. Press in the clips on both sides of the Teach Pendant plug, as illustrated, and pull down to disconnect from the Teach Pendant port. 6. Fully open/loosen the plastic grommet at the bottom of the Control Box and remove the Teach Pendant plug and cable.
  • Page 46 1. Turn the Teach Pendant around and place it carefully on something soft. Be careful not to damage the E-stop button. 2. Remove the 18 bolts connecting the front frame to the back plate using a T8 Torx screwdriver. 3. Pull the front frame and back plate apart. This will in some cases require some force but note that there is a cable connecting the two parts, be careful that this cable or connectors does not get damaged.
  • Page 47 4. On the front frame, cut the cable tie and unplug the cable that are connecting the front frame and back plate. 5. Unplug the Teach Pendant cable. 6. On the back plate remove the 4 bolts on the Teach Pendant cable bracket, using a T8 Torx screwdriver, and remove the bracket.
  • Page 48 7. Teach Pendant cable can now be removed. 8. Find the new Teach Pendant cable from the kit. Pull it through the hole the back plate. Make sure that the rubber cable collar is mounted correctly in the hole. 9. Mount the Teach Pendant cable bracket again and mount the 4 bolts with 0.3 Nm using a T8 Torx screwdriver.
  • Page 49 11. Connect the cable between the front frame and back plate on the other PCB and mount the new cable tie from the kit. 12. Connect the front frame and back plate again. 13. Mount the 18 bolts connecting the front frame to the back plate with 0.3 Nm, using a T8 Torx screwdriver.

  • Page 50: Software

    5. Software 5. Software Under 5.1.3: Universal Robots do not recommend or support downgrading of Polyscope software. Downgrading can in some cases break hardware compatibility or corrupt program functionality. In doubt reach out to Universal Robots. 5.1. Long Term Support Since Polyscope software release 5.12 Universal Robots has introduced a long-term support strategy to ensure hardware compatibility with requiring updating to latest sofwtare version.

  • Page 51: Update Procedure

    5. Software READ MANUAL Read these instructions and the instructions on our support website (www.universal-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. 5.2.1.
  • Page 52 5. Software 7. On the left side menu, select System. 8. Press Update, then Search to locate software update on USB stick. 9. Select the desired software update and press Update. Service Manual UR20...
  • Page 53 5. Software 10. Press Install Software to update the software. 11. The robot will power off and power on again. Once the update is complete, the Control Box automatically reboots. Do not power off or unplug the robot from the outlet during startup. 12.

  • Page 54: Using Support File

    5. Software 5.3. 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 55: Backup Of Data

    This section explains the process of moving required files during a robot backup. 5.5.1. Hardware Requirements The following hardware is needed: • SD Card (Universal Robots 4GB Industrial grade SD card) • A standard SD card reader UR20 Service Manual...

  • Page 56: Software 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 Windows Linux reader can be used as well (these are however not tested by Universal Robots). NOTICE "Linux File Systems for Windows”...
  • Page 57 5. Software • programs/ [all of the following files: .urp, .txt, .script, .installation, .variable, .old] • root/ur-serial • root/log_history.txt • 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 UR20 Service Manual...

  • Page 58: Troubleshooting

    6. Troubleshooting 6. Troubleshooting 6.1. Adding External Equipment for Troubleshooting Purpose For troubleshooting it can be useful to add a mouse, keyboard or monitor. Most USB mouse and keyboard types are supported. You can plug the mouse or keyboard in one of the available USB ports.

  • Page 59: Led Indicators And Fuse On Safety Control Board

    6. Troubleshooting 6.3. LED indicators and Fuse on Safety Control Board 6.3.1. LED Indicators on Safety Control Board The below LEDs are “power” LEDs. They are either on or off. LED for power • Green color permanent = Power on • No color permanent = Error or no power Below are “communication”...

  • Page 60: Complete Rebooting Sequence

    6. Troubleshooting CAUTION Using an inferior fuse can lead to safety hazards. • Never use a different fuse than specified. Only use high grade components. Fuse specifications: • Interrupting Rating: 1000A @ 32 VDC • Voltage Rating: 32 VDC • Component Level Temperature Range: -40˚C to +125˚C •...

  • Page 61: 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 62: Ignoring Robot Stops

    6. Troubleshooting 6.5.1. Ignoring Robot Stops Ignoring protective stops is considered abuse of the robot which voids the warranty. These faults can be hidden from view under the following two circumstances: 1. Personnel simply resetting a fault without review of why the fault has happened. WARNING Ignoring protective stops masks fault detection, which can increase the risk of injury.
  • Page 63 6. Troubleshooting i. If there has been a collision or similar: Remove the obstacle and ensure that operators are out of the way before resuming operation.  See Section 2 of Service Manual (see link below). ii. If there has been NO collision or similar: The robot is operating too close to the limits, the application should be adjusted to reduce the load on the robot, for instance by reducing accelerations, by correct use of blends or similar measures.

  • Page 64: Electrical Drawings

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

  • Page 65: Spare Parts

    8. Spare Parts 8. Spare Parts NOTICE Ensure you have the correct part numbers when ordering spare parts. The full list of spare parts have been moved to the support section on Universal Robot's website: https://www.universal-robots.com/support/ UR20 Service Manual...

  • Page 66: Packing And Shipping Of Robot/Spare Parts

    9. 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 67 9. Packing and Shipping of Robot/Spare Parts 4. Power down, disconnect main power, and disconnect the Robot Arm from controller. 5. Pack the Robot Arm and Control Box in designated boxes. Ensure the Robot Arm is orientated correctly in the box. NOTICE Transporting the robot without its original packaging voids all warranties from Universal Robots A/S.
  • Page 68 9. Packing and Shipping of Robot/Spare Parts Service Manual UR20...
  • Page 69 9. Packing and Shipping of Robot/Spare Parts UR20 Service Manual...

  • Page 70: Change Log

    10. Change log 10. Change log Date Revision Action Changes March 2023 1.0.0 Started July 2023 1.1.0 Safety msgs etc Dec 2023 1.2.0 Added UR30 Software Name: PolyScope Software Version: 5.15 Document Version: Service Manual UR20...

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