Universal Robots e Series User manual

UniversalRobots e-Series
User Manual
e-Series Control Box
Original instructions (en)

Contents
1.Introduction 4
1.0.1. Control Box Bracket 4
2.Electrical Warnings and Cautions 5
3.Ethernet 7
4.Connections 8
4.1. Mains Connection 8
4.2. Robot Connection: Robot Cable 9
4.2.1. Robot Cable connector 9
4.3. Robot Connection: Base Flange Cable 10
4.3.1. Base Flange Cable connector 10
5.General Purpose I/O 11
5.0.1. Digital Inputs from a button 11
5.0.2. Communication with other machines or PLCs 11
5.0.3. General purpose analog I/O 12
5.0.4. Remote ON/OFF control 13
5.1. Controller I/O 14
5.2. Safety I/O 16
6.Index 21
User Manual e-Series Control Box
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

1.Introduction
This chapter describes electrical interface groups for the Robot Arm in the Control Box. Examples
are given for most types of I/O. The term I/O refers to both digital and analog control signals to or
from the electrical interface groups listed below.
•Mains connection
•Robot connection
•Controller I/O
•Tool I/O
•Ethernet
1.0.1. Control Box Bracket
On the underside of the I/O interface groups, there is a bracket with ports that allows for additional
connections (illustrated below). The base of the Control Box has a capped opening for easy
connection (see ).
The Mini Displayport supports monitors with Displayport and requires an active Mini Display to DVI
or HDMI converter to connect monitors with DVI/HDMI interface. Passive converters do not work
with DVI/HDMI ports.
The Fuse must be UL marked, Mini Blade type with maximum current rating: 10A and minimum
voltage rating: 32V
e-Series Control Box User Manual
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

2.Electrical Warnings and Cautions
Observe the following warnings for all the aforementioned interface groups, in addition to when the
robot application is designed and installed.
All voltages and currents are in Direct Current (DC) unless otherwise specified.
WARNING
1. Never connect safety signals to a PLC which is not a safety PLC with the
correct safety level. Failure to follow this warning could result in serious
injury or death as the safety functions could be overridden. It is important to
keep safety interface signals separated from the normal I/O interface
signals.
2. All safety-related signals are constructed redundantly (two independent
channels). Keep the two channels separate so that a single fault cannot lead
to loss of the safety function.
3. Some I/Os inside the Control Box can be configured for either normal or
safety-related I/O. Read and understand the complete section.
WARNING
1. Make sure all equipment not rated for water exposure remain dry. If water is
allowed to enter the product, lockout-tagout all power and then contact your
local Universal Robots service provider for assistance.
2. Only use the original cables supplied with the robot only. Do not use the
robot for applications where the cables are subject to flexing.
3. Negative connections are referred to as Ground (GND) and are connected to
the casing of the robot and the Control Box. All mentioned GND connections
are only for powering and signalling. For PE (Protective Earth) use the M6-
size screw connections marked with earth symbols inside the Control Box.
The grounding conductor shall have at least the current rating of the highest
current in the system.
4. Use caution when installing interface cables to the robot I/O. The metal plate
in the bottom is intended for interface cables and connectors. Remove the
plate before drilling holes. Make sure that all shavings are removed before
reinstalling the plate. Remember to use correct gland sizes.
User Manual e-Series Control Box
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

CAUTION
1. The robot has been tested according to international IEC standards for
ElectroMagnetic Compatibility (EMC). Disturbing signals with levels higher
than those defined in the specific IEC standards can cause unexpected
behaviors from the robot. Very high signal levels or excessive exposure can
damage the robot permanently. EMC problems are found to happen usually
in welding processes and are normally prompted by error messages in the
log. Universal Robots cannot be held responsible for any damages caused by
EMC problems.
2. I/O cables going from the Control Box to other machinery and factory
equipment may not be longer than 30m, unless additional tests are
performed.
e-Series Control Box User Manual
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

3.Ethernet
The Ethernet interface can be used for:
•MODBUS, EtherNet/IP and PROFINET (see part).
•Remote access and control.
To connect the Ethernet cable by passing it through the hole at the base of the Control Box, and
plugging it into the Ethernet port on the underside of the bracket.
Replace the cap at the base of the Control Box with an appropriate cable gland to connect the
cable to the Ethernet port.
The electrical specifications are shown in the table below.
Parameter Min Typ Max Unit
Communication speed 10 - 1000 Mb/s
User Manual e-Series Control Box
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

4.Connections
4.1. Mains Connection
The mains cable from the Control Box has a standard IEC plug at the end. Connect a country
specific mains plug, or cable, to the IEC plug.
NOTE
•IEC 61000-6-4: Chapter 1 Scope: "This part of IEC 61000 for emission
requirement applies to electrical and electronic equipment intended for use
within the environment of existing at industrial locations".
•IEC 61000-6-4: Chapter 3.1.12 industrial location: “Locations characterized
by a separate power network, supplied from a high- or medium-voltage
transformer, dedicated for the supply of the installation".
To power the robot, the Control Box must be connected to the mains via the standard IEC C20 plug
at the bottom of the Control Box, through a corresponding IEC C19 cord (see illustration below).
The mains supply is equipped with the following:
•Connection to ground
•Main fuse
•Residual current device
It is recommended to install a main switch to power off all equipment in the robot application as an
easy means for lockout-tagout under service. The electrical specifications are shown in the table
below.
e-Series Control Box User Manual
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

Parameter Min Typ Max Unit
Input voltage 100 - 240 VAC
External mains fuse (@ 100-200V) 15 - 16 A
External mains fuse (@ 200-265V) 8 - 16 A
Input frequency 47 - 440 Hz
Stand-by power - - <1.5 W
Nominal operating power 90 250 500 W
WARNING
1. Ensure the robot is grounded correctly (electrical connection to ground). Use
the unused bolts associated with grounding symbols inside the Control Box
to create common grounding of all equipment in the system. The grounding
conductor shall have at least the current rating of the highest current in the
system.
2. Ensure the input power to the Control Box is protected with a Residual
Current Device (RCD) and a correct fuse.
3. Lockout-tagout all power for the complete robot installation during service.
Other equipment shall not supply voltage to the robot I/O when the system is
locked out.
4. Ensure all cables are connected correctly before the Control Box is powered.
Always use the original power cord.
4.2. Robot Connection: Robot Cable
This subsection describes the connection for a robot arm configured with a fixed 6 meter Robot
Cable. For information on connecting a robot arm configured with a Base Flange Cable connector,
see 4.3. Robot Connection: Base Flange Cableon the next page.
4.2.1. Robot Cable connector
Establish the robot connection by connecting the robot arm to the Control Box with the Robot
Cable.
Plug and lock the cable from the robot into the connector at the bottom of the Control Box (see
illustration below). Twist the connector twice to ensure it is properly locked before turning on the
robot arm.
You can turn the connector to the right to make it easier to lock after the cable is plugged in.
User Manual e-Series Control Box
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

CAUTION
Improper robot connection can result in loss of power to the robot arm.
•Do not disconnect the Robot Cable when the robot arm is turned on.
•Do not extend or modify the original Robot Cable.
4.3. Robot Connection: Base Flange Cable
This subsection describes the connection for a robot arm configured with a Base Flange Cable
connector. For information on connecting a robot arm configured with a fixed 6 meter Robot Cable,
see 4.2. Robot Connection: Robot Cableon the previous page.
4.3.1. Base Flange Cable connector
Establish the robot connection by connecting the robot arm to the Control Box with the Robot
Cable. The Robot Cable connects to the Base Flange Cable connector and to the Control Box
connector.
You can lock each connector when robot connection is established.
CAUTION
The maximum robot connection from the robot arm to the Control Box is 12 m.
Improper robot connection can result in loss of power to the robot arm.
•Do not extend a 6 m Robot Cable.
NOTICE
Connecting the Base Flange Cable directly to any Control Box can result in
equipment or property damage.
•Do not connect the Base Flange Cable directly to the Control Box.
e-Series Control Box User Manual
Copyright © 2009–2022 by UniversalRobotsA/S. All rights reserved.

5.General Purpose I/O
This section describes the general purpose 24V I/O (Gray terminals) and the configurable I/O
(Yellow terminals with black text) when not configured as safety I/O. The common specifications
in section must be observed.
The general purpose I/O can be used to drive equipment like pneumatic relays directly or for
communication with other PLC systems. All Digital Outputs can be disabled automatically when
program execution is stopped, see part. In this mode, the output is always low when a program is
not running. Examples are shown in the following subsections. These examples use regular Digital
Outputs but any configurable outputs could also have be used if they are not configured to perform
a safety function.
Load controlled by a Digital Outputs
This example shows how a load is controlled from a Digital Outputs when connected.
0V
DO1
0V
DO2
0V
DO3
0V
DO0
Digital Outputs
0V
DO5
0V
DO6
0V
DO7
0V
DO4
LOAD
5.0.1. Digital Inputs from a button
This example illustrates connecting a simple button to a Digital Inputs.
24V
DI1
24V
DI2
24V
DI3
24V
DI0
Digital Inputs
24V
DI5
24V
DI6
24V
DI7
24V
DI4
5.0.2. Communication with other machines or PLCs
You can use the digital I/O to communicate with other equipment if a common GND (0V) is
established and if the machine uses PNP technology, see below.
24V
DI1
24V
DI2
24V
DI3
24V
DI0
Digital Inputs
24V
DI5
24V
DI6
24V
DI7
24V
DI4
0V
DO1
0V
DO2
0V
DO3
0V
DO0
Digital Outputs
0V
DO5
0V
DO6
0V
DO7
0V
DO4
24V
DI1
24V
DI2
24V
DI3
24V
DI0
Digital Inputs
24V
DI5
24V
DI6
24V
DI7
24V
DI4
0V
DO1
0V
DO2
0V
DO3
0V
DO0
Digital Outputs
0V
DO5
0V
DO6
0V
DO7
0V
DO4
A B
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5.0.3. General purpose analog I/O
The analog I/O interface is the green terminal. It is used to set or measure voltage (0-10V) or
current (4-20mA) to and from other equipment.
The following directions is recommended to achieve the highest accuracy.
•Use the AG terminal closest to the I/O. The pair share a common mode filter.
•Use the same GND (0V) for equipment and Control Box. The analog I/O is not galvanically
isolated from the Control Box.
•Use a shielded cable or twisted pairs. Connect the shield to the GND terminal at the terminal
called Power.
•Use equipment that works in current mode. Current signals are less sensitive to
interferences.
In the GUI you can select input modes (see part). The electrical specifications are shown below.
Terminals Parameter Min Typ Max Unit
Analog Input in current mode
[AIx - AG] Current 4 - 20 mA
[AIx - AG] Resistance - 20 - ohm
[AIx - AG] Resolution - 12 - bit
Analog Input in voltage mode
[AIx - AG] Voltage 0 - 10 V
[AIx - AG] Resistance - 10 - Kohm
[AIx - AG] Resolution - 12 - bit
Analog Output in current mode
[AOx - AG] Current 4 - 20 mA
[AOx - AG] Voltage 0 - 24 V
[AOx - AG] Resolution - 12 - bit
Analog Output in voltage mode
[AOx - AG] Voltage 0 - 10 V
[AOx - AG] Current -20 - 20 mA
[AOx - AG] Resistance - 1 - ohm
[AOx - AG] Resolution - 12 - bit
Using an Analog Output
This example illustrates controlling a conveyor belt with an analog speed control input.
e-Series Control Box User Manual
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AG
AI1
AG
AO0
AG
AO1
AG
AI0
Analog
Analog Outputs
Analog Inputs
24V
0V
PWR
GND
Power
Using an Analog Input
This example illustrates connecting an analog sensor.
AG
AI1
AG
AO0
AG
AO1
AG
AI0
Analog
Analog Outputs
Analog Inputs
24V
0V
PWR
GND
Power
5.0.4. Remote ON/OFF control
Use remote ON/OFF control to turn the Control Box on and off without using the Teach Pendant. It
is typically used:
•When the Teach Pendant is inaccessible.
•When a PLC system must have full control.
•When several robots must be turned on or off at the same time.
The remote ON/OFF control provides a auxiliary 12V supply, kept active when the Control Box is
turned off. The ON input is intended only for short time activation and works in the same way as
the POWER button. The OFF input can be held down as desired. Use a software feature to load and
start programs automatically (see part).
The electrical specifications are shown below.
Terminals Parameter Min Typ Max Unit
[12V - GND] Voltage 10 12 13 V
[12V - GND] Current - - 100 mA
[ON / OFF] Inactive voltage 0 - 0.5 V
[ON / OFF] Active voltage 5 - 12 V
[ON / OFF] Input current - 1 - mA
[ON] Activation time 200 - 600 ms
Remote ON button
This example illustrates connecting a remote ON button.
User Manual e-Series Control Box
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ON
OFF
12V
Remote
GND
Remote OFF button
This example illustrates connecting a remote OFF button.
ON
OFF
12V
Remote
GND
CAUTION
Do not press and hold the ON input or the POWER button as it switches off the
Control Box without saving. You must use the OFF input for remote off control as
this signal allows the Control Box to save open files and shut down correctly.
5.1. Controller I/O
You can use the I/O inside the Control Box for a wide range of equipment including pneumatic
relays, PLCs and emergency stop buttons.
The illustration below shows the layout of electrical interface groups inside the Control Box.
24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
ON
OF F
12V
Remot e
24V
0V
P W R
GND
P o we r
24V
CI1
24V
CI2
24V
CI3
24V
CI0
Con figu rable I np ut s
24V
CI5
24V
CI6
24V
CI7
24V
CI4
0V
CO1
0V
CO2
0V
CO3
0V
CO0
Con figu rable Ou tp uts
0V
CO5
0V
CO6
0V
CO7
0V
CO4
24V
DI1
24V
DI2
24V
DI3
24V
DI0
Digit al In pu ts
24V
DI5
24V
DI6
24V
DI7
24V
DI4
0V
DO1
0V
DO2
0V
DO3
0V
DO0
Digit al Out puts
0V
DO5
0V
DO6
0V
DO7
0V
DO4
AG
AI1
AG
AO0
AG
AO1
AG
AI0
Analog
Anal og Ou tput s
Anal og Inp ut s
Safegu ard St op
Emerg ency Stop
GND
0V
24V
DI8
DI9
DI10
DI11
You can use the horizontal Digital Inputs block (DI8-DI11), illustrated below, for quadrature
encoding Conveyor Tracking (see Common specifications for all digital I/O) for these types of
input.
0V
24V
DI8
DI9
DI10
DI11
The meaning of the color schemes listed below must be observed and maintained.
Yellow with red text Dedicated safety signals
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Yellow with black text Configurable for safety
Gray with black text General purpose digital I/O
Green with black text General purpose analog I/O
In the GUI, you can set up configurable I/O as either safety-related I/O or general purpose I/O (see
partPart II PolyScope Manual).
Common specifications for all digital I/O
This section defines electrical specifications for the following 24V digital I/O of the Control Box.
•Safety I/O.
•Configurable I/O.
•General purpose I/O.
Install the robot according to the electrical specifications which are the same for all three inputs.
It is possible to power the digital I/O from an internal 24V power supply or from an external power
source by configuring the terminal block called Power. This block consists of four terminals. The
upper two (PWR and GND) are 24V and ground from the internal 24V supply. The lower two
terminals (24V and 0V) in the block are the 24V input to supply the I/O. The default configuration
uses the internal power supply (see below).
24V
0V
PWR
GND
Power
If more current is needed, connect an external power supply as shown below.
24V
0V
PWR
GND
Power
The electrical specifications for both the internal and external power supply are shown below.
Terminals Parameter Min Typ Max Unit
Internal 24V power supply
[PWR - GND] Voltage 23 24 25 V
[PWR - GND] Current 0 - 2* A
External 24V input requirements
[24V - 0V] Voltage 20 24 29 V
[24V - 0V] Current 0 - 6 A
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*3.5A for 500ms or 33% duty cycle.
The digital I/O are constructed in compliance with IEC 61131-2. The electrical specifications are
shown below.
Terminals Parameter Min Typ Max Unit
Digital Outputs
[COx / DOx] Current* 0 - 1 A
[COx / DOx] Voltage drop 0 - 0.5 V
[COx / DOx] Leakage current 0 - 0.1 mA
[COx / DOx] Function - PNP - Type
[COx / DOx] IEC 61131-2 - 1A - Type
Digital Inputs
[EIx/SIx/CIx/DIx] Voltage -3 - 30 V
[EIx/SIx/CIx/DIx] OFF region -3 - 5 V
[EIx/SIx/CIx/DIx] ON region 11 - 30 V
[EIx/SIx/CIx/DIx] Current (11-30V) 2 - 15 mA
[EIx/SIx/CIx/DIx] Function - PNP + - Type
[EIx/SIx/CIx/DIx] IEC 61131-2 - 3 - Type
*For resistive loads or inductive loads of maximum 1H.
NOTE
The word configurable is used for I/O configured as either safety-related I/O or
normal I/O. These are the yellow terminals with black text.
5.2. Safety I/O
This section describes dedicated safety input (Yellow terminal with red text) and configurable I/O
(Yellow terminals with black text) when configured as safety I/O. Follow the Common
specifications for all digital I/O in sectionCommon specifications for all digital I/O.
Safety devices and equipment must be installed according to the safety instructions and the risk
assessment in chapter.
All safety I/O are paired (redundant) and must be kept as two separate branches. A single fault
does not cause loss of the safety function.
There are two permanent safety input types:
•Robot Emergency Stop for emergency stop equipment only
•Safeguard Stop for protective devices
The functional difference is shown below.
Emergency Stop Safeguard Stop
Robot stops moving Yes Yes
Program execution Pauses Pauses
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Emergency Stop Safeguard Stop
Drive power Off On
Reset Manual Automatic or manual
Frequency of use Infrequent Every cycle to infrequent
Requires re-initialization Brake release only No
Stop Category (IEC60204-1) 1 2
Performance level of
monitoring function (ISO13849-1) PLd PLd
Use the configurable I/O to set up additional safety I/O functionality, e.g. Emergency Stop Output.
Configuring a set of configurable I/O for safety functions are done through the GUI, (see partPart II
PolyScope Manual).
WARNING
1. Never connect safety signals to a PLC that is not a safety PLC with the
correct safety level. Failure to follow this warning could result in serious
injury or death as the safety functions could be overridden. It is important to
keep safety interface signals separated from the normal I/O interface
signals.
2. All safety-related I/O are constructed redundantly (two independent
channels). Keep the two channels separate so that a single fault cannot lead
to loss of the safety function.
3. Safety functions must be verified before putting the robot into operation.
Safety functions must be tested regularly.
4. The robot installation shall conform to these specifications. Failure to do so
could result in serious injury or death as the safety function could be
overridden.
OSSD Signals
All configured and permanent safety inputs are filtered to allow the use of OSSD safety equipment
with pulse lengths under 3ms. The safety input is sampled every millisecond and the state of the
input is determined by the most frequently seen input signal over the last 7 milliseconds. OSSD
pulses on the safety outputs are detailed in partPart II PolyScope Manual.
Default safety configuration
The robot is delivered with a default configuration, which enables operation without any additional
safety equipment (see illustration below).
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24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
Safeguard Stop
Emergency Stop
Connecting emergency stop buttons
Most applications require one or more extra emergency stop buttons. The illustration below shows
how one or more emergency stop buttons can be connected.
24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
Safeguard Stop
Emergency Stop
24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
Safeguard Stop
Emergency Stop
Sharing the Emergency Stop with other machines
You can set up a shared emergency stop function between the robot and other machines by
configuring the following I/O functions via the GUI. The Robot Emergency Stop Input cannot be
used for sharing purposes. If more than two UR robots or other machines need to be connected, a
safety PLC must be used to control the emergency stop signals.
•Configurable input pair: External emergency stop.
•Configurable output pair: System emergency stop.
The illustration below shows how two UR robots share their emergency stop functions. In this
example the configured I/Os used are CI0-CI1 and CO0-CO1.
24V
CI1
24V
CI2
24V
CI3
24V
CI0
Configurable Inputs
24V
CI5
24V
CI6
24V
CI7
24V
CI4
0V
CO1
0V
CO2
0V
CO3
0V
CO0
Configurable Outputs
0V
CO5
0V
CO6
0V
CO7
0V
CO4
24V
CI1
24V
CI2
24V
CI3
24V
CI0
Configurable Inputs
24V
CI5
24V
CI6
24V
CI7
24V
CI4
0V
CO1
0V
CO2
0V
CO3
0V
CO0
Configurable Outputs
0V
CO5
0V
CO6
0V
CO7
0V
CO4
AB
e-Series Control Box User Manual
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Safeguard stop with automatic resume
An example of a basic safeguard stop device is a door switch where the robot is stopped when a
door is opened (see illustration below).
24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
Safeguard Stop
Emergency Stop
This configuration is only intended for applications where the operator cannot go through the door
and close it behind him. The configurable I/O is used to setup a reset button outside the door to
reactivate robot motion.
Another example where automatic resume is appropriate is when using a safety mat or a safety-
related laser scanner (see below).
24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
Safeguard Stop
Emergency Stop
24V 0V
24V
0V
WARNING
1. The robot resumes movement automatically when the signal is re-
established. Do not use this configuration if signal can be re-established
from the inside of the safety perimeter.
Safeguard Stop with reset button
If the safeguard interface is used to interact with a light curtain, a reset outside the safety
perimeter is required. The reset button must be a two channel type. In this example the I/O
configured for reset is CI0-CI1 (see below).
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24V
EI1
24V
SI0
24V
SI1
24V
EI0
Safety
Safeguard Stop
Emergency Stop
24V 0V
24V
0V
24V
CI1
24V
CI2
24V
CI3
24V
CI0
Configurable Inputs
24V
CI5
24V
CI6
24V
CI7
24V
CI4
Three-Position Enabling Device
The illustration below shows how to connect a Three-Position Enabling Device. See sectionThree-
Position Enabling Device for more about Three-Position Enabling Device.
NOTE
The Universal Robots safety system does not support multiple external Three-
Position Enabling Devices.
24V
CI1
24V
CI2
24V
CI3
24V
CI0
24V
CI5
24V
CI6
24V
CI7
24V
CI4
Configurable Inputs 3-Position Switch
NOTE
The two input channels for the Three-Position Enabling Device input have a
disagreement tolerance of 1 second.
Operational Mode Switch
The illustration below shows an Operational Mode Switch. See sectionOperational Modes for more
about operational Modes.
24V
CI1
24V
CI2
24V
CI3
24V
CI0
24V
CI5
24V
CI6
24V
CI7
24V
CI4
Configurable Inputs Operational mode Switch
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